Plockmatic BM500

Booklet Maker Service Manual

T08125H
20 May 2019
 WARNING:
This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take
adequate measures.

The product (System) which is connected to this machine will be class A

NOTE
The domestic environment is an environment where the use of broadcast radio and television receivers may be expected within a distance of 10 m of the
apparatus concerned.
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BM500 ii Cover
Introduction

This manual contains instructions on the operation and maintenance of this machine. To get the maximum versatility from this machine all operators
should carefully read and follow the instructions in this manual. Keep this manual in a handy place near the machine.
Please read the Safety Information before using this machine. It contains information related to USER SAFETY and PREVENTING EQUIPMENT PROB-
LEMS.

How to read this manual

Notation conventions

Whenever necessary, the following points for attention are indicated in this manual.

WARNING:
Indicates a potentially hazardous situation which, if instructions are not followed, could result in death or serious injury.

CAUTION:
Indicates a potentiality hazardous situation which, if instructions are not followed, may result in minor or moderate injury or damage to machine or prop-
erty.

NOTE
This sign refers to:
Remarks for making the operation much easier. You get practical hints or knowledge to assist you in the machine operation such as:
Preparations required before operating
How to prevent papers from being misfed or damaged
Precautions required or actions to take after misoperation
Limitations like numerical limits, functions that cannot be used together or conditions under which a particular function cannot be used or obtained.
Information.
[ ]
Keys that appear on the machine’s display panel.

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BM500 iii Cover
Safety Information

When using this machine, following safety precautions should always be followed.

Safety during operation

WARNING:
• To avoid hazardous situations such as electric shock or danger while exposed to moving, rotating or cutting devices, do not remove any
covers, guards or screws other than those specified in this manual.
• Turn off the power and disconnect the power plug (by pulling the plug, not the cable) if any of the following conditions exist:
• Before disassembling or assembling parts of the System and peripherals.
• You drop objects or spill something into the equipment.
• You suspect that your equipment needs service or repair.
• Machine covers have been damaged
• You notice unusual noises or odours when operating the equipment.
• If the power cable or plug becomes worn out or otherwise damaged.
• Before cleaning and care (unless otherwise specifically instructed).
• If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hand away
from electrical or mechanically driven components.
• Note that components of the System and peripherals can be supplied with electric voltage even if the main power switch is turned off
and the power cord is disconnected.
• Electromagnetic compliance:
• This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may be re-
quired to take adequate measures.
• The product (System) which is connected to this machine will be class A.

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BM500 iv Cover
General Safety

WARNING:
• Always connect the equipment to a properly grounded power source (wall outlet). Wall outlet should be located near the system and eas-
ily accessible. If in doubt, have the power source checked by a qualified electrician.
• Improper grounding of the equipment can result in electrical shock. Never connect the machine to a power source that lacks a ground
connection terminal. This machine is destined for specific purpose only. Any use going beyond this specific purpose is regarded as
beyond the determination. The manufacturer will not be liable for damages resulting from any use beyond the determination, unallowed
operation, respectively. The user alone bears the risk.
• Do not make arbitrary changes or modifications to the machine. The manufacturer will not be liable for modifications made at the ma-
chine on your own and damages resulting thereof. EC declaration of conformity and the mark CE will be invalidated, if you make changes
at the machine or at the individual components.
• Do not override or bypass electrical or mechanical interlock devices.
• The machine is to be used only by authorized and instructed persons. The responsibilities on operating the machine have to be strictly
laid down and observed so that there are no unclear competences regarding safety aspects.
• Vent holes serve for air circulation to protect the machine from overheating. Make sure that the holes are not covered.
• Do not expose fingers or other parts of the body to moving, rotating or cutting devices such as for instance between upper and lower
trimmer knives.
• Always locate the equipment on a solid support surface with adequate strength tor the weight of the machine.

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 TABLE OF CONTENTS
1 Installation procedure.................................................... 1-1
2 Preventive Maintenance (PM)........................................ 2-1
3 Repairs and Adjustments (REP and ADJ)..................... 3-1
4 Troubleshooting (RAP)................................................... 4-1
5 Service tables (GP)......................................................... 5-1
6 Detailed Description....................................................... 6-1
7 Specifications.................................................................. 7-1
8 Wiring............................................................................... 8-1
9 Booklet Quality (BQ)....................................................... 9-1

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 1.6 CST installation
1 INSTALLATION PROCEDURE 1.6.1 Accessory check.................................................................................... 1-40
Contents 1.6.2 Installation procedure............................................................................ 1-41

1.1 Unpacking Instruction 1.6.3 Docking CST with AF602....................................................................... 1-43

1.1.1 AF602/VF602 Feeder.............................................................................. 1-3 1.6.4 Docking CST with ACF510.................................................................... 1-44

1.1.2 CST Module............................................................................................ 1-7

1.7 CR500 installation
1.1.3 CR500 creaser........................................................................................ 1-14
1.7.1 Accessory check.................................................................................... 1-45
1.1.4 BM350 / BM500 Booklet Maker............................................................. 1-19
1.7.2 Height adjustment.................................................................................. 1-45
1.1.5 SquareFold Module................................................................................ 1-22
1.7.3 CR500 to AF602/VF602.......................................................................... 1-45
1.1.6 Trimmer Module..................................................................................... 1-24
1.7.5 CR500 to ACF510................................................................................... 1-46
1.1.7 BST 4000-1 Belt Stacker Module.......................................................... 1-26
1.7.4 Removal of Front Cover........................................................................ 1-46

1.2 Installation Requirements 1.7.6 Adjustment............................................................................................. 1-47

1.2.1 Minimum Space Requirements............................................................. 1-28 1.7.7 When docking CR500 To AF602/VF602................................................ 1-47

1.2.2 Power Requirements............................................................................. 1-29 1.7.8 When docking CR500 To ACF510......................................................... 1-48

1.2.3 Pre Installation Information................................................................... 1-29 1.7.9 Cables and cable protector................................................................... 1-49

1.2.4 Tools........................................................................................................ 1-29 1.7.10 Downsteam docking.............................................................................. 1-49

1.3 Installation Precautions 1.8 BM500 Upgrade kit

1.8.1 Installation procedure............................................................................ 1-50
1.4 AF602/VF602 Installation
1.4.1 Accessory check.................................................................................... 1-31 1.9 BM500 Installation
1.4.2 Removal of covers................................................................................. 1-32 1.9.1 Accessory Check................................................................................... 1-51

1.4.3 Height adjustment.................................................................................. 1-33 1.9.2 BM500 Installation procedure............................................................... 1-52

1.4.4 Wide paper supports (VF602 only)....................................................... 1-33

1.10 Square Fold Module installation
1.4.5 Connectors............................................................................................. 1-34
1.10.1 Accessory Check................................................................................... 1-54
1.4.6 Re-mounting covers.............................................................................. 1-34
1.10.2 Installation procedure............................................................................ 1-54
1.4.7 Calibration.............................................................................................. 1-34
1.4.8 Downstream docking to BM.................................................................. 1-34 1.11 Trimmer Module installation
1.11.1 Accessory Check................................................................................... 1-57
1.5 ACF510 installation 1.11.2 Installation procedure, Trimmer to Square Fold................................. 1-57
1.5.1 Installation of Base 11400008 for ACF510........................................... 1-35
1.11.3 Installation procedure, Trimmer to Booklet Maker............................. 1-59
1.5.2 Installation of ACF510............................................................................ 1-38

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1.12 Belt Stacker installation

1.13 BST4000-1 Belt Stacker installation

1.14 Cables, plugs and jumpers

1.14.1 Basic rules.............................................................................................. 1-68
1.14.2 Example of a stand-alone Booklet Maker ........................................... 1-68
1.14.3 Example of a complete system............................................................. 1-69
1.14.4 Connecting BST4000-1 Belt Stacker.................................................... 1-70
1.14.5 main power cord, BM500 Booklet Maker............................................. 1-72
1.14.6 main power cord, Rotate Crease Trim Module.................................... 1-72
1.14.7 main power cord, BST4000-1 Belt Stacker Module............................. 1-72

1.15 After switching on the power

1.15.1 Setting NVM value for the Trimmer...................................................... 1-73
1.15.2 Checking software versions................................................................. 1-73
1.15.3 Performing a self diagnostic................................................................. 1-74

1.16 Checking the installation

1.16.1 System alignment.................................................................................. 1-75
1.16.2 Adjusting/checking the CST bleed trim............................................... 1-78
1.16.3 Checking the CST crease...................................................................... 1-79
1.16.4 Checking the CR.................................................................................... 1-80
1.17.1 Checking the Booklet Maker................................................................. 1-80
1.16.5 Checking the Square Fold..................................................................... 1-81
1.16.6 Checking the Trimmer........................................................................... 1-81

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1.1 UNPACKING INSTRUCTION [2] Remove packaging foam and plastic wrap

1.1.1 AF602/VF602 FEEDER

[1] Remove packaging foam

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1-3
[3] Remove electronics [4] Remove rear cover

Rear Cover Front Cover

[C]

[B]

[A]

1. Loosen screw [A]

2. Lift up cover [B]
3. Tilt out top [C]
4. Remove cover

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[5] Remove front cover [6a] Place packaging foam as shown
[D]
[E]

[6b] Place unpacking ramp as shown

[F]

1. Unlock the latches to open the bins by following steps 2-4

2. Cut red tie wrap [D] (transport protection)
3. Lift the latch [E] and push in the bin
4. Repeat on second bin
5. Open the door [F]
6. Lift and remove front cover

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[7a] Lower wheels (x4) [8] Stand on edge of ramp to stabilize; carefully roll
unit down ramp

[7b] Remove packaging supports

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1.1.2 CST MODULE

[C]

CAUTION:
Ensure that the waste box is saved.

[B]

[D]

[A]

1. Remove the straps [A] 3. Remove the Waste Box and ensure it is saved [C].
2. Remove the lid [B]. 4. Remove the Ramp Support [D] .

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 [E]

[G]

[F]

5. Remove the Protection Foam Blocks (x2) [E]. 7. Remove from the Corners the Protection Foam Blocks (x4) [G].
6. Remove Ramp Support Foam (x2) [F].

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 [H]

[K]

[I]

[L]

[J]

8. Remove the Paper Box [H]. 11. Open the bottom corners of the box [K].
9. Remove the Plastic Cover [I]. 12. Remove the Protection Foam [L].
10. Remove Accessories Box [J]
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 [M] [N]

13. Open Top Cover and remove two screws securing Front Cover [M]. 15. Remove two screws securing the Rear Cover [N].

14. Lift Front Cover and remove. 16. Lift Rear Cover and remove.

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 [O]

17. Retrieve the 24mm open wrench [O] from behind the Booklet Maker
Rear Cover.

44mm/
1.75”

WARNING:
Two persons are required to remove the foam blocks.

18. Adjust the height of the casters on the CST to 44mm (1.75”). 19. Pull out the foam blocks (x2) underneath the CST.

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 [P] [D]

20. Mount Ramp Support Foam according to picture [P]. 21. Place Ramp [D] as illustrated.

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 [Q]

WARNING:
Two persons are required to carefully roll the CST off the pallet.

22. Carefully roll CST off the pallet. 23. Remove material packed inside the CST [Q].

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1.1.3 CR500 CREASER

[B] [C]

[A] [D]

[E]

1. Remove straps [A] 3. Remove instructions [C] and ramp board [D].
2. Remove lid [B]. 4. Remove protective foam block (x1) [E].

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 [J]

[F]

[I]
[G]

[H]

[K]

1. Remove protective foam block (x4) [F].

2. Remove ramp support foam (x2) [G]. 4. Remove accessories box [I] and protective card board boxes (x2) [J].
3. Remove card board sleeve [H]. 5. Remove protective foam blocks (x2) [K] .

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 [L]

[N]
[O]

[M]

1. Plastic bag [L] is secured with tape at top of machine. 3. Open bottom corners [N].
2. Pull down plastic bag and remove silica gel (desiccant) bags [M]. 4. Note position (inside front and rear cover) of board reinforced foam
blocks under machine (x2) [O].

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 1
1
2 [L]
2

1 1
[O]
2
2

1. Tilt machine and remove first board reinforced foam block (x1) [O].
2. Tilt machine other way and remove second board reinforced foam 3. Tilt machine and move plastic bag [L] in under machine.
block (x1) [O]. 4. Tilt machine other way and remove and remove plastic bag [L].

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 [G]

[G]

1. Install ramp support foam (x2) [G] 3. Roll machine off of pallet.
2. Install ramp board [D].

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1.1.4 BM350 / BM500 BOOKLET MAKER

1. Remove lid. 3. Remove Ramp.

2. Remove box containing accessories. 4. Remove remove Ramp support (x2).

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5. Remove card board tubes (x2). 7. Remove card board tubes (x2), foam (x2) and plastic cover.

6. Remove box sides. 8. Remove bubble wrap from stacker.

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9. Carefully pull out the foam blocks (x2) from underneath the Booklet
Maker.
11. Place Ramp on Ramp support according to picture.
WARNING: 12. Carefully roll Booklet Maker off the pallet.
Two persons are required to remove the foam blocks.

10. Mount Ramp Support according to picture.

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1.1.5 SQUAREFOLD MODULE

1. Remove straps. 3. Remove foam.

2. Remove lid. 4. Remove box sides.

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5. Remove plastic cover. 7. Remove accessories.

6. Tilt the unit to upright position.

WARNING:
Two persons are required to tilt the unit to the upright position.

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1.1.6 TRIMMER MODULE

1. Remove straps. 3. Remove foam.

2. Remove lid. 4. Remove box sides.

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5. Remove plastic cover.

7. Remove accessories from inside the trim bin.

6. Tilt the unit to upright position.

WARNING:
Two persons are required to tilt the Trimmer to the upright position.

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1.1.7 BST 4000-1 BELT STACKER MODULE

1. 3.

2. 4.

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5. 7.

6. 8.

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1.2 INSTALLATION REQUIREMENTS
1.2.1 MINIMUM SPACE REQUIREMENTS

Ensure that the minimum required floor space is available for the system
that you are about to install (Figure 1).

The optional high capacity Belt Stacker BST4000-1 can be placed either in-line or angled to
the Booklet Making system.

The BST4000-1 measures 1730x440mm / 68x17”.

NOTE:
BM500 Upgrade kit and Plockmatic Cover Feeder does not impact floor space requirements.

105 mm
550 mm
90 mm

22”

4”
3.5”

1835 mm

1990 mm
860 mm
750 mm

700 mm

33.8”

72.2”

78.3”
29.5”

27.5”
400 mm
16”

420-630 mm 360 mm 360 mm 850 mm 530 mm 710 mm

17-26” 14” 14” 33.5” 21” 28”

2700-2910 mm
106.7-114.6”

Plockmatic BM500 Booklet Maker floor plan

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1.2.2 POWER REQUIREMENTS 1.2.4 TOOLS

1. Ensure that a power outlet is available nearby the system, To complete installation, following tools are needed:
fused to withstand the system’s combined rated current.
The current consumption can be seen on the machine labels. Supplied with the Booklet Maker, located behind rear cover:
Example: if the machine label says “100-240 V, 4-2 A” • 24 mm spanner/box or open end wrench.
then the rated current is 4 A at 100V and 2 A at 230V. • 17 mm spanner/box or open end wrench.
2. Make sure to route power cords to avoid people from tripping on them. • Torx T20 driver, min 115mm (4.5”) long.
3. Avoid using excessively long extension cords. • USB to RS-232 adapter, Software download cable and USB stick.
Not supplied:
1.2.3 PRE INSTALLATION INFORMATION • 7mm spanner/box or open end wrench
You are about to install one or more of the following modules: • 8mm spanner/box or open end wrench or hex nut driver
• Flat blade screwdriver size 4 or 5
• AF602 Feeder
• VF602 Feeder
• CST500 Creaser Side Trimmer
• CR500 Creaser Module
• BM350 Booklet Maker
• BM500 Upgrade Kit
spanner/box or open end
• SQF500 Square Fold Module wrench
• FTR500 Trim Module
• BST4000-1 Belt Stacker Module

This installation instruction covers all of the above in the following order: hexnut driver

• BM Rotate Crease Trim Module (or CR500 Creaser Module)

• BM500 Upgrade Kit
• BM350/BM500 Booklet Maker
Torx T20 screwdriver
• BM Book Fold Module
• Trim Module - either attached to BM Book Fold Module or attached
Location of tools
directly to Booklet Maker without a Square Fold in between Tools needed
supplied. Actual look
• BST4000-1 Belt Stacker Module may differ.
• Installation of the rail (main rail part and the extensions) is described
as the installation of the modules progresses.
If you do not install a certain module or option, just skip to the next section.
If you were not present during unpacking, check the unpacking instruction
to make sure all boxes and parts supplied with each modules and op- NOTE:
tions are present and ensure that all packaging material, strech film etc. is Check the Booklet Maker installation section for how to remove the rear
removed from the modules. cover in order to obtain the supplied tools.

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1.3 INSTALLATION PRECAUTIONS
CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communication problems. Failure to use proper ESD proce-
dures will cause damage to electronic components (example: PCBs). ESD
problems can be minimized by maintaining all machine ground connec-
tions, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs. Failure to use ESD protec-
tion is likely to result in a PCB failure.

WARNING:
If installation/s to be performed are additions to an existing, already in-
stalled system, turn off the main power Switch/es and disconnect the main
power Cord/s before disconnecting, removing or replacing any electrical
components. Do not connect power cord/s unless instructed.

WARNING:
To avoid hazardous situations like for instance electric shock or danger
while exposed to moving, rotating or cutting devices, exercise extreme
care when operating modules with covers, guards or protection removed
or when electrical or mechanical interlock devices are overrided or by-
passed.

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1.4 AF602/VF602 INSTALLATION
If you don’t have an AF602/VF602, proceed to next section. 1 2 3

1.4.1 ACCESSORY CHECK

Item Qty Description Part no* 4 5 6

1 1 Power Cord EUR/IEC-C13 4,5m 87156
2 1 Power Cord USA/IEC-C13 AWG18 4,5m 87157
3 1 Power Cord UK/IEC-C13 4,5m 88530
4 1 Power Cord AUS/IEC-C13 4,5m 60122
5 1 Power Cord Switzerland/IEC-C13 4,5m 93464
7 8 9
6 1 Power Cord Denmark/IEC-C13 4,5m 93465
7 1 Termination Plug, Female 140226
8 1 Communication Cable CAN 1,6m 450239
9 1 Spanner 24mm 95196
10 1 DSD Calibration Strip 76329 10 11 12
11 1 USB to STM32F Dongle 960-108436
12 1 US DSD Calibration Strip 125-108536
13 1 Docking bracket 125-107845
2 Screw M4x10 99471
14
14 1 Software Loading Adapter 16p to 8p 960-110000 13
15 4 Wide paper support 131-110182
16 1 Female Docking Bracket 122-109998
(for docking to BM)
17 2 Screws M6S M6x12 washer o18x1,6 99400
*Part numbers are subject to change. 15 16 17
For part number information, see AF602/VF602 Parts Catalog

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1.4.2 REMOVAL OF COVERS NOTE! Make sure that there is no paper in bin.
With back cover off there is a tilt risk at fully [D]
loaded bin.
Front cover
Rear cover

[C]

[B]

[E]

[A]

Rear Cover
1. Loosen screw [A] Front Cover
2. Lift up cover [B]
1. Lift the latch [D] (x2) and push in the bins
3. Tilt out top [C]
2. Open the front door [E]
4. Remove cover
3. Lift and remove front cover

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1.4.3 HEIGHT ADJUSTMENT 1.4.4 WIDE PAPER SUPPORTS (VF602 ONLY)

1. Place the machine where it will be operating. 1. Open up upper tray

2. Using the 24mm spanner [A] located inside the back cover, adjust 2. Push the side guide in to gain access to the Paper Support Holder [A]
the height of the machine to 100 mm between chassis and floor.
3. Place the Paper Supports [B] in the Paper Support Holder
Adjust the casters at an even rate, i.e. do not rotate a single caster
4. Repeat the procedure for the lower tray
more than 2 full rotations without adjusting the other casters to
level the machine.
3. Keep the height of the left front wheel and adjust the other three to
level the machine, using a water level.
4. Lock the jam nuts [B] (x4) against the chassis.

[B]

[A]

[A]

[B]
100 mm

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1.4.5 CONNECTORS 1.4.8 DOWNSTREAM DOCKING TO BM
If the feeder is going to be installed directly to the Booklet maker, install
1. Connect the power cord to connector [A]
the female Docking Bracket on the downstream side of the feeder. Position
2. Connect the termination plug to Connector [B] it sideways as shown in picture below.
3. Connect the COM-cable to connector [C]

[A] [B] [C]

1.4.6 RE-MOUNTING COVERS

Re-mount the covers by reversing the cover removal procedures.

1.4.7 CALIBRATION
After system integration, use accessory items 10 and 12 to calibrate
the AF602/VF602. For detailed calibration procedures, refer to the
AF602/VF602 Feeder Settings sections of the Operators Manual.

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1.5 ACF510 INSTALLATION
If you don’t have an ACF, proceed to section 1.6.

1.5.1 INSTALLATION OF BASE 11400008 FOR ACF510

Base Accessory Check

Item Q’ty Description Part no
B
A A 2 Caster with brake 88464
B 2 Caster, fixed 87126
C 4 Screw M10x40 99247
D 4 Screw M10x30 99194
C D
E 8 Washer 11x40x4 97174
F 4 Washer 10.5x22x2 97041
G 4 Serrated washer 10.5 97013
H 4 Nut M10 98015
J J 4 Screw M6x10 99015
E L
K 2 Nut M6 98001
F K L 2 Washer 6.4x12x1.5 97006
M
M 2 Screw M6x30 99023
G
N 1 Base
H P 1 Base support 114-103461
R 1 Docking Interface 114-108743
P
N

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Installing Casters on ACF510 Base

N Item Q’y Description Part no

A 2 Caster with brake 88464
B 2 Caster, fixed 87126
C 4 Screw M10x40 99247
E 8 Washer 11x40x4 97174
C
C F 4 Washer 10.5x22x2 97041
F G 4 Serrated washer 10.5 97013
F
E E H 4 Nut M10 98015
E E N 1 Base
A
B

H
H
MOUNTING DIRECTION
WARNING
Fixed castors have to be mount-
ed in direction as shown.

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Installing Base Support Installing Feeder ACF510 onto Base

To meet safety requirements the base to model 510 has a tip protection.

WARNING
N The Feeder is heavy. Ob-
serve and follow local work
safety regulations while lifting
J Feeder.

Place the Feeder onto the

Base and secure it with
screws [M] and washers [L].
K

M L
P

Item Q’ty Description Part no

J 2 Screw M6x10 99015
K 2 Nut M6 98001 Item Q’ty Description Part no
N 1 Base L 2 Washer 6.4x12x1.5 97006
P 1 Base support 114-103461 M 2 Screw M6x30 99023

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1.5.2 INSTALLATION OF ACF510

If you don’t have an ACF510, go to next section

ACF510 Accessory Check

Item Q´ty Description Part no*

A ** Power Cord EUR 87156
A B C D
A ** Power Cord USA/Japan 87157
A ** Power Cord AUS/CHN 60122
A ** Power Cord UK 88530
E F
A ** Power cord Swiss 93464
A ** Power Cord Danish 93465
B 1 Termination Plug, male 140227
C 1 Termination Plug, female 140226
D 1 Calibration strip 76329
E 1 Logotype Morgana ACF510 114-107970
F 1 Logotype Plockmatic ACF510 114-102695
G 1 Communication Cable 450239

*Part numbers are subject to change.

**Depending on market.

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Tapping the transformer 3. Move lines [4] and [5] to required voltage.

The Collator/Feeder is delivered tapped for 230 Vac (EUR) or 120 Vac
(U.S). If there is need to tap it differently, proceed as follows.

1. Loosen the four screws [1] and remove cover.

2. Loosen screw [2] two turns, the screw is not to be removed, just
loosen. Press down and remove cover [3].

1
2

4 5

4. When done, mount the covers and screws back on the machine in
reverse order as step 1 and 2.

Install Termination Plug (item C previous page) as shown.

The Communication Cable (item G previous page) goes to the next down-
stream module.

1
G
C
3

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1.6 CST INSTALLATION
If you don’t have a CST, proceed to next section. K L

1.6.1 ACCESSORY CHECK

B
A Item Q´ty Description Part no*
A 1 Power cord EUR 87156
A 1 Power Cord USA 87157
A 1 Power Cord AUS/CHN 60122
E A 1 Power Cord GBR 88530
A 1 Power Cord Swiss 93464
A 1 Power Cord Danish 93465
B 1 Communication Cable 450239
D 1 Infeed Docking Bracket (for docking to 122-107005
D ACF510)
E 1 Feeler Gauge 0,5mm 122-108011

F F 1 Cable protector 890700

G 1 Intermediate Cover (for docking to ACF510) 122-108737
H 4 Nut M4 (for installing item G) 98055
I 2 Nut M6 98056
G
J 2 Screw M4x10 (for installing item D) 99399
K 1 Female Docking Bracket 122-109998
(for docking to BM)
L 2 Screws M6S M6x12 washer o18x1,6 99400

* Part numbers are subject to change.

H I J
Please refer to Spare Part Manual for correct numbers.

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1.6.2 INSTALLATION PROCEDURE

1. Remove rear cover by loosening screws 1. 3. Adjust height to match upstreams device.
Lift cover over edge 2. As a general rule, the exit path of the upstream device should be
slightly shifted down with respect to to the infeed path of the CST
1 2 (see picture below).

2. Remove front cover by loosening screws 3.

Open Slide Door slightly and lift/remove front cover 4.

Plockmatic BM500 system 20 May 2019 1. Installation Procedure

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4. Install female Docking Bracket on the downstream side of the CST.
Position it sideways as shown in picture below.

Intentionally blank.

Plockmatic BM500 system 20 May 2019 1. Installation Procedure

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1.6.3 DOCKING CST WITH AF602

If you don’t have an AF602, proceed to next section. 2.Push CST and AF602 together and lock them together with the indicated
latch.
Note: the docking bracket should be already installed on the machine, if
not, perform step below.
1.Remove Docking Plate A from AF602
(open AF602 door and pull latch shown in picture to the right) and mount it
to CST with two M4x10 screws B.

3.Use a spirit level (included in Booklet

Maker) to make sure that both AF602 and
CST are fully leveled in both directions.

4.Connect the Communication Cable be-

tween Feeder and CST.

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1.6.4 DOCKING CST WITH ACF510

If you don’t have an ACF510, proceed to next section.

1.Install Intermediate Cover G with nuts H (4x). 3.Make sure the door on ACF510 can be opened, see picture.

G
6±3mm

H 4.Connect the Communication Cable between Feeder and CST.

2.Install Infeed Docking Bracket D with screws J.

Ensure that screws J initially are positioned in the middle of the slot
before tightening.

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1.7 CR500 INSTALLATION
1.7.2 HEIGHT ADJUSTMENT
If you don’t have a CR500, proceed to next section.
Depending of what upstream device the CR500 is installed to, height ad-
1.7.1 ACCESSORY CHECK justment may be necessary.

1.7.3 CR500 TO AF602/VF602

F Remove docking studs [A] from AF602 Exit side.

E

A B C D

Item Q´ty Description Part no*

A 1 Docking, CR to ACF510** 127-108927
A
2 Screw M4x10 99399
B 1 Communication Cable 450239
C 1 Cable protector 890700
Align AF602 exit and CR entry in height
2 Screw M5x10 99467
D 1 Power cord EUR 87156
1 Power Cord USA 87157
1 Power Cord AUS/CHN 60122
1 Power Cord GBR 88530
1 Power Cord Swiss 93464 Dock the units an lock latch from
inside AF602 door.
1 Power Cord Danish 93465
E 1 Female Docking Bracket 122-109998
(for docking to BM)
F 2 Screws M6S M6x12 washer o18x1,6 99400

* Part numbers are subject to change. Please refer to Spare Part Manual for correct numbers.
** Configuration with ACF510 is not yet launched (may 2016)

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1.7.5 CR500 TO ACF510 1.7.4 REMOVAL OF FRONT COVER

Height adjustment is correct when the door on the ACF510 [A] can be
opened without touching jam clearance baffle [B] in CR500.
1. Loosen screws [A]
A B
2. Lift off front cover [B]
A

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1.7.6 ADJUSTMENT 1.7.7 WHEN DOCKING CR500 TO AF602/VF602

1. Loosen nuts (x4) [A] and turn casters(x4) [B] to adjust height. 1. Make sure the gas spring is installed to the frontmost hole in the
bracket [A].
NOTE: A
Do not turn each nut more than 2 full revolutions before adjusting the other
nuts. Each turn of a nut equals to a 1,5 mm (1/16”) travel.

A B

Note: the docking bracket should be already installed on the machine, if

not, perform step below.
2. The docking bracket for docking to AF602/VF602 is not symmetrical. It
should be installed with the smaller distance [B] towards the operator
side.

B C
B<C

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3. Pull and lift at [D] to unlock docking device on AF602/VF602. 2. Install the docking bracket as illustrated using the enclosed screws [B].
Center screws in oblong holes in bracket.

D
4. Roll CR500 up to AF602/VF602, dock and
lock docking device.
3. Pull locking device on docking bracket [C].

1.7.8 WHEN DOCKING CR500 TO ACF510

1. Make sure the gas spring is installed to the rearmost hole in the
bracket [A]. 4. Roll CR500 up to ACF510, dock and lock by pushing the locking de-
vice [C].
A

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1.7.9 CABLES AND CABLE PROTECTOR 1.7.10 DOWNSTEAM DOCKING
1. Install cable protector [A] using screws [B]. Install female Docking Bracket on the downstream side of the CR500.
2. Connect communication cable [C] to upstream device i.e. AF602/ Position it sideways as shown in picture below.
VF602/ACF510.
3. Connect communication cable [D] to downstream device i.e. BM500.
4. Connect power cable [E] to outlet.

C E D

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1.8 BM500 UPGRADE KIT 1.8.1 INSTALLATION PROCEDURE

• This section describes how to install the BM500 Upgrade Kit to a

BM350 Booklet Maker. 1. Loosen screws [D].
• If you don’t have this option, go to next section. 2. Remove screws [E].

ACCESSORY CHECK

D E

3. Tilt the front cover outward and then lift it off the stud on the right hand
side.

F G

Check the quantity and condition of the accessories in the box against the
following list:

Description Q’ty
Machine logo, Plockmatic 1
Machine logo, Morgana 1 4. Plug in connector [F].
Active logo hardware 1 5. Install and fasten the PCB with screws [G].
6. Reinstall Front Cover.
7. Attach logotype.
8. The machine is now ready to use.

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1.9 BM500 INSTALLATION
1.9.1 ACCESSORY CHECK
Item Q´ty Description Part no*
A 1 Power cord EUR 87156
A B C D E A 1 Power Cord USA 93001
A 1 Power Cord AUS/CHN 60122
A 1 Power Cord GBR 88530
A 1 Power Cord Swiss 93464
A 1 Power Cord Danish 93465
B 1 Termination Plug, female 140226
C 1 Termination Plug, male 140227
D 1 Interlock Jumper 770224
E 1 USB to Serial Converter (inside machine) 93536
F G H J
F 1 Software Download Cable (inside machine) 770010
G 1 Spirit Level 101-102792
H 1 Logotype Plockmatic BM350 102-108279
J 1 Logotype Morgana BM350 102-108278
K 1 Safety Instruction N0001641
L 1 Operator Manual T10200
M 1 Cable protector with screws 890700
M
N 1 Docking Bracket assembly 102-110046

K L
Note: More accessories are found inside machine, see section 1.2.4

Plockmatic 350/500
Booklet Maker System

Operating Instruction
Stapler Folder Reference
N

Read this manual carefully before you use this product and keep it handy for future
reference.
For safety, please follow the instructions in this manual.

Doc no: T10200

Date: 27 March 2015

* Part numbers are subject to change. Please refer to Spare Part Manual
for correct part numbers.

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1.9.2 BM500 INSTALLATION PROCEDURE 1.9.2.2 INSTALLATION TO UPSTREAM UNIT AF602, VF602, CST OR
CR500
1.9.2.1 MANUAL FEED
Install docking bracket [N] on BM with nuts [O] (4x) and [P] (2x).
The Manual Feed Tray is hooked up to the inlet without tools.

When not in use, place it in the holder underneath the inlet.

P
Adjust the lenght of bolts [Q] to protrude about 21mm for docking to
upstream device. Tighten the jam nuts [R] after a successful and straight
docking is achieved.
R
Q

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Roll the Booklet Maker up to upstreams device and release the locking Attach desired logotype in the recess of the front cover.
mechanism. If a height adjustment is necessary, remove the front and rear
cover of the booklet maker.
Adjust the height of the Booklet maker by turning the four nuts [S].
Two on the front side and two on the back side.
Adjust alignment by turning only two of the nuts on either the infeed or exit
side.

S S

Install the Cable Protector [T] and Cable Holders [U]

This is the end of the Booklet Maker installation procedure. Installing con-
nectors and cables and checking of installation will be done later on.

T Continue with next section below.

1.9.2.3 INSTALLATION TO UPSTREAM UNIT ACF510

See T09321A Inst instr Base 510-BM500

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1.10 SQUARE FOLD MODULE INSTALLATION 1.10.2 INSTALLATION PROCEDURE

1.10.1 ACCESSORY CHECK

If you don’t have a SQF, proceed to next section.

[1] [2]

[B] [A]

1. Loosen two screws [A] on the Booklet Maker.

2. Disconnect the Belt Stacker cable [B] from Booklet Maker.
3. Remove belt stacker from the Booklet Maker.
4. Tighten screws [A].
[3] [4]

Check the quantity and condition of the accessories against the following
list:

Description Q’ty
1. Communication cable 1
2. Power cord 1
3. Cable protector with 2 screws 1
4. Cable holder 1

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5. Roll the SquareFolder up to the Booklet Maker.
Purpose is to check alignment top to bottom and height adjustment.

Alignment is correct when the distance between the Booklet Maker

and the SquareFolder is equal top to bottom [C].
[D]
Height adjustment is correct when the top surface of the
Square Folder front cover is at the same height as the
top surface ot the Booklet Maker front cover [D].

If adjustment is necessary, begin with adjusting alignment and con-

tinue with adjusting height.
6. Remove four screws [F] and remove the front cover. [C]
7. Adjust the height of the SquareFolder by turning the four nuts [G].
Two on the front side and two on the back side.
Adjust alignment by turning only two of the nuts on either the infeed or
exit side.

NOTE:
Do not turn each nut more than 2 full revolutions before adjusting the other
nuts.
Each turn of a nut equals to a 1,5 mm (1/16”) travel.

[G]

[F]

Continued on next page

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 8. Reinstall front and rear covers after adjustment.
[H]
9. Dock the Square Folder to the Booklet Maker.
10. Lift the docking latch [H] and secure by tightening two nuts [I].
11. Install the cable protector [J] (two screws) and the cable holder [K] to
the Square Fold.

[I]

This is the end of the SquareFold Module installation procedure.

Installing connectors and cables and checking of installation will be done
later on.

Continue with next section below.

[J]

[K]

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1.11 TRIMMER MODULE INSTALLATION 1.11.2 INSTALLATION PROCEDURE, TRIMMER TO SQUARE FOLD

This section describes how to install a Trimmer to the SquareFolder.

To install the Trimmer directly onto the Booklet Maker,

[B]
proceed to section 1.10.

1.11.1 ACCESSORY CHECK

[1] [2]
[A]

[3] [4] 1. Roll the Trimmer up to the Square Fold.

Purpose is to check alignment top to bottom and height adjustment.
2. Alignment is correct when the distance between the Square Fold and
Check the quantity and condition of the accessories against the following the Trimmer is equal top to bottom [A].
list: Height adjustment is correct when the top surface of the Trimmer front
cover is at the same height as the top surface ot the Square Fold front
Description Q’ty cover [B].
1. Communication cable 1 If adjustment is necessary, begin with adjusting alignment and con-
2. Power cord 1 tinue with adjusting height.
3. Cable protector with 2 screws 1 3. Remove four screws [D] and remove Trimmer front cover.
4. Cable holder 1 4. Adjust the height of the Trimmer by turning the four nuts [E].
Two on the front side and two on the back side.
Adjust alignment by turning only two of the nuts on either the infeed or
exit side.

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 [D]
[F]

NOTE: [G]
Do not turn each nut more than 2 full revolutions before adjusting the other
nuts. Each turn of a nut equals a 1,5 mm (1/16”) travel.

[E]

[H]

[I]
5. Reinstall front and rear covers after adjustment.
6. Dock the Trimmer to the Square Fold.
7. Lift the docking latch [F] and secure by tightening two nuts [G]. This is the end of the Trimmer to Square Fold installation procedure.
8. Install the cable protector [H] (two screws) to the Trimmer and the Installing connectors and cables and checking of installation will be done
cable holder [I] to the Trimmer base. later on.

Continue with section 1.11 to install Belt Stacker

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1.11.3 INSTALLATION PROCEDURE, TRIMMER TO BOOKLET MAKER

[E]

5. Open the Top Cover and remove the two screws holding the docking
studs.
[B] [A]

1. Loosen two nuts [A] on the Booklet Maker.

2. Disconnect the Belt Stacker cable [B] from Booklet Maker.
3. Remove Belt Stacker from the Booklet Maker.
4. Tighten nuts [A].

In order to dock a Trimmer to the Booklet Maker, the docking studs [C] on
the Booklet Maker have to be relocated to the lower holes [D] in the exit
cover.
[C]
[D]

6. Relocate docking studs to the lower holes [D] and tighten the screws.
[D]

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7. Roll the Trimmer up to the Booklet Maker. 8. Remove four screws [I] and remove Trimmer front cover.
Purpose is to check alignment top to bottom and height adjustment.
Alignment is correct when the distance between the Booklet Maker
and the Trimmer is equal top to bottom [F]. Height adjustment is cor-
rect when the top surface of the Trimmer front cover is at the same [I]
height as the top surface ot the Booklet Maker front cover [G].

[G]

[F]
9. Adjust the height of the Trimmer by turning the four nuts [J]. Two on
the front side and two on the back side. Adjust alignment by turning
only two of the nuts on either the infeed or exit side.

NOTE:
Do not turn each nut more than 2 full revolutions before adjusting the other
nuts. Each turn of a nut equals to a 1,5 mm (1/16”) travel.
[J]

If adjustment is necessary, begin with adjusting alignment and con-

tinue with adjusting height.

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 1.12 BELT STACKER INSTALLATION
10. Reinstall front and rear covers after adjustment.
11. Dock the Trimmer to the Booklet Maker.
12. Lift the docking latch [K] and secure by tightening two nuts [L]. 1. Loosen the two screws [O] on the Trimmer or Square Fold.
2. Install the Belt Stacker to the Trimmer and secure by tightening two
screws [O].

[K] [O]

[L]

13. Install the cable protector [M] (two screws) to the Trimmer and the
cable holder [N] to the Trimmer base.

[M]

[N]

This is the end of the Trimmer Module to BM Booklet Maker installation

procedure. Installing connectors and cables and checking of installation
will be done later on.

Continue with next section below.

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1.13 BST4000-1 BELT STACKER INSTALLATION
• This section describes how to install a BST4000-1 Belt Stacker Module.
• If you don’t have this option, go to next section.

1.13.1 INSTALLATION PROCEDURE

x8

2.

1. Locate the orange cable inside the frame, plug in and secure connec-
tor.

3.

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4.

Plockmatic BM500 system 20 May 2019 1. Installation Procedure

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 A A

5. Measure height [A]

A=B

B
B

6. Adjust distance [B] to match height [A]

Plockmatic BM500 system 20 May 2019 1. Installation Procedure

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7. 9.

8.

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10. 12.

11. 13.

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14. Alt. 2

This is the end of the BST4000-1 Belt Stacker installation procedure.

Installing connectors and cables will be done later on.

Continue with next section below.

Alt. 1

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1.14 CABLES, PLUGS AND JUMPERS

1.14.1 BASIC RULES 1.14.2 EXAMPLE OF A STAND-ALONE BOOKLET MAKER

Termination Plugs must always be inserted at each end of the booklet

maker system, even on a stand-alone booklet maker.
The female plug is placed on the first module in a system (e.g. the feeder).
Once you have connected the termination plugs correctly you cannot go
wrong.

Female Male

The communication cables have male

and female plugs.
They shall be connected from module to
module.

The Interlock Jumper must be installed on a Booklet

Maker without Square Fold or Trimmer connected.

The Square Fold and Trimmer modules are

powered from the booklet maker. The black
cables are used for this purpose.

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1.14.3 EXAMPLE OF A COMPLETE SYSTEM

Plockmatic BM500 system 20 May 2019 1. Installation Procedure

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1.14.4 CONNECTING BST4000-1 BELT STACKER

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Plockmatic BM500 system 20 May 2019 1. Installation Procedure
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1.14.5 MAIN POWER CORD, BM500 BOOKLET MAKER 1.14.7 MAIN POWER CORD, BST4000-1 BELT STACKER MODULE

1.14.6 MAIN POWER CORD, ROTATE CREASE TRIM MODULE

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1.15 AFTER SWITCHING ON THE POWER 1.15.2 CHECKING SOFTWARE VERSIONS
This section describes settings and adjustments that could not be done 1. Turn on the power for all units.
before the system was electrically connected and powered on. 2. Press the [Tools] button.
1.15.1 SETTING NVM VALUE FOR THE TRIMMER 3. Press the [Software version] button to to check installed software
version.
4. If needed, download and install latest software according to
procedure described in system service manual.

1. Open Trimmer Top Cover and retrieve the hand written number from
the sticker “NVM value no. 11, Trim zero: XX”. Close Trimmer Top
Cover.
2. Press the [Tools] button and then the [Service mode] button.
3. Key in password 1974 and press the [OK] button.
4. Press the [BM] button.
5. Scroll to “NVM” and press that line.
6. Scroll to “11. BM Knife(Zero)” and press that line.
7. Press the [+] or [-] buttons to enter the value retrieved from the Trim-
mer.
8. Press the [OK] button.
9. Press [Home] button once to go back to Service mode.
10. Press [Exit Service] button to leave Service mode.

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1.15.3 PERFORMING A SELF DIAGNOSTIC
[A]
1. Turn on the power for the Booklet Maker
2. Open the booklet maker top cover.
Put a finger onto the screen and hold it there.
3. Turn on the power for the booklet maker.
4. Close the top cover.
If you keep holding your finger onto the screen
you will get the Service Menu. [B]
Key in password 1974 and press [OK].
5. Press the button for the module to be diagnosed.
6. Press the line “Diagnostics”.
7. Press [Start] button.
8. Press [Home] to go back.
9. Repeat step 6 through 8 until all modules have been diagnosed.
10. On all modules, you should get the message:
Complete!
0 errors found
If you should receive a fault code after performing a
detailed self diagnostic, a service manual and trained technician is
required to solve the problem.
11. Exit diagnostic mode by powering off the system.
12. Reinstall the two staple cartridges and close the top cover.

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1.16 CHECKING THE INSTALLATION
This section describes how to perform tests to verify that the system is
properly installed and that the output from the system equals to the specifi-
cations. If booklet quality issues should be found, a trained service techni-
cian and a service manual is needed. Make a note of this issue and pass it
on to a trained service technician.

Depending on how you system is configurated, some settings may not be [B]
applicable and tests may be ignored. For example - if you do not have a
CST installed, setting bleed trim is not possible and test involving the CST
can be ignored. Continue with the next section.

• System alignment • Checking Square Fold

• Checking CST bleed trim • Checking Trimmer
• Checking CST crease
• Checking Booklet Maker
2. Open the Booklet maker top cover and install an interlock cheater [B] to
be able to run the Booklet maker with the top cover open.
1.16.1 SYSTEM ALIGNMENT Set up the Booklet maker to:

WARNING: Input Sheet Size: SRA3 or 12x18”

To avoid hazardous situations, please read and follow the safety informa- Face Trim: 0,0mm or 0.000”
tion in section 1.3 in this manual. Bleed Trim: 0,0mm or 0.000”
Staple: ON
Cover: OFF
Book Fold: OFF
Fold position: AUTO
Crease: Status: OFF, Offset: -
3. Using 80 gsm/20 lb Bond sheets, send five sets of 2 sheets of
SRA3/12x18” 80 gsm/20 lb Bond (2 sheets of SRA3/12x18” equals a
booklet containing 8 pages of SRA4/12x9”) to the Booklet Maker system.
4. Check for the correct feeding of the sheets in the CST and the Booklet
[A] Maker.

NOTE:
It is critical that you use SRA3/12x18” sheets during alignment.
Use of smaller paper sizes during alignment can cause SRA3/12x18”
to have infeed issues.
1. Open the CST top cover and install an interlock cheater [A] to be able
to run the CST with the top cover open.
Plockmatic BM500 system 20 May 2019 1. Installation Procedure
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 sheet (non-operator)
[C] edge

[D]
[F]

[G]

sheet (operator) edge

5. The sheets edges (on operator side) [C] should enter the CST at the
corresponding mark on the label [D] ± 3mm (0.12”). If not, the infeed
docking bracket on the CST must be adjusted.

7. The sheets [F] should enter the Booklet Maker centered between
the side guides [G]. If not, the position of the Booklet Maker must be
adjusted.

[E]

6. Loosen screws [E] and adjust Infeed Docking Bracket on the CST to
achieve tolerance.
Repeat step 3 to 6 until alignment is correct.

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 • Undock the Booklet Maker from the upstreams device

[H]

• Adjust the docking bracket by loosening the two nuts [H] and sliding
the alignment pin in desired direction.

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1.16.2 ADJUSTING/CHECKING THE CST BLEED TRIM 12. Compare operator trim strip lead edge and trail edge. Repeat step 11
- 12 until OB trim strip have the same width in both lead and trail edge.
WARNING: Trimmer cut is now parallell to registration edge (on operator side).
To avoid hazardous situations, please read and follow the safety informa- 13. Check that the actual sheet width corresponds to sheet width set in
tion in section 1.3 in this manual. [Custom booklet size] ±0.5mm/0.02”.
If not, this is a Booklet Quality issue. Not an Installation issue.
Purpose is to adjust CST bleed trimmer registration angle in order to en- To correct this, a trained service technician and a service manual is
sure a parallell cut. needed. Make a note of this issue and pass it on to a trained service
technician.
1. Note indication on reference scale [A]. Turn adjustment screw [B]
counter clockwise 1,5 - 2 turns. Make sure adjustment is reflected on
reference scale [A]. If not, push at [C]. Purpose is to make operator
trim strip lead edge wider than trail edge and also take up any slack.
2. In the UI, press [Finished Booklet Size].
3. Press [Custom Booklet Size].
4. Press [Edit].
5. Press [Clear] to clear width setting.
6. Set width to 297,0mm/11.000” and press [OK]. You can see that you
will recieve booklets 297mm/11” tall.
7. Press [OK]. You can now see that the SRA3/12x11” sheets will have a
Bleed Trim of 11,5mm/0.500” on each side. [A]
Booklet maker setup should read: [C]
Input Sheet Size: SRA3 or 12x18”
Face Trim: 0,0mm or 0.000” [B]
Bleed Trim: 11,5mm or 0.500”
Staple: ON non-operator trim strip
Cover: OFF
Book Fold: OFF Lead Trail
Fold position: AUTO edge edge
Crease: Status: OFF, Offset: - Turn adjustment screw
8. Make sure that you after run can identify lead edge of operator trim clockwise to remedy Process direction
strip from CST. Marking sheets is one solution. this misalignment
9. Using 80 gsm/20 lb Bond sheets, send five sets of 2 sheet
SRA3/12x18” (2 sheets of SRA3/12x18” equals a booklet containing 8
pages) to the Booklet Maker system. Operator side trim strip
10. Compare Operator trim strip lead edge and trail edge. Operator trim
strip lead edge should now be wider than trail edge. NOTE:
If not, repeat step 1, 8 - 10. Sheets may show wrinkles in the process direction if adjustment is set too
11. Turn adjustment screw [B] clockwise and send five more sets of 2 tight.
sheet SRA3/12x18”. Turn adjustment screw counter clockwise until wrinkles disappear.

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1.16.3 CHECKING THE CST CREASE

WARNING:
To avoid hazardous situations, please read and follow the safety informa- Reference
tion in section 1.3 in this manual. marks

1. In the UI, press [Crease].

2. Press [ON Fine].
3. Press [OK].
Booklet maker setup should read: [B]
Input Sheet Size: SRA3 or 12x18”
Face Trim: 0,0mm or 0.000”
Bleed Trim: 11,5mm or 0.500”
Staple: ON [A]
Cover: OFF
Book Fold: OFF
Fold position: AUTO
Crease: Status: ON, Offset: 0,0mm/0.000”
4. Using 120 gsm/32 lb Bond sheets,
send five sets of 1 sheet SRA3/12x18” to the Booklet Maker system.
5. Repeat check selecting [ON Coarse] in the Crease settings and
using sheets of 220 gsm/80 lb Cover.
6. Check that crease is perpendicular to the registration (Operator side)
edge.

If not, loosen star shaped knob [A].

Turn knurled excenter [B] to move reference mark in desired direction.
Tighten star shaped knob [A]. Process direction Lower the operator side of the creaser to
remedy the misalignment
Repeat step 4 - 6 until crease is perpendicular to registration (Operator
side) edge.
7. Check that the distance from the lead edge to the crease is
half the sheet length according to [Input Sheet Size]
i.e. 225mm/9” ±0.5mm/0.02” on both operator and non-operator side
edge.

If not, this is a Booklet Quality issue. Not an Installation issue.

To correct this, a trained service technician and a service manual is
needed.
Make a note of this issue and pass it on to a trained service technician.

Plockmatic BM500 system 20 May 2019 1. Installation Procedure

1-79
1.16.4 CHECKING THE CR Staple: ON
Cover: OFF
1. Run test jobs according to below table, save all sheets. Book Fold: OFF
Fold position: AUTO
Paper # of # of Paper Size Image Crease Crease SQF
Crease: Status: OFF, Offset: 0,0mm/0.000”
Size sheets sets Weight Offset Tool Offset
6. Using 80 gsm/20 lb Bond sheets, send five sets of 2 sheet
SRA3 / 1 10 120 gsm SRA3T / 0 Fine 0 Auto
12x18 12x18T SRA3/12x18” (2 sheets of SRA3/12x18” equals a booklet containing 8
pages) to the Booklet Maker system.
SRA3 / 1 10 220 gsm SRA3T / 0 Coarse 0 Auto
12x18 12x18T 7. Using 80 gsm/20 lb Bond sheets, send five sets of 20 sheet A3/11x17”
(20 sheets of A3/11x17” equals a booklet containing 80 pages) to the
2. Inspect the output and measure distances [A], [B] and [C]. Booklet Maker system.
• Distance [B] shall equal half the actual paper setting set in the Book- 8. Set up the Booklet maker to:
let Maker < 0,5mm. Input Sheet Size: SRA4 or 12x18”
• Distances [A] and [B] shall not differ from each other more than Face Trim: 0,0mm or 0.000”
0,5mm. Bleed Trim: 0,0mm or 0.000”
non operator side Staple: ON
A Cover: OFF
Book Fold: OFF
Fold position: AUTO
lead trail
Crease: Status: OFF, Offset: 0,0mm/0.000”
edge B feed direction edge 9. Using 80 gsm/20 lb Bond sheets, send five sets of 2 sheet A4/8.5x11”
(2 sheets of A4/8.5x11” equals a booklet containing 8 pages) to the
Booklet Maker system.
C 10. Using 80 gsm/20 lb Bond sheets, send five sets of 20 sheet A4/8.5x11”
operator side (20 sheets of A4/8.5x11” equals a booklet containing 80 pages) to the
Booklet Maker system.
To correct any issues go to CR2000 service manual, Booklet Quality
Section. 11. Check that the booklets are stapled and folded at the middle of the
sheets.
3. Re-run jobs jobs after adjustments and check output quality.
If not, this is a Booklet Quality issue. Not an Installation issue.
1.17.1 CHECKING THE BOOKLET MAKER
To correct this issue, a trained service technician and a service manual
is needed. Make a note of this issue and pass it on to a trained service
WARNING:
technician.
To avoid hazardous situations, please read and follow the safety informa-
tion in section 1.3 in this manual. 12. Remove the cheater and put it back in its resting position at the upper
left of the non-operator frame of the Booklet Maker.
4. Open the Booklet maker top cover and install an interlock cheater to
be able to run the Booklet maker with the top cover open.
5. Set up the Booklet maker to:
Input Sheet Size: SRA3 or 12x18”
Face Trim: 0,0mm or 0.000”
Bleed Trim: 0,0mm or 0.000”
Plockmatic BM500 system 20 May 2019 1. Installation Procedure
1-80
1.16.5 CHECKING THE SQUARE FOLD 1.16.6 CHECKING THE TRIMMER

WARNING: WARNING:
To avoid hazardous situations, please read and follow the safety informa- To avoid hazardous situations, please read and follow the safety informa-
tion in section 1.3 in this manual. tion in section 1.3 in this manual.

1. In the UI, press [Book Fold]. 11. In the UI, press [Finished Booklet Size].
2. Press [Auto]. 12. Press [Edit].
3. Press [OK]. 13. Press [Clear] to clear length setting.
4. Press [Crease]. 14. Set length to 210,0mm/8.500” and press [OK]. You can see that you
5. Press [AUTO] will receive booklets 297mm/11” tall and 210mm/8.5” wide.
6. Press [OK] 15. Press [OK].
Booklet maker setup should read: You can now see that the SRA3/12x11” sheets will have a Bleed Trim
Input Sheet Size: SRA3 or 12x18” of 11,5mm/0.500” on each side and Face Trim of 15,0mm/0.500.
Face Trim: 0,0mm or 0.000” Booklet maker setup should read:
Bleed Trim: 11,5mm or 0.500” Input Sheet Size: SRA3 or 12x18”
Staple: ON Face Trim: 15,0mm or 0.500”
Cover: OFF Bleed Trim: 11,5mm or 0.500”
Book Fold: Status: ON, Mode: Auto Staple: ON
Fold position: AUTO Cover: OFF
Crease: Status: AUTO, Offset: 0,0mm/0.000” Book Fold: Status: ON, Mode: Auto
7. Using 80 gsm/20 lb Bond sheets, send five sets of 2 sheet Fold position: AUTO
SRA3/12x18” (2 sheets of SRA3/12x18” equals a booklet containing 8 Crease: Status: ON, Offset: 0,0mm/0.000”
pages) to the Booklet Maker system. 16. Using 80 gsm/20 lb Bond sheets, send five sets of 2 sheet
8. Check that the booklet cover do have a crease and that the booklets SRA3/12x18” (2 sheets of SRA3/12x18” equals a booklet containing 8
not have a Book Folded spine. pages) to the Booklet Maker system.
9. Send five sets of 10 sheet SRA3/12x18” (10 sheets of SRA3/12x18” 17. Check that the bookets are trimmed and 210,0mm/8.500” wide.
equals a booklet containing 40 pages) to the Booklet Maker system.
10. Check that the booklet cover does not have a crease and that the
booklets have a Book Folded spine.

Plockmatic BM500 system 20 May 2019 1. Installation Procedure

1-81
2 PREVENTIVE MAINTENANCE (PM)

Contents
Booklet Maker 2-2

Square Folder 2-3

Trimmer 2-4

CST 2-5

CR 500 2-5

AF602 2-6

VF602 2-8

Plockmatic BM500 system 20 May 2019 2. Preventive Maintenance (PM)

2-1
Purpose Procedure
This section contains the activities that should be performed at certain intervals 1. Turn off the power on all the modules.
/ booklets from the previous preventative maintenance action. 2. Disconnect the power cords from all the modules.

NOTE: Caution!
Normally it is assumed that all system modules will require preventive If any of the checkpoints or other parts show indication of wear at any
maintenance at the same time. However, if any particular module has been point, replace the part.
replaced, check each module’s service log before beginning the preventive When lubricating, clean the surface before applying new lubricant.
maintenance activities and proceed accordingly.

Note: Booklet Maker set counts are based on 4 sheets / set.

Booklet Maker
Check point Instruction Part Name Spare Qty Service Spare Parts Maintenance
Part No. manual manual Interval
Paper Path Use a vacuum cleaner, towel and brushes to 125K
clean the machine from paper dust
Interior adjacent to Remove power supply cover. Use a vacuum REP 7.8 125K
Power Supplies cleaner to remove objects that otherwise can
end up inside power supply causing a short-
age
Sensors Use compressed air or a brush to clean sen- 125K
sors
Thickness meter in Sta- Clean the measuring rod and the guide hole REP 7.7 125K
pler assembly using film remover
Length adjustment shaft Lubricate with bearing grease REP 6.0 125K
Fold roller bearings and Lubricate metal to metal surfaces with MoS2 REP 6.5 125K
brackets (6+2) grease
Cams to upper fold roll- Lubricate metal to metal surfaces with MoS2 ADJ 6.6 125K
ers (x2) grease
Fold transmission Cou- Lubricate metal to metal surfaces with MoS2 REP 6.4 125K
pling assemblies grease
Drive chain, fold trans- Lubricate chain with Oil ADJ 6.4 125K
mission

Plockmatic BM500 system 20 May 2019 2. Preventive Maintenance (PM)

2-2
Booklet Maker
Check point Instruction Part Name Spare Qty Service Spare Parts Maintenance
Part No. manual manual Interval
Clinchers Replace Clinch Isaberg RP952 782020 2 REP 4.0 PL 7.0, It. 3&4 1M
w. bracket
Staplers Replace Stapler Isaberg RP952 782021 2 REP 4.0 PL 7.0, It. 1&2 1M
w. bracket
Bearings, Fold roller step Replace Ball bearing 10/26x8 60827 4 REP 6.6, 6.7 PL 6.1, It.1 1M
1 6000-2ZC3
Timing belt, paper trans- Replace Timing belt 6T2,5/145 45698 1 REP 4.3 PL 5.0, It. 5 1M
port assy
Roller assy. "Black box" Replace Roller assy 781014 2 REP 3.11 PL 5.3, It. 15 1M
driver roller tires
Upper infeed motor BM- Replace Motor Nichibo HS5B 781058 1 REP 3.12 PL 5.3, It. 19 1M
M1 6:1 E2
Staple & fold pos motor Replace Motor Nichibo HS5B 781058 1 REP 5.1 PL 6.2, It. 4 1M
BM-M9 6:1 E2
Drive motor, fold roller, Replace Motor 24V KSV 771128 1 REP 6.4 PL 6.0 2M
BM-M6
Back jogger motor BM- Replace Motor 24V 30:1 Mic 762042 1 REP 3.9 PL 5.2, It. 4 2M
M2
Bearing (upper infeed Replace Bearing Acetal D6/10x4- 102- 3 REP 3.11 PL 5.3, It. 14 2M
roller, black box) 14x2 104062
Tyre, drive wheel set Replace Tyre 30/38x6 102- 2 REP 4.3 PL 5.0, It. 4 2M
transport 104204
Set transport motor BM- Replace Motor 24V 10:1 781022 1 REP 4.3 PL 5.0, It. 6 3M
M5

Plockmatic BM500 system 20 May 2019 2. Preventive Maintenance (PM)

2-3
Square Folder
Note: Square Folder set counts are based on 6 sheets / set.
Check point Instruction Part Name Spare Qty Service Spare Parts Maintenance
Part No. manual manual Interval
Paper path Use a vacuum cleaner, towel and brushes to 125K
clean the machine from paper dust
Sensors Use compressed air or a brush to clean sen- 125K
sors
Upper transport belts (x2) Use film remover to clean belts REP 11.19 125K
Lower transport belts (x2) Use film remover to clean belts REP 11.20 125K
Pressure Roller Inspect Timing Belt. for tension and wear. REP 11.19 125K
Lower and upper clamp Silicon grease on clamps against guides REP 11.22 125K
Plastic guides Silicon grease on guides against clamps REP 11.22 125K
Transport belt kit, upper Replace Transport belt 488x32 17232 2 REP 11.17, PL10.3, It.3 2M
& lower, 2+2 belts UU 20U 11.20
Clamp motor BF-M3 Replace Motor Wevin with con- 782044 1 REP 11.8 PL10.5, It.5 3M
nector
Roller motor BF-M4, with Replace Motor, roller 172052 1 REP 11.9 PL10.6, It.4 3M
Harness
Bushing, Clamp linkage Replace Sintered bearing 24653 4 REP 11.22 PL10.2, It.10 3M
8/12x8-16x2
Trimmer
Note: Trimmer set counts are based on 4 sheets / set and one trim stroke / booklet..
Check point Instruction Part Name Spare Qty Service Spare Parts Maintenance
Part No. manual manual Interval
Paper Path Use a vacuum cleaner, towel and brushes to 125K
clean the machine from paper dust
Sensors Use compressed air or a brush to clean sen- 125K
sors
Infeed belts (2x4) Use film remover to clean belts REP 10.27 125K
Lower Exit belts (x2) Use film remover to clean belts REP 10.22 125K
Upper Exit belts (x2) Use film remover to clean belts REP 10.23 125K
Trim Knife Inspect trim result; 2 and 50 sheets REP 10.16, 125K
10.17

Plockmatic BM500 system 20 May 2019 2. Preventive Maintenance (PM)

2-4
Trimmer
Check point Instruction Part Name Spare Qty Service Spare Parts Maintenance
Part No. manual manual Interval
Transmission chain / Lubricate with chain oil REP 10.26 125K
Chain sprocket
Knife support chain Lubricate with chain oil and check tension REP 10.27 125K
Knife chain Lubricate with chain oil and check tension REP 10.28 125K
Stop gate lifting eccen- Clean and lubricate with silicone grease on Eccentric 103- 2 REP 10.19 PL11.9 It. 15 125K
trics (cams) eccentrics agains stop gate 102546 - 21
Stop gate guides Clean and lubricate with silicone grease in Guide 103- 2 REP 10.19 PL 11.19 It. 2 125K
slot wher stop gate sits 103551 - 21
Transport belts, Infeed Replace Transport belt 43x12 103- 8 REP 10.29 PL 11.5, It.9 2M
T2,5 grey 104619
Transport belt upper and Replace Transport belt 445x20 103- 4 REP 10.24, PL 11.7, 11.8 3M
lower exit 103677 10.25
Trim knife motor TR-M2 Replace Motor Wevin with con- 782044 1 REP 10.14 PL 11.2, It. 3 3M
nector
Transport and knife mo- Replace Motor Wevin with con- 782044 1 REP 10.12 PL 11.2, It. 4 3M
tor TR-M1 nector
Length adjustment motor Replace Motor 24V 30:1 762042 1 REP 10.22 PL 11.9, It.1 3M
TR-M3

CR500
Note: All CR counter values are based on sheet counts
Check point Instruction Part Name Spare Qty Service Spare Parts Maintenance
Part No. manual manual Interval
Paper paths Use a vacuum cleaner, towel and brushes to Operators 125K
clean the machine from paper dust manual
Sensors Use compressed air or a brush to clean sen- 125K
sors
Fixing rollers Use film remover to clean Rollers 125K
Creaser tools Use film remover to clean Rollers 125K
Creaser Timing Belt Replace Timing belt 16T5/460- 57444 REP 16.14 PL 1.7 3M
DL
Transport timing belt Replace Timing belt 10T5/1295- 127- REP 16.11 PL 1.2 3M
DL 108931

Plockmatic BM500 system 20 May 2019 2. Preventive Maintenance (PM)

2-5
CST
Note: All CST counter values are based on sheet counts.
Check point Instruction Part Name Spare Qty Service Spare Parts Maintenance
Part No. manual manual Interval
Paper Path Use a vacuum cleaner, towel and brushes 125K
to clean the machine from paper dust
Sensors Use compressed air or a brush to clean 125K
sensors
Transportation Nip Roll- Use film remover to clean Rollers Op. Man. 125K
ers Sec.7
Fixing Rollers Use film remover to clean Rollers Op. Man. 125K
Sec.7
Registration Cross Roll- Use film remover to clean Rollers Op. Man. 125K
ers Sec.7
Rotator Rollers Use film remover to clean Rollers Op. Man. 125K
Sec.7
Creaser Tools Use film remover to clean Creaser tools Op. Man. 125K
Sec.7
O-ring, waste transport Replace Round belt urethane o5 1 REP 12.25 PL 12.14, It.2 2M
drive belt L=930mm
Secondary drive belt M1 Replace Timing belt 10T5/4625- 53986 1 REP 12.11 PL 12.8, It.15 3M
DL 12290018
Primary drive belt M1 Replace Timing belt 10T5/2280- 12290016 1 REP 12.10 PL 12.8, It. 10 3M
DL
Rubber drive wheel, reg- Replace Guide wheel Ø49 R7,5 122- 6 REP 12.47 PL 12.22, It. 1 2M
istration cross roller 109691
Upper and Lower knife Replace Upper and Lower knife 531019 2 REP 13.1, 13.2 PL 12.42, It. 1 2M
replacement kit

Plockmatic BM500 system 20 May 2019 2. Preventive Maintenance (PM)

2-6
AF602
Sheet Count Range: 500K - 6M Total Sheet Count

Check point Instructions SP Manual 500K 1M 1,5M 2M 2,5M 3M 3,5M 4M 4,5M 5M 5,5M 6M
Use compressed air, towel and brushes to clean the
Paper path etc N/A x x x x x x x x x x x x
machine from paper dust.
Outfeed sensor (Q303) Use compressed air to clean sensor. PL 3.1a x x x x x x x x x x x x
Optical DSD sensors
Clean with moist cloth and calibrate sensor. PL 6.3 x x x x x x x x x x x x
(Q101/Q201)
Ultrasonic DSD sensors
Clean with moist cloth and calibrate sensor. PL 6.3 x x x x x x x x x x x x
(Q102/Q202)
Use rubber reactivator alcohol fluid to clean feed rollers.
Feed rollers PL 2.3a/b x x x x x x x x x x x x
Check for wear, if worn replace.
Use rubber reactivator alcohol fluid to clean separator pads.
Separator pads PL 2.3a/b x x x x x x x x x x x x
If worn, replace both pads.
Use rubber reactivator alcohol fluid to clean feed rollers.
Drive shaft PL 3.0 x x x x x x x x x x x x
Check for wear, if worn replace.
Use rubber reactivator alcohol fluid to clean feed rollers.
Drive shaft PL 3.1b x x x x x x x x x x x x
Check for wear, if worn replace.
Timing belt 10T5/1800 (M301) Replace PL 4.0 x x

Timing belt 10T5/1315 (M301) Replace PL 4.0 x x

Timing belt 10T5/2500 (M201) Replace PL 2.0 x x

Timing belt 10T5/2500 (M101) Replace PL 2.0 x x

Clutch 24v (SOL101/SOL201) Replace PL 2.3a x x

Timing belt 10T5/330 Replace PL 2.3a/b x x

Timing wheel Replace PL 2.3 a/b x x

Timing wheel, slotted Replace PL 2.3a x x

Timing belt 8T5/100 Replace PL 2.3a/b x x

Solenoid Bin Lock
Replace PL 2.0 x
(SOL102/SOL202)
Interlock switch x3 Replace PL 2.0 / 3.0 x

Blower Fan x8 Replace PL 2.1a/b x

Coupling shaft Replace PL 4.0 x

Plockmatic BM500 system 20 May 2019 2. Preventive Maintenance (PM)

2-7
AF602 (CONTINUED)

Sheet Count Range: 6,5M - 12M Total Sheet Count

Check point Instructions SP Manual 6,5M 7M 7,5M 8M 8,5M 9M 9,5M 10M 10,5M 11M 11,5M 12M
Use compressed air, towel and brushes to clean the
Paper path etc N/A x x x x x x x x x x x x
machine from paper dust.
Outfeed sensor (Q303) Use compressed air to clean sensor. PL 3.1a x x x x x x x x x x x x
Optical DSD sensors
Clean with moist cloth and calibrate sensor. PL 6.3 x x x x x x x x x x x x
(Q101/Q201)
Ultrasonic DSD sensors
Clean with moist cloth and calibrate sensor. PL 6.3 x x x x x x x x x x x x
(Q102/Q202)
Use rubber reactivator alcohol fluid to clean feed rollers.
Feed rollers PL 2.3a/b x x x x x x x x x x x x
Check for wear, if worn replace.
Use rubber reactivator alcohol fluid to clean separator
Separator pads PL 2.3a/b x x x x x x x x x x x x
pads. If worn, replace both pads.
Use rubber reactivator alcohol fluid to clean feed rollers.
Drive shaft PL 3.0 x x x x x x x x x x x x
Check for wear, if worn replace.
Use rubber reactivator alcohol fluid to clean feed rollers.
Drive shaft PL 3.1b x x x x x x x x x x x x
Check for wear, if worn replace.
Timing belt 10T5/1800 (M301) Replace PL 4.0 x x

Timing belt 10T5/1315 (M301) Replace PL 4.0 x x

Timing belt 10T5/2500 (M201) Replace PL 2.0 x x

Timing belt 10T5/2500 (M101) Replace PL 2.0 x x

Clutch 24v (SOL101/SOL201) Replace PL 2.3a x x

Timing belt 10T5/330 Replace PL 2.3a/b x x

Timing wheel Replace PL 2.3 a/b x x

Timing wheel, slotted Replace PL 2.3a x x

Timing belt 8T5/100 Replace PL 2.3a/b x x

Solenoid Bin Lock
Replace PL 2.0 x
(SOL102/SOL202)
Interlock switch x3 Replace PL 2.0 / 3.0 x

Blower Fan x8 Replace PL 2.1a/b x

Coupling shaft Replace PL 4.0 x

Plockmatic BM500 system 20 May 2019 2. Preventive Maintenance (PM)

2-8
VF602

Sheet Count Range: 500K - 6M Total Sheet Count

Check point Instructions SP Manual 500K 1M 1,5M 2M 2,5M 3M 3,5M 4M 4,5M 5M 5,5M 6M
Use compressed air, towel and brushes to clean the machine
Paper path etc N/A x x x x x x x x x x x x
from paper dust.
Exit feed sensor (Q303) Use compressed air to clean sensor. PL 3.1A x x x x x x x x x x x x
Optical DSD sensors
Clean with moist cloth and calibrate sensor. PL 2.3 x x x x x x x x x x x x
(Q101/201)
Ultrasonic DSD sensors
Clean with moist cloth and calibrate sensor. PL 2.3 x x x x x x x x x x x x
(Q102/Q202)
Use rubber reactivator alcohol fluid to clean separator pads.
Separator pads PL 2.4 x x x x x x x x x x x x
Always replace both separator pads.
Use rubber reactivator alcohol fluid to clean feed rollers.
Drive shaft PL 3.0 x x x x x x x x x x x x
Replace if worn.
Use rubber reactivator alcohol fluid to clean feed rollers.
Drive shaft, exit area PL 3.1A x x x x x x x x x x x x
Replace if worn.
Timing belt 10T5/1800 (M301) Replace PL 4.0 x x

Timing belt 10T5/1315 (M301) Replace PL 4.0 x x

Timing belt 10T5/2500 (M201) Replace PL 2.0 x x

Timing belt 10T5/2500 (M101) Replace PL 2.0 x x

Clutch 24v (SOL101/201) Replace PL 2.3 x x

Clutch 24v (SOL104/204) Replace PL 2.3 x x

Timing belt 10T5/330, Tray,
Replace PL 2.3 x x
Feeder
Solenoid Bin Lock
Replace PL 2.3 x
(SOL102/SOL202)
Interlock switches Replace PL 2.0, 3.0 x

Blower Fan x12 Replace PL 2.1, 2.3 x

Coupling shaft x2 Replace PL 4.0 x

Solenoid Vacuum Release
Replace PL2.3 x x
(SOL103/203)
Suction Belts (Feeder Use rubber reactivator alcohol fluid to clean suction belts.
PL 2.3 x x
Assembly) Replace if worn.

Plockmatic BM500 system 20 May 2019 2. Preventive Maintenance (PM)

2-9
VF602 (CONTINUED)

Sheet Count Range: 6,5M - 12M Total Sheet Count

Check point Instructions SP Manual 6,5M 7M 7,5M 8M 8,5M 9M 9,5M 10M 10,5M 11M 11,5M 12M
Use compressed air, towel and brushes to clean the machine
Paper path etc N/A x x x x x x x x x x x x
from paper dust.
Exit feed sensor (Q303) Use compressed air to clean sensor. PL 3.1A x x x x x x x x x x x x
Optical DSD sensors
Clean with moist cloth and calibrate sensor. PL 2.3 x x x x x x x x x x x x
(Q101/201)
Ultrasonic DSD sensors
Clean with moist cloth and calibrate sensor. PL 2.3 x x x x x x x x x x x x
(Q102/Q202)
Use rubber reactivator alcohol fluid to clean separator pads.
Separator pads PL 2.4 x x x x x x x x x x x x
Always replace both separator pads.
Use rubber reactivator alcohol fluid to clean feed rollers.
Drive shaft PL 3.0 x x x x x x x x x x x x
Replace if worn.
Use rubber reactivator alcohol fluid to clean feed rollers.
Drive shaft, exit area PL 3.1A x x x x x x x x x x x x
Replace if worn.
Timing belt 10T5/1800 (M301) Replace PL 4.0 x x

Timing belt 10T5/1315 (M301) Replace PL 4.0 x x

Timing belt 10T5/2500 (M201) Replace PL 2.0 x x

Timing belt 10T5/2500 (M101) Replace PL 2.0 x x

Clutch 24v (SOL101/201) Replace PL 2.3 x x

Clutch 24v (SOL104/204) Replace PL 2.3 x x

Timing belt 10T5/330, Tray,
Replace PL 2.3 x x
Feeder
Solenoid Bin Lock
Replace PL 2.3 x
(SOL102/SOL202)
Interlock switches Replace PL 2.0, 3.0 x

Blower Fan x12 Replace PL 2.1, 2.3 x

Coupling shaft x2 Replace PL 4.0 x

Solenoid Vacuum Release
Replace PL2.3 x x
(SOL103/203)
Suction Belts (Feeder Use rubber reactivator alcohol fluid to clean suction belts.
PL 2.3 x x
Assembly) Replace if worn.

Plockmatic BM500 system 20 May 2019 2. Preventive Maintenance (PM)

2-10
General
Check point Instruction Part Name Spare Qty Service Spare Parts Maintenance
Part No. manual manual Interval
Check Booklet Quality Section 9 BQ 125K

Plockmatic BM500 system 20 May 2019 2. Preventive Maintenance (PM)

2-11
3 REPAIRS AND ADJUSTMENTS (REP AND ADJ)
Contents REP 4.2 BM-Q47 Stapler Home Position Sensor Right &
BM-Q50 Stapler Home Position Sensor Left...........................................3-37
General cautions........................................................................................................3-8
REP 4.3 BM-M5 Set Transport Motor &
Recommended tools..................................................................................................3-9 BM-Q40 Set Transport Motor Sensor ......................................................3-38
REP 4.4 BM-M22 Stop Gate Stapler Motor ............................................................3-39
Booklet Maker REPs
REP 4.5 BM-Q41 Stop Gate (M22) Motor Sensor .................................................3-40
REP 1.0 Undocking BM / TR / SQF.........................................................................3-10
REP 4.6 BM-Q42 Home Position Stop Gate Stapler (M22) sensor......................3-41
REP 1.1 Front and Rear Cover................................................................................3-13
REP 5.0 BM-Q4 Start Sensor Saddle Stapling Sensor.........................................3-42
REP 1.2 Lower Infeed Cover and Infeeder.............................................................3-14
REP 5.1 BM-M9 Staple Fold Positioning Motor &
REP 1.3 Upper and Lower Exit Cover....................................................................3-16
BM-Q10 Stapler Fold Positioning Motor Sensor.....................................3-43
REP 1.4 Top Cover and Hand feed cover...............................................................3-17
REP 6.0 Length Transmission Shaft &
REP 1.5 Top Cover Assembly.................................................................................3-18 BM-Q11 Staple Fold Home positioning Sensor.......................................3-44

REP 1.6 Interlock Switch Assembly.......................................................................3-19 REP 6.1 BM-M8 Stop Gate Folder Motor,
BM-Q7 Stop Gate Folder Sensor &
REP 1.7 Sensor Q53 Handfeed Unit infeed sensor...............................................3-20 BM- Q48 Clinch Trigger Sensor Right......................................................3-45
REP 3.0 Infeed Module............................................................................................3-21 REP 6.2 Fold Stop Gate...........................................................................................3-46
REP 3.1 BM-Q1 Paper Infeed Sensor.....................................................................3-22 REP 6.3 BM-M7 Fold Knife Motor &
REP 3.2 Paper / Side Guides...................................................................................3-22 BM-Q15 Fold Knife Home Position Sensor.............................................3-47

REP 3.3 BM-M3 Side Jogger Motor & REP 6.4 Fold Transmission Module, BM-M6 Fold Roller Motor,
BM-Q12 Side Jogger Motor Sensor .........................................................3-23 BM-Q9 Fold roller sensor & fold transmission chain.............................3-48

REP 3.4 Side Guide Transmission & REP 6.5 Spring Support..........................................................................................3-50
BM-Q13 Side Jogger home position sensor ..........................................3-24 REP 6.6 Upper Fold Rollers....................................................................................3-51
REP 3.5 Side Guide Transmission Belt..................................................................3-26 REP 6.7 Lower Fold Rollers....................................................................................3-53
REP 3.6 Back Jogger Module & REP 6.8 BM-Q44 Home Position Stop Gate Folder Sensor..................................3-54
BM-Q3 Back Jogger Home Position Sensor ..........................................3-27
REP 6.9 BM-Q8 Exit Sensor....................................................................................3-54
REP 3.7 Back Jogger Assembly.............................................................................3-28
REP 7.0 MD6DC PCB ”H” (upper)...........................................................................3-55
REP 3.8 Back Jogger Fingers and cam.................................................................3-29
REP 7.1 MD6DC PCB ”B” (middle).........................................................................3-56
REP 3.9 BM-M2 Back Jogger Motor & BM-Q45 Back Jogger Motor Sensor......3-30
REP 7.2 MD6DC PCB ”C” (lower)...........................................................................3-57
REP 3.10 Infeed Transport Module.........................................................................3-31
REP 7.3 PCB Controller, PCB ”A”..........................................................................3-58
REP 3.11 Infeed Transport Wheel...........................................................................3-32
REP 7.4 Addon PCB ”F”..........................................................................................3-59
REP 3.12 BM-M1 Infeed Motor & BM-Q2 Infeed Motor Sensor............................3-32
REP 7.5 Expansion PCB ”J” 4 In 4 Out..................................................................3-60
REP 4.0 Stapler Heads, Stapler Assy and Clincher..............................................3-33
REP 7.6 User Interface assembly...........................................................................3-60
REP 4.1 Staple Quality (forming)............................................................................3-37

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-1
 REP 7.7 BM-M23 Thick Sensor Motor REP 10.20 TR-M3 Stop Gate Motor,
BM-Q37 Thick Set Motor Sensor & TR-Q7 Stop Gate Home Position sensor &
BM-Q36 Thick Set Motor Home Sensor...................................................3-61 TR-Q11 length adjustment home position sensor..................................3-83
REP 7.8 Removing Power Supply unit...................................................................3-62 REP 10.21 TR-M4 Length Adjustment Motor &
TR-Q12 (M4) Motor Encoder.....................................................................3-84
REP 7.9 Accessing Rear Side of Connection Bracket..........................................3-63
REP 10.22 Lower Exit Belts and foam rollers........................................................3-85
REP 7.10 BM-M19 Infeed module motor M19 &
BM-Q34 Infeed motor sensor....................................................................3-63 REP 10.23 Upper Exit Belts and foam rollers........................................................3-87
REP 10.24 Transmission Chain..............................................................................3-89
Belt Stacker REP’s
REP 10.25 Knife Support Chain..............................................................................3-89
REP 8.0 Stacker Module..........................................................................................3-64
REP 10.26 Knife Chain.............................................................................................3-90
REP 8.1 ST-M1 Stacker Motor.................................................................................3-65
REP 10.27 Infeed Belts............................................................................................3-91

Trimmer REPs REP 10.28 MD6DC PCB ”A”....................................................................................3-93

REP 10.0 Front and Rear Cover..............................................................................3-66 REP 10.29 Latch, Docking.......................................................................................3-94

REP 10.1 Top Cover.................................................................................................3-67 REP 10.30 TR-M8 Lifter Motor &
TR-Q15 Lift Motor Home Pos. Sensor......................................................3-94
REP 10.2 Infeed Cover.............................................................................................3-68
REP 10.31 Plunger, upper knife beam....................................................................3-95
REP 10.3 TR-M5 / M6 Blower Motor (Blower Assembly)......................................3-69
REP 10.4 Upper Exit Cover.....................................................................................3-69 Square Folder REPs
REP 10.5 TR-SW10 Interlock Switch & TR-Q1 Interlock sensor..........................3-70 REP 11.0 Front and Rear Cover..............................................................................3-96
REP 10.6 Protection Cover......................................................................................3-71 REP 11.1 Infeed Cover.............................................................................................3-96
REP 10.7 TR-Q8 Trim Bin Full Sensor....................................................................3-72 REP 11.2 Exit Cover Assembly...............................................................................3-97
REP 10.8 TR-Q13 Infeed Sensor.............................................................................3-72 REP 11.3 Top Cover.................................................................................................3-98
REP 10.9 TR-Q2 Infeed Shaft Sensor.....................................................................3-73 REP 11.4 Tilt the Machine........................................................................................3-99
REP 10.10 TR-Q3 Exit Belt Sensor ........................................................................3-73 REP 11.5 Antistatic Brushes.................................................................................3-101
REP 10.11 TR-M1 Transport / Knife Motor ...........................................................3-74 REP 11.6 SQF-M1 Transport Belt Motor...............................................................3-101
REP 10.12 TR-Q4 Transport Belt Sensor ..............................................................3-74 REP 11.7 SQF-M2 Stop Gate Motor......................................................................3-102
REP 10.13 TR-M2 Trim Knife Motor........................................................................3-75 REP 11.8 SQF-M3 Clamp Motor............................................................................3-103
REP 10.14 TR-Q5 Trim Knife Home Position Sensor............................................3-76 REP 11.9 SQF-M4 Roll Motor................................................................................3-104
REP 10.15 Knife guard ............................................................................................3-77 REP 11.10 SQF-Q1 (M2) Stop Gate Sensor..........................................................3-106
REP 10.16 Upper Trim Knife....................................................................................3-78 REP 11.11 SQF-M4 Roll Motor,
SQF-Q2 (M4) Right sensor & SQF-Q3 (M4) Left Sensor.......................3-107
REP 10.17 Lower Trim Knife...................................................................................3-79
REP 11.12 SQF-Q4 Clamp Motor (M3) Encoder...................................................3-107
REP 10.18 TR-Q14 Paper Path & TR-Q6 Exit Sensor ...........................................3-81
REP 11.13 SQF-Q5 Infeed Sensors.......................................................................3-108
REP 10.19 Stop Gate Carriage................................................................................3-82
REP 11.14 SQF-Q7 Exit Sensors...........................................................................3-108

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 11.15 SQF-Q6 Clamp Sensor........................................................................3-109 REP 12.19 Transmission Shaft.............................................................................3-138
REP 11.16 SQF-M4 Roll Motor & SQF-Q8 (M4) Motor Sensor............................3-109 REP 12.20 Lower Drive Shaft................................................................................3-139
REP 11.17 Upper Transport Belt Assembly.........................................................3-110 REP 12.21 Chassis Counter..................................................................................3-140
REP 11.18 SQF-SW2 Interlock Switches.............................................................. 3-111 REP 12.22 Waste Transport Belt...........................................................................3-141
REP 11.19 Upper Transport Belt, SQF-SOL1/3 Clutches & Foam Rollers........ 3-111 REP 12.23 Waste Bin Full Sensor (CT-Q11).........................................................3-142
REP 11.20 Lower Transport Belt, SQF-SOL2/4 Clutches & Foam rollers.........3-113 REP 12.24 Waste Transport Sensor (CT-Q14).....................................................3-143
REP 11.21 Teflon Tape Lower Transport Belt......................................................3-115 REP 12.25 Upper Drive Shaft................................................................................3-144
REP 11.22 Set Clamps...........................................................................................3-116 REP 12.26 Rotator Sensor (CT-Q2).......................................................................3-145
REP 11.23 Stop Gate..............................................................................................3-118 REP 12.27 Rotator Timing Belt.............................................................................3-145
REP 11.24 MD6DC PCB ”D”..................................................................................3-119 REP 12.28 Rotator Disengage Solenoid (CT-SOL1)............................................3-146
REP 11.25 Accessing Rear Side of Connection Bracket....................................3-120 REP 12.29 Rotator Disengage Solenoid (CT-SOL1) Idler Shaft.........................3-147
REP 12.30 Rotator Disengage Solenoid (CT-SOL1) Mechanism.......................3-147
CST REPs
REP 12.31 Rotator Disengage Solenoid (CT-SOL2)............................................3-148
REP 12.0 Front and Rear Cover ...........................................................................3-121
REP 12.32 Rotator Disengage Solenoid (CT-SOL2) Idler Shaft.........................3-149
REP 12.1 Infeed and Exit Cover ...........................................................................3-122
REP 12.33 Rotator Disengage Solenoid (CT-SOL2) Mechanism.......................3-149
REP 12.2 Top Cover...............................................................................................3-123
REP 12.34 Rotator Upper Drive Shaft..................................................................3-150
REP 12.3 Top Cover Assembly.............................................................................3-124
REP 12.35 Rotator Lower Drive Shaft..................................................................3-150
REP 12.4 Interlock Switch Assy Top Cover CT-SW3 (CT-Q9)
& Main power switch CT-SW1.................................................................3-126 REP 12.36 Rotator Motor (CT-M3).........................................................................3-151

REP 12.5 Interlock Switch Slide Door CT-SW2 (CT-Q8).....................................3-127 REP 12.37 Rotator Motor (CT-M3) Drive Shaft.....................................................3-152

REP 12.6 Entrance Sensor (CT-Q1)......................................................................3-127 REP 12.38 Registration Lead Screw.....................................................................3-152

REP 12.7 Exit Sensor (CT-Q7)...............................................................................3-128 REP 12.39 Registration Width Adjustment Motor (CT-M4).................................3-153

REP 12.8 Drive Motor (CT-M1)..............................................................................3-129 REP 12.40 Registration M4 Home Sensor (CT-Q3).............................................3-154

REP 12.9 Drive Motor (CT-M1) Primary Timing Belt...........................................3-130 REP 12.41 Registration Cross Rolls Drive Shaft.................................................3-155

REP 12.10 Drive Motor (M1) Secondary Timing Belt..........................................3-131 REP 12.42 Registration Cross Rollers Timing Belt.............................................3-156

REP 12.11 Infeed Drive Shaft................................................................................3-132 REP 12.43 Registration Cross Rollers ...............................................................3-157

REP 12.12 Infeed Idler Roller................................................................................3-132 REP 12.44 Registration Cross Rollers Idler Rollers...........................................3-158

REP 12.13 Infeed Baffle.........................................................................................3-133 REP 12.45 Registration Primary Alignment Rail.................................................3-159

REP 12.14 Exit Drive Shaft....................................................................................3-133 REP 12.46 Registration Secondary Alignment Rail............................................3-159

REP 12.15 Exit Idler Roller....................................................................................3-134 REP 12.47 Registration Disengage Solenoid (CT-SOL5)....................................3-160

REP 12.16 Exit Baffle.............................................................................................3-135 REP 12.48 Registration Disengage Solenoid (SOL5) Linkage...........................3-161

REP 12.17 Pre Trimmer Fixing Roller...................................................................3-136 REP 12.49 Creaser Assembly...............................................................................3-162

REP 12.18 Post Trimmer Fixing Roller.................................................................3-137 REP 12.50 Creaser Trigger Sensor (CT-Q4) LED.................................................3-164

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-3
 REP 12.51 Creaser Trigger Sensor (CT-Q4) Phototransistor.............................3-164 REP 13.26 Stepper Motor Driver (M4) PCB “D”...................................................3-191
REP 12.52 Creaser Tools Home Sensor (CT-Q5).................................................3-165 REP 13.27 Stepper Motor Driver (M1) PCB “E”...................................................3-192
REP 12.53 Creaser Timing Belt.............................................................................3-165 REP 13.28 PCB Printer Interface PCB “F”...........................................................3-193
REP 12.54 Creaser Tools.......................................................................................3-166 REP 13.29 I/O Extension PCB “G”........................................................................3-194
REP 12.55 Creaser Motor (CT-M6)........................................................................3-167 REP 13.30 Stepper Motor Driver (M6) PCB “H”...................................................3-195
REP 12.56 Creaser Baffle......................................................................................3-168 REP 13.31 Stepper Motor Driver (M3) PCB “J”...................................................3-196
REP 13.0 Bleed Trimmer Drive Shaft....................................................................3-169 REP 13.32 SCP (Short Circuit Protection) PCB “K”...........................................3-197
REP 13.1 Bleed Trimmer Upper Knives...............................................................3-170 REP 13.33 SCP (Short Circuit Protection) PCB “L”............................................3-197
REP 13.2 Bleed Trimmer Lower Knives...............................................................3-172 REP 13.34 SCP (Short Circuit Protection) PCB “M”...........................................3-198
REP 13.3 Bleed Trimmer CT-M7 Home Sensor (CT-Q6)......................................3-173 REP 13.35 SCP (Short Circuit Protection) PCB “N”...........................................3-199
REP 13.4 Bleed Trimmer Width Adjustment Motor (CT-M7)...............................3-174 REP 13.36 12V Power Supply Unit.......................................................................3-200
REP 13.5 Bleed Trimmer Disengage Solenoid (CT-SOL3)..................................3-175 REP 13.37 24V Power Supply Unit (1)..................................................................3-201
REP 13.6 Bleed Trimmer Disengage Shaft..........................................................3-176 REP 13.38 24V (48V) Power Supply Unit (2)........................................................3-202
REP 13.7 Bleed Trimmer Gratings Upper............................................................3-177 REP 13.39 High Voltage Power Supply Unit (Optional, For Antistatic Bars)....3-203
REP 13.8 Bleed Trimmer Gratings Lower............................................................3-177 REP 13.40 Interlock Relay (CT-REL1)...................................................................3-206
REP 13.9 Slide Guide.............................................................................................3-178 REP 13.41 Temp Sensor (CT-Q13)........................................................................3-207
REP 13.10 Slide Drive Shaft Transportation........................................................3-179 REP 13.42 Cooling Fan (CT-FAN1).......................................................................3-207
REP 13.11 Transportation Disengage Solenoid (CT-SOL4)................................3-180
AF602 REPs
REP 13.12 Transportation Disengage Solenoid (CT-SOL4) Idler Shaft.............3-181
REP 14.0 Cover, Rear.............................................................................................3-208
REP 13.13 Transportation Disengage Solenoid (SOL4) Mechanism.................3-181
REP 14.1 Cover, Front...........................................................................................3-208
REP 13.14 Slide Latch Mechanism.......................................................................3-182
REP 14.2 Cover, Bin...............................................................................................3-209
REP 13.15 Slide Fixing Roller...............................................................................3-183
REP 14.3 Door........................................................................................................3-209
REP 13.16 Slide “B” Baffle....................................................................................3-184
REP 14.4 Cover, Upper Exit...................................................................................3-210
REP 13.17 Slide “B” Paper Path...........................................................................3-184
REP 14.5 Cover, Top..............................................................................................3-210
REP 13.18 Slide “C” Baffle....................................................................................3-185
REP 14.6 Cover, Side.............................................................................................3-211
REP 13.19 Slide “C” Paper Path...........................................................................3-185
REP 14.7 Timing Belt.............................................................................................3-211
REP 13.20 Slide L/H Lower (CT-SOL4) Baffle......................................................3-186
REP 14.8 Tray Table...............................................................................................3-212
REP 13.21 Slide R/H Lower Baffle........................................................................3-187
REP 14.9 Solenoid SOL101/201............................................................................3-213
REP 13.22 Registration Solenoid SOL5 Trigger Sensor (CT-Q10).....................3-187
REP 14.10 Blower Fans, FAN101 - FAN204..........................................................3-213
REP 13.23 CPU / Controller PCB “A”...................................................................3-188
REP 14.11 Torsion Spring, Paper Stop Upper, Side Guides..............................3-214
REP 13.24 Solenoid Driver PCB “B”....................................................................3-189
REP 14.12 Lead Screw Assembly.........................................................................3-214
REP 13.25 Stepper Motor Driver (M7) PCB “C”...................................................3-190
REP 14.13 Stepper Motor M101 / M201................................................................3-216
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-4
 REP 14.14 Side Guide Adjustment Cable............................................................3-217 REP 15.4 Cover, Upper Exit...................................................................................3-237
REP 14.15 Pivot Bracket OB (AF602 V1)..............................................................3-217 REP 15.5 Cover, Top..............................................................................................3-237
REP 14.16 Pivot Bracket IB (AF602 V1)...............................................................3-219 REP 15.6 Cover, Side.............................................................................................3-238
REP 14.17 Timing Belt Long, Feed Roller............................................................3-220 REP 15.7 Cover, Lower Exit..................................................................................3-238
REP 14.18 PCB LED (Q101LED, Q201LED) (Optical DSD).................................3-220 REP 15.8 Timing Belt.............................................................................................3-239
REP 14.19 PCB Sensor (Q101PHT, Q201PHT) (Optical DSD).............................3-221 REP 15.9 Tray Table...............................................................................................3-240
REP 14.20 Ultrasound DSD Sensor (Matched Pair)............................................3-221 REP 15.10 Solenoid SOL 102/202 (Bin Lock Solenoid)......................................3-241
REP 14.21 PCB White LED Lamp (LAMP101, LAMP201)....................................3-222 REP 15.11 Solenoid SOL 103/203 (Vacuum Feed Solenoid)..............................3-241
REP 14.22 Routing Timing Belts..........................................................................3-223 REP 15.12 Blower Fans and Fan Exhaust Plastic Inserts..................................3-243
REP 14.23 Gear Shaft Timing Wheel....................................................................3-223 REP 15.13 Separation Fan Replacement (FAN105, FAN 205)............................3-244
REP 14.24 Chain.....................................................................................................3-224 REP 15.14 Vacuum Fan Replacement (FAN106, FAN206)..................................3-244
REP 14.25 Structural Shaft/Associated Parts (AF602 V2)..................................3-225 REP 15.15 Torsion Spring, Paper Stop Upper (Side Guides).............................3-245
REP 14.26 Feeder Shaft Assembly / Separator Arm Assembly.........................3-226 REP 15.16 Lead Screw Assembly.........................................................................3-245
REP 14.27 Exit Sensor...........................................................................................3-227 REP 15.17 Stepper Motor M101 / M201................................................................3-247
REP 14.28 Exit Feed Stepper Motor (M301).........................................................3-227 REP 15.18 Side Guide Adjustment Cable............................................................3-248
REP 14.29 Drive Shaft, Paper Path.......................................................................3-228 REP 15.19 PCB LED (Q101LED, Q201LED) (Optical DSD).................................3-248
REP 14.30 Drive Shaft, Exit Feed..........................................................................3-229 REP 15.20 PCB Sensor (Q101PHT, Q201PHT) (Optical DSD).............................3-249
REP 14.31 Idler Shaft Exit.....................................................................................3-229 REP 15.21 Ultrasound DSD Sensor (Matched Pair)............................................3-249
REP 14.32 Coupling Shaft.....................................................................................3-230 REP 15.22 PCB White LED Lamp (LAMP101, LAMP201)....................................3-250
REP 14.33 Power Supply RS-75-12 (PSU1) 12 Vdc.............................................3-230 REP 15.23 Timing Belts, Routing.........................................................................3-250
REP 14.34 Power Supply SP-240-24 (PSU2) 24 Vdc...........................................3-231 REP 15.24 Gear Shaft Timing Wheel....................................................................3-251
REP 14.35 Power Supply SP-750-27 (PSU3) 24Vdc (48V)..................................3-231 REP 15.25 Separation Pads..................................................................................3-251
REP 14.36 Relay DPNO 16A/250V.........................................................................3-232 REP 15.26 Chain.....................................................................................................3-252
REP 14.37 Main PCBs............................................................................................3-232 REP 15.27 Vacuum Belt.........................................................................................3-253
REP 14.38 Support PCBS......................................................................................3-233 REP 15.28 Upper Support Assy............................................................................3-254
REP 14.39 Bin Interlock Switch............................................................................3-234 REP 15.29 Exit Sensor (Q303)...............................................................................3-256
REP 14.40 Door Interlock Switch..........................................................................3-234 REP 15.30 Exit Feed Stepper Motor (M301).........................................................3-256
REP 15.31 Drive Shaft, Paper Path.......................................................................3-257
VF602 REPs
REP 15.32 Drive Shaft, Exit Feed..........................................................................3-258
REP 15.0 Cover, Rear.............................................................................................3-235
REP 15.33 Idler Shaft, Exit....................................................................................3-258
REP 15.1 Cover, Front...........................................................................................3-235
REP 15.34 Baffle Hardware...................................................................................3-259
REP 15.2 Cover, Bin...............................................................................................3-236
REP 15.35 SP Sensor.............................................................................................3-260
REP 15.3 Door........................................................................................................3-236
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-5
 REP 15.36 Vacuum fan assembly.........................................................................3-261 REP 16.20 Sensors, Creaser trigger sensors CR-Q1 to Q4, phototransistors.3-296
REP 15.37 Coupling Shaft.....................................................................................3-262 REP 16.21 Creaser trigger sensors CR-Q1 to Q4, LED’s....................................3-296
REP 15.38 Power Supply RS-75-12 (PSU1) 12Vdc..............................................3-262 REP 16.22 Sensors, Exit sensor CR-Q5...............................................................3-297
REP 15.39 Power Supply SP-240-24 (PSU2) 24Vdc............................................3-263 REP 16.23 Sensors Creaser tools home position sensor CR-Q6......................3-297
REP 15.40 Power Supply SP-750-27 (PSU3) 24Vdc (48V)..................................3-263 REP 16.24 Sensors, Lead screw home position sensor CR-Q7........................3-298
REP 15.41 Relay DPNO 16A/250V.........................................................................3-264 REP 16.25 Electronics, PCB CPU APP 32, PCB “A”...........................................3-299
REP 15.42 Main PCBs............................................................................................3-264 REP 16.26 Electronics, PCB M21H, PCB “E” (CR-M1)........................................3-299
REP 15.43 Support PCBs......................................................................................3-265 REP 16.27 Electronics, PCB M21H, PCB “G”......................................................3-300
REP 15.44 Bin Interlock Switch............................................................................3-266 REP 16.28 Electronics, PCB M21H, PCB “H” (CR-M3).......................................3-300
REP 15.45 Door Interlock Switch..........................................................................3-266 REP 16.29 Electronics, PCB “K” PTC110, short circuit protection...................3-301
REP 15.46 Transformer (TR1)...............................................................................3-267 REP 16.30 Electronics, PCB “L” PTC110, short circuit protection...................3-301
REP 16.31 Electronics, PCB “M” SCP Universal, short circuit protection.......3-302
CR500 REPs
REP 16.32 Electronics, PCB “N” SCP Universal, short circuit protection.......3-303
REP 16.1 Front Cover............................................................................................3-268
REP 16.33 Electronics, PSU1 Power supply, RS-35-12 Meanwell.....................3-303
REP 16.2 Rear Cover.............................................................................................3-268
REP 16.34 Electronics, PSU2 Power supply, SP-240-24 Meanw........................3-305
REP 16.3 Top Cover...............................................................................................3-269
REP 16.35 Electronics, Relay, interlock CR-REL1..............................................3-307
REP 16.4 Frame cover plates................................................................................3-271
REP 16.36 Electronics, Counter...........................................................................3-308
REP 16.5 Electronics cover...................................................................................3-271
REP 16.6 Front side, Interlock switch CR-SW2, CR-SW3...................................3-273 Trim Waste Conveyor (TWC) REPs
REP 16.7 Front side, Main power Switch CR-SW1..............................................3-273 REP 17.0 Docking/Undocking TWC......................................................................3-309
REP 16.8 Front side, Lead screw motor CR-M2..................................................3-274 REP 17.1 Cable Protection....................................................................................3-311
REP 16.9 Front side, Lead screw bearing assembly..........................................3-275 REP 17.2 Belt Protection.......................................................................................3-311
REP 16.10 Front side, Lead screw assembly......................................................3-275 REP 17.4 Antistatic Brush.....................................................................................3-312
REP 16.11 Rear side, Transport timing belt.........................................................3-276 REP 17.3 Tray assembly........................................................................................3-312
REP 16.12 Rear side, Paper transport motor CR-M1..........................................3-277 REP 17.5 Support Rollers......................................................................................3-313
REP 16.13 Creaser.................................................................................................3-278 REP 17.6 Corrugator Roller...................................................................................3-313
REP 16.14 Creaser Timing belt.............................................................................3-279 REP 17.7 Plastic Waste Guides............................................................................3-314
REP 16.15 Creaser motor CR-M3..........................................................................3-282 REP 17.8 Caster Bracket.......................................................................................3-314
REP 16.16 Creaser baffle.......................................................................................3-283 REP 17.9 Idler Roller..............................................................................................3-315
REP 16.17 Creaser assembly................................................................................3-285 REP 17.10 Drive Shaft............................................................................................3-315
REP 16.18 Creaser tools........................................................................................3-290 REP 17.11 Conveyor Belt......................................................................................3-316
REP 16.19 Rollers, Idler and Fixing rollers..........................................................3-294 REP 17.12 O-ring....................................................................................................3-316

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-6
 Booklet Maker ADJs ADJ 12.31 Rotator Disengage Solenoid (CT-SOL1)............................................3-344

ADJ 1.4 Top Cover Height.....................................................................................3-317 ADJ 12.34 Rotator Disengage Solenoid (CT-SOL2)............................................3-344

ADJ 1.6 Interlock Switch Assembly.....................................................................3-319 ADJ 12.43 Registration M4 Home Sensor (CT-Q3)..............................................3-345

ADJ 4.1 Staple Quality...........................................................................................3-321 ADJ 12.44 Registration Cross Rollers Drive Shaft.............................................3-346

ADJ 4.2 Set Transport Calibration........................................................................3-325 ADJ 12.47 Registration Cross Rollers Idler Roller..............................................3-347

ADJ 4.3 Set Transport Drive..................................................................................3-326 ADJ 12.48 Registration Primary Alignment Rail.................................................3-348

ADJ 6.1 BM-M8 Stop Gate Folder Motor, ADJ 12.49 Registration Secondary Alignment Rail............................................3-349
BM-Q7Stop Gate Folder sensor &
ADJ 12.50 Registration Disengage Solenoid (CT-SOL5)....................................3-350
BM-Q48 Clinch Trigger Sensor Right.....................................................3-327
ADJ 12.52 Creaser Assembly...............................................................................3-351
ADJ 6.4 Fold Transmission Chain........................................................................3-328
ADJ 12.54 Creaser Trigger Sensor (CT-Q4) Phototransistor.............................3-352
ADJ 6.6 Upper Fold Roller.....................................................................................3-328
ADJ 12.55 Creaser Tools M6 Home Sensor (CT-Q5)...........................................3-352
ADJ 6.7 Lower Fold Roller....................................................................................3-329
ADJ 12.56 Creaser Timing Belt ............................................................................3-353
ADJ 8.0 Stacker Module........................................................................................3-329
ADJ 12.57 Creaser Tools.......................................................................................3-354
Trimmer ADJs ADJ 12.59 Creaser Baffle......................................................................................3-355
ADJ 10.1 Top Cover...............................................................................................3-330 ADJ 13.4 Bleed Trimmer Home Sensor (CT-Q6)..................................................3-355
ADJ 10.5 TR-SW10 Interlock Switch & TR-Q1 Interlock Sensor........................3-331 ADJ 13.6 Bleed Trimmer Disengage Solenoid (CT-SOL3)..................................3-356
ADJ 10.13 TR-Q4 Transport Belt Sensor.............................................................3-333 ADJ 13.7 Bleed Trimmer Disengage Shaft...........................................................3-356
ADJ 10.19 Lower Trim Knife..................................................................................3-333 ADJ 13.12 Transportation Disengage Solenoid (SOL4).....................................3-357
ADJ 10.21 TR-Q11 Length Adjustment Home Position Sensor.........................3-333 ADJ 13.15 Slide Latch Mechanism.......................................................................3-358
ADJ 13.21 Slide R/H Lower Baffle........................................................................3-359
Square Folder ADJs
ADJ 13.36 12V Power Supply Unit........................................................................3-359
ADJ 11.3 Top Cover...............................................................................................3-334
ADJ 13.37 24V Power Supply Unit (1)..................................................................3-359
ADJ 11.9 SQF-M4 Roll Motor Assembly ..............................................................3-335
ADJ 13.38 24V (48V) Power Supply Unit (2)........................................................3-359
ADJ 11.18 SQF-SW1 Interlock Switch..................................................................3-336

CST ADJs
ADJ 12.6 Interlock Switch Slide Door..................................................................3-338
ADJ 12.10 Drive Motor (M1) Primary Timing Belt...............................................3-339
ADJ 12.11 Drive Motor (CT-M1) Secondary Timing Belt.....................................3-340
ADJ 12.12 Docking Bracket, Infeed......................................................................3-341
ADJ 12.13 Docking Bracket, Exit..........................................................................3-342
ADJ 12.23 Lower Drive Shaft................................................................................3-343
ADJ 12.28 Upper Drive Shaft................................................................................3-343

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-7
General cautions 7. New replacement PCBs and ESD sensitive components, as well as old defective PCBs should
be handled during unpacking and repacking using the ESD ground strap. During the transfer
from or to the packaging material, the PCB should be placed on the ESD bag the replacement
PCB came in.
WARNING:
Unless instructed otherwise, turn off the main power and unplug the machine before attempting any
of the procedures in this section.
To avoid hazardous situations like for instance electric shock or danger while exposed to moving,
rotating or cutting devices, exercise extreme care when operating modules with covers, guards or
protection removed or when electrical or mechanical interlock devices are overrided or bypassed.

CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, data and/or communica-
tions problems.

Failure to use proper ESD procedures will cause damage to electronic components (example:
PCBs). ESD problems can be minimized by maintaining all machine ground connections, ensuring
the proper handling of circuit boards/ sensors.

Use ESD protection when working near PCBs. Failure to use ESD protection is likely to result in a
PCB failure.

Using the ESD Ground Strap

Purpose
The purpose of the ESD (Electrostatic Discharge) ground strap is to preserve the inherent reliability
and quality of electronic components handled by the Service Representative. The strap should be
used whenever handling the circuit boards or any other ESD sensitive components.

Procedure
NOTE:
All procedures requiring use of the ESD ground strap will contain a caution referring to this proce-
dure.

1. Switch off the main power switch.

2. Make sure the power cord connects the machine to the wall outlet.
The power cord and wall outlet must have ground.
3. Connect the claw end of the grounding cord to a chassis ground, such as earth wires
screwed to chassis ground, unpainted frame or an unpainted bracket secured to the frame.
4. Connect the snap end of the blue cord to the snap on the adjustable wrist strap.
5. Place the adjustable wrist strap securely on the wrist.
Wait for one minute to let the electrostatic be discharged from your body.
6. ESD sensitive components can now be handled without causing any ESD related damage.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-8
Recommended tools
Supplied with the Booklet Maker:

• 24 mm spanner/box or open end wrench.

• 17 mm spanner/box or open end wrench.
• Torx T20 driver, min 115mm (4.5”) long. Preferably magnetic.

NOTE:
Supplied tools are located behind the Booklet Maker front
cover. Actual look may differ.

You will also need:

• 5.5, 7, 10 13 and 19mm spanner/box or open end wrench

• 8mm spanner/box or open end wrench or hex nut driver
• 1.5, 2, 2.5, 3, 4, 5mm allen keys
• Flat blade screwdriver size 4 or 5
• Circlip pliers
• Metric feeler gauge set
• Metric sliding caliper

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-9
REP 1.0 Undocking BM / TR / SQF
Parts List on PL 1.0, 1.1, 2.0, 10.0, 11.0, 11.1, 11.2, 12.0

Removal (Booklet Maker from CST)

1. Turn off the main power and disconnect the Power Cord.
2. Open the docking mechanism [A] according to the arrows in figure.
3. Undock the Booklet Maker (system).

NOTE:
Ensure cables on the rear of the machine are not interfering when moving the system.

[B]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-10
Removal (Square Folder from Booklet Maker ) Replacement

1. Turn off the main power and disconnect the Power Cord. 1. When re-installing, ensure that the Docking Plate latches with
the Docking Stud in the outmost position on both operator and non-operator side [A].
2. Loosen the locking nuts (x2) [A].
3. Push Locking Bracket down [B].

NOTE:
Ensure cables on the rear of the machine are not interfering when moving the SQF / TR.

[A]
[A]

[B]

Continued on next page

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-11
 WARNING:
If Top cover closes when undocking the SQF and TR (while Power is not switched off ),
the BM500 system could initiate a test-run, and the knife might be moving in the knife cam
areas and result in personal injury.

Moving parts in the knife

cam areas

Removal (Trimmer from Square Folder )

1. Turn off the main power and disconnect the power cord.
2. Loosen locking nuts (x2) [A].
3. Push Locking Bracket down [B].
4. Move Trimmer aside.

NOTE:
Ensure cables on the rear of the machine are not interfering when moving the TR / SQF.

[B]

[A]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-12
REP 1.1 Front and Rear Cover Removal Rear cover
1. Turn off the main power and disconnect the power cord.
Parts List on PL 2.0 and 2.1 2. Undock the Booklet Maker and Trimmer/ Square folder
(REP 1.0 Undocking BM / TR / SQF).
Removal Front cover
3. Open top cover.
1. Turn off the main power and disconnect the power cord.
4. Remove screws (x2) [A].
2. Loosen screws (x2) [A].
5. Loosen screws (x3) [B].
3. Remove screws (x2) [B].
6. Lift and unhook the rear cover.
4. Tilt the front cover outward and then lift it off the stud [C] on the right hand side.

[A]

[A] [B]

[B]

[C]

Replacement Replacement

1. Reverse removal procedure. 1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 1.2 Lower Infeed Cover and Infeeder Replacement
Parts List on PL 2.0
1. Reverse removal procedure.
Removal Lower Infeed Cover
1. Turn off the main power and disconnect the power cord.
2. Undock the Booklet Maker and Trimmer/Square Folder
(REP 1.0 Undocking BM / TR / SQF).
3. Remove Front and Rear Cover (REP 1.1 Front and Rear Cover).
4. Loosen screws (x2) [A] .
5. Lift up and remove the Lower Infeed Cover [B].

WARNING:
Lower Infeed Cover is very heavy and could cause injury if it falls down.

[A]

continued on next page

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-14
Removal Infeeder Replacement
1. Remove Hand feed cover (REP 1.4 second part)
1. Reverse removal procedure.
2. Disconnect connectors from motor [A].
3. Loosen screws [B] (x4) and remove Cover lower, infeed (x2) [C].
4. Loosen screws [D] (x4).
5. Remove Infeeder.

[C]

[B]

[A]

[D]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-15
REP 1.3 Upper and Lower Exit Cover

Parts List on PL 2.1

Removal
Upper Exit Cover

1. Set the machine to paper size 12x18”.

[A]
2. Turn off the main power and disconnect the power cord.
3. Undock the BM, TR and SQF (REP 1.0 Undocking BM / TR / SQF).
4. Remove Front and Rear Cover (REP 1.1 Front and Rear Cove).
5. Remove User Interface (REP 7.6 User Interface assembly).
6. If present, remove stacker module (REP 8.0 Stacker Module).
7. Remove screws (x5) [A] (two screws in the rear frame and two screws in the rear frame).
8. Remove screws (x2) [B] .
9. Loosen screws (x2) [C] .
10. Pull out lower end of the Exit Cover, lift it up enough to clear the Exit Sensor [D].
[B]
11. Pull out upper end of the Exit Cover and lower it until it touches the Fold Gate.

Replacement

1. Reverse removal procedure.

[C] [D]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-16
REP 1.4 Top Cover and Hand feed cover Removal, Hand feed cover
Parts List on PL 2.0
1. Open the lid and loosen screws [F]
Removal, Top cover 2. Slide cover to the right and remove

1. Turn off the main power and disconnect

the power cord.
2. Open the Top Cover.
3. Remove screws [A] (x4). [F]

4. Remove screws [B] (x2).

5. Remove screws [C] (x2).
6. Remove screws [D] (x3).
[A]
7. Remove top cover [E].

[B]
[C]

[E]

[D]
Replacement

1. Reverse removal procedure.

2. Check adjustment according to (ADJ 1.4 Top Cover Height)

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 1.5 Top Cover Assembly

Parts List on PL 2.0 7. Note position of screws [D] and [E] in regard to the cut-outs.
Remove screws [D] and [F] (x2).
Removal 8. Move Top cover towards the front side.
1. Turn off the main power and disconnect the power cord. 9. Note position of screws [F] in regard to the adjustment plates [G].
2. Remove Front and Rear cover (REP 1.1 Front and Rear Cove). Remove screws [F] (x2) and adjustment plates [G] (x2).
3. Remove User Interface (REP 7.6 User Interface assembly). 10. Lift off the Top cover.
4. If a Cover Feeder is installed - disconnect connectors (plugs) [A] (x2).
5. Squeeze the barbs on the sides and remove connectors (jacks) [B] from Top cover (x2).
6. Note position of the adjustment plates [G] in regard to the screws holding nuts [C].
Remove nuts [C] (x4).

[C] [C]

[F] [G] [F] [G]

[D] [E]

[A] [B]

continued on next page

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-18
 REP 1.5 Top Cover Assembly, continued REP 1.6 Interlock Switch Assembly
Replacement Parts List on PL 2.0
1. Reverse the removal procedure.
Removal
1. Adjustment 1. Turn off the main power and disconnect the power cord.
1. Make sure that the Top cover rests on the rubber supports [H] (x3) when closed. 2. Undock the BM, TR and SQF (REP 1.0 Undocking BM / TR / SQF).
Loosen screw [D], [E] and screws [F] to adjust. 3. Remove the Front Cover (REP 1.1 Front and Rear Cove).
2. Check that the Top cover lock works without binding. 4. Note position and remove connectors [A] (x4).
3. Check that the Top cover Interlock switch is correctly adjusted 5. Remove screws [B] to remove interlock box (x4).
(REP 1.6 Interlock Switch Assembly).
[A]

SW1.2 SW1.4 SW1.3 SW1.1 [B]

[J] [I] [J]

[H]

Replacement
1 Reverse removal procedure.
[K] 2 Check adjustment according to (ADJ 1.6 Interlock Switch Assembly).

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-19
REP 1.7 Sensor Q53 Handfeed Unit infeed sensor
Parts List on PL 2.0

Removal
1. Turn off the main power and disconnect the power cord.
2. Undock the BM, TR and SQF (REP 1.0 Undocking BM / TR / SQF).
3. Loosen screws [A] (x4) and remove Cover lower, infeed (x2) [B].
4. Disconnect the Sensor [C] reach in from under side.
5. Remove sensor by removing screw [D] and nut [E] .

[B]

[A]

[C]

(Picture from inside of infeeder)

[D]

[E]

Replacement
1 Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-20
 REP 3.0 Infeed Module
Parts List on PL 5.3

Removal
1. Turn off the main power and disconnect the power cord.
2. Undock the BM, TR and SQF (REP 1.0 Undocking BM / TR / SQF).
3. Remove Front and Rear Cover (REP 1.1 Front and Rear Cove).
4. Remove Upper Infeed Cover and Cover support (REP 1.3 Upper and Lower Exit Cover).
5. Removing Infeeder is not required but facilitates removal of Infeed Module
(REP 1.2 Lower Infeed Cover and Infeeder).
6. Remove connectors [A] (x2). [D] [E]
7. Remove R-pin [B] and unhook the length adjustment strap [C] (x1).
8. Remove screws [D] on the Front side of the Booklet Maker (x2).
9. Remove screws [E] on the Rear side of the Booklet Maker (x2).
10. Pull out the Infeeder carefully.

NOTE:
Make sure that the Side jogger motor M3 is not catching the frame of the Booklet Maker.

[A]

[C]

[B]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-21
 REP 3.1 BM-Q1 Paper Infeed Sensor REP 3.2 Paper / Side Guides
Parts List on PL 5.3 Removal
1. Turn off the main power and disconnect the power cord.
Removal
2. Undock the BM, TR and SQF (REP 1.0 Undocking BM / TR / SQF).
1. Turn off the main power and disconnect the power cord.
3. Remove Front and Rear Cover (REP 1.1 Front and Rear Cove).
2. Undock the Booklet Maker and Trimmer (REP 1.0 Undocking BM / TR / SQF).
4. Remove screws [A] and remove the paper guide [B] (x2).
3. Remove Front and Rear Cover (REP 1.1 Front and Rear Cove). NOTE:
4. Remove Infeed Cover (REP 1.2 Lower Infeed Cover and Infeeder). Be careful not to drop the screws in the machine.

5. Remove screw [A] (x1). 5. Procedure is the same for the other paper guide.
NOTE: [B]
It is not necessary to remove the Infeed module in order to remove the screw.
After removing the Infeeder, the screw can be reach through the hole in the Infeed module

6. Remove sensor from connector and remove sensor (x1).

Infeed module

[A]

Replacement
[A] NOTE:
Make sure that you are using the correct screws (M4 x 8mm) when reinstalling the side
guides. If you are using longer screws, you may damage the side guide shaft.

Replacement
1. Reverse removal procedure.

1. Reverse removal procedure. 2. Perform BQ 4 Paper / Side Guide Parallelism (staple skew).

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-22
 REP 3.3 BM-M3 Side Jogger Motor &
BM-Q12 Side Jogger Motor Sensor
Parts List on PL 5.3

Removal
1. Turn off the main power and disconnect the power cord.
2. Undock the BM, TR and SQF (REP 1.0 Undocking BM / TR / SQF).
3. Remove Front and Rear Cover (REP 1.1 Front and Rear Cove).
4. Remove Infeed Cover (REP 1.2 Lower Infeed Cover and Infeeder).
5. Remove the Infeed Module (REP 3.0 Infeed Module).
6. Remove connectors [A] (x2).
7. Loosen allen screw [B] to pulley (x1).
8. Remove screws [C] to motor bracket (x2).
[D]
9. Remove Side jogger motor BM-M3 & sensor BM-Q12.
NOTE: The sensor BM-Q12 is located on the motor.
10. Remove screws (x3) in order to remove the Side Jogger Motor and Sensor [D].
Replacement

1. Push Pulley down while re-installing the motor.

2. Ensure that the Allen screw is tightened on the flat spot on the Motor shaft [A].
[A]
3. Reverse the rest of the removal procedure.

[A]

[C]

[B]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-23
 REP 3.4 Side Guide Transmission & Removal Side Guide Transmission
BM-Q13 Side Jogger home position sensor
1. Remove Side jogger motor
(REP 3.3 BM-M3 Side Jogger Motor & BM-Q12 Side Jogger Motor Sensor).
Parts List on PL 5.3
2. Loosen nuts [C] (x2).
Removal BM-Q13 Sensor 3. In order to slack the drive belt,
1. Turn off the main power and disconnect the power cord. use a screwdriver [D] to press the springs [E] (x2) together.
Tighten nuts [C] again (x2).
2. Undock the BM, TR and SQF.
4. Remove screwdriver [D] (x1).
3. Remove Front and Rear Cover (REP 1.1 Front and Rear Cove).
5. Loosen the screws [F] (x4).
4. Remove Infeed Cover (REP 1.2 Lower Infeed Cover and Infeeder).
6. Remove E-clip [G] and move shaft [H] to the left (x1).
5. Remove the Infeed Module (REP 3.0 Infeed Module).
Disconnect connector [A] to sensor BM-Q13 [B] (x1). 7. Unscrew and remove shaft [I] by inserting a screwdriver.
NOTE: 8. Remove the pulley [J] and the timing belt [K].
Make sure that the side guides are in there most inner position
and move the Back jogger module by hand, to easier gain access to the sensor.
6. Pinch the barbs on sensor BM-Q13 [B] to remove sensor.

[C]

[G] [K] [E] [F] [H] [I] [J] [D]

[A] [B]

Replacement
1. Reverse the rest of the removal procedure.
continued on next page

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-24
Replacement

1. Refit the pulley [J] and timing belt [K].

2. Install shaft [I].
3. Move the shaft [H] to the right and install the E-clip [G].
4. Install Side jogger motor
(REP 3.3 BM-M3 Side Jogger Motor & BM-Q12 Side Jogger Motor Sensor).
5. Loosen nuts [C] to regain tension and tigthen nuts again.
6. Position both sides guides centered. For example use the cut-outs [L] as reference.
7. Place the timing belt [K] in the clamps [M] and tighten the screws [F].
8. Verify the centering by moving the side guides and check against, for example, the cut-outs
[L].
9. Reverse removal procedure starting from step 6.

[M]

[L]

[G] [F] [H] [K] [J] [I]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-25
 REP 3.5 Side Guide Transmission Belt
Parts List on PL 5.3 [C]

Removal
1. Turn off the main power and disconnect the power cord.
2. Undock the BM, TR and SQF (REP 1.0 Undocking BM / TR / SQF).
3. Remove Front and Rear Cover (REP 1.1 Front and Rear Cove).
4. Remove Infeed Cover (REP 1.2 Lower Infeed Cover and Infeeder).
5. Remove the Infeed Module (REP 3.0 Infeed Module).
6. Remove Side Jogger Motor M3
(REP 3.3 BM-M3 Side Jogger Motor & BM-Q12 Side Jogger Motor Sensor).
7. Remove Sensor BM-Q13 (REP 3.4).
8. Loose Belt tension by loosen the nuts (x2) [A] and
pushing the belt to the left (with a screwdriver) [B].

9. Tighten nuts (x2) [A] and remove screw driver.

10. Loosen screws (x4) [C].
11. Remove Pulley and Belt [D]

[B]

[A]

[D]

[C]

continued on next page

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-26
Replacement REP 3.6 Back Jogger Module &
BM-Q3 Back Jogger Home Position Sensor
1. Reverse removal procedure.
2. Loosen nuts (x2) [A] and let springs tension the belt. Parts List on PL 5.2
3. Ensure the Side guides are centered [B].
Removal BM-Q3 Back Jogger Home Position Sensor

1. Turn off the main power and disconnect the power cord.
2. Undock the Booklet Maker and Trimmer (REP 1.0 Undocking BM / TR / SQF).
3. Remove Front and Rear Cover (REP 1.1 Front and Rear Cove).
NOTE:
It is possible to reach in and remove the Sensor at this point (refer to below Figure).
If you are unable to access the sensor at this point, follow the rest of the procedure.

4. Remove Infeed Cover (REP 1.2 Lower Infeed Cover and Infeeder).
NOTE:
It is not necessary to remove Infeed module to replace Sensor BM-Q3.

5. Disconnect connector [A] to Sensor BM-Q3 (x1).

6. Remove sensor by pinching the plastic locks in the back [B].
[A]

[B]

[B]
[A]

Replacement Sensor Q3
1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-27
REP 3.7 Back Jogger Assembly

Parts List on PL 5.2

Removal
1. Remove the Infeed module (REP 3.0)
2. Remove the Infeed Transport Module (REP 3.10)
3. Insert a screwdriver into the Shaft [B] and turn counter clockwise.
Keep turning until it is completely loose. Remove Shaft by pulling it out.
4. Remove the Back Jogger Assembly.

[B]

Replacement

1. Reverse removal procedure

2. Make sure to fit hte side guides into the slots on the outer finger assemblies.

continued on next page

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-28
REP 3.8 Back Jogger Fingers and cam
Parts List on PL 5.2

Removal [D]

1. Remove the Back Jogger Assembly (3.7)

2. Loosen the spring linkage, by removing the screw and bushing [A].
3. Remove screws (x2) [B]
4. Remove E-clips (x2) [C]
5. Loosen set screws (x2) [D]
6. Push in the two sintered bearings [E], take out the shaft, and slide required parts off the Shaft.

NOTE: Make sure to notice the orientation of the Back jogger fingers,
the bushings and the orientation of the cam [F].

NOTE:There are four types of he Back jogger fingers assembly,

the two different left fingers are mirror images of the two right fingers.

[A]

[G]

[H]
[F]

Replacement

1. When re-installing Fingers and the cam on Shaft ensure following: the left and right
fingers are placed in correct positions.
[E] [E]
2. Adjust the two set collar [G] so they are as close against the cam as possible,
and tighten the set screws (x2) [D].

[B] 3. Reverse removal procedure.

[B]
NOTE: Make sure to position the middle finger tabs fully into the slots [H]

[C]
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-29
REP 3.9 BM-M2 Back Jogger Motor & BM-Q45 Back Jogger
Motor Sensor
Replacement
Parts List on PL 5.2
1. Reinstall screws [E] to the motor (x3).
Removal
2. Reinstall connector [D] (x1).
1. Turn off the main power and disconnect the power cord.
3. Reinstall screw (x1) [A] and nut [B] (x1).
2. Open Top Cover. NOTE:
3. Remove Back jogger module ( REP 3.8 Make sure that the screw [A] is positioned against flat of the motor shaft, and that the mo-
tor shaft is level [F] with the Bracket [C].
4. Loosen screw (x1) [A] and nut [B] (x1).
5. Remove the crank [C] from the motor shaft. 4. Reverse the rest of the removal procedure.
6. Remove connector [D] (x1).
7. Remove screws [E] to the motor (x3).

[A]

[E]

[C]
[D] [B] [F]
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-30
REP 3.10 Infeed Transport Module
Parts List on PL 5.3
[C]
Removal

1. Remove pin and e-clips [A].

2. Remove screw [B].
3. Cut cable ties (x2) [C].
4. Remove connectors [D] (x2).
5. Remove Infeed transport module.
[D]

[A]

[B]

Replacement
1. Reverse removal procedure.
NOTE:
Mount the pin [A] in the lower holes.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-31
REP 3.11 Infeed Transport Wheel REP 3.12 BM-M1 Infeed Motor & BM-Q2 Infeed Motor Sensor
Parts List on PL 5.3
Parts List on PL 5.3
Removal
1. Turn off the main power and disconnect the power cord. Removal
2. Open Top Cover. 1. Turn off the main power and disconnect the power cord.

3. Remove nuts [A] (x3). 2. Open Top Cover.

4. Remove E-clip [B] (x1). 3. Remove the Infeed Transport Module (REP 3.10 Infeed Transport Module).
NOTE: 4. Remove nuts (x3) and lift up assembly [A].
Be careful not to drop the plastic bushings located at the ends of the Infeed wheel shaft
after removing the E-clip. 5. Loosen allen screw [B].

5. Removing the Infeed transport module (REP 3.10 Infeed Transport Module) 6. Remove screws (x3) and slide the motor and sensor out from the bracket [C].
facilitates replacement of the Infeed transport wheel.

[A] [A]

[B] [C]

[B]

Figure shows infeed module removed for clarity

Replacement Replacement
1. Reverse removal procedure. 1. Reverse removal procedure.
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-32
 REP 4.0 Stapler Heads, Stapler Assy and Clincher Removal of stapler head
Parts List on PL 7.0 CAUTION:
Never loosen the screws fastening the stapler head to the adapter plate (red marked),
Staple Cartridge Replacement since the assembly is factory mounted to ensure proper alignment.
1. Open the Booklet Maker top cover.
Replacement of staple cartridge 2. Disconnect connectors to actual stapler head [A] (x3).
1. Open the Booklet Maker top cover.
3. Cut cable ties. Right stapler head (x5) [B], left head (x4) [C].
2. DIsconnect connectors to staple heads (x3) P43/P44/P47.
4. Remove nuts [D] fastening actual stapler to the bracket(x4) and lift out the stapler head.
3. Press the staple cartridge ejector [A].
4. Pull out the staple cartridge [B]. CAUTION:
Do not remove any screws that are redmarked.
5. Replace by pushing a new staple cartridge into the staple head,
until it snaps in position. [A]

[A]

[B] [D, right stapler] [D, left stapler]

[C]
[B]

Continued on next page.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-33
 Replacement of stapler head
1. Reverse the removal procedure.

NOTE:
Right stapler: The harness to the thickness sensor should be routed together
with the haness to the stapler, and tighten by 5 tie wraps [A].

The left stapler is tighten with 4 cables retainer [B].

2. Check adjustment according to (ADJ 4.1 Staple Quality).

[left stapler]
[right stapler]

[right stapler] [left stapler]

[A]

[B]
[A]

Viewed from bottom

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-34
 Removal of stapler/ clincher assembly [D, clincher left] [D, clincher right]
1. Remove Infeeder (REP 3.0 Infeed Module).
2. Disconnect connector P49 [A], see above (x1).
3. Disconnect connectors to staplers [B] (x2) and connector P47 [C].
4. Disconnect connectors to both clinchers [D] (x2).
5. Remove screws [E] on both sides (x4).

6. Remove stapler/ clincher assembly [F].

[A]

[E]

[B]

[B] [C]

continued on next page

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 Removal of clincher
1. Remove stapler / clincher assembly, see previosly section.
2. Remove screws [A] (x4) for each clincher in order to remove clincher assy (x4).
3. Remove screws [B] (x2) for each clincher, to remove clincher [C] (x2) from
bracket [D] (x2).

[A]

[F] [B]

[D]

[C]

Replacement of clincher
1. Reverse the removal procedure.
Replacement of stapler head bracket assembly
1. Reverse the removal procedure. 2. Check adjustment according to ( ADJ 4.1 Staple Quality).

2. Check adjustment according to (ADJ 4.1 Staple Quality).

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 4.1 Staple Quality (forming) REP 4.2 BM-Q47 Stapler Home Position Sensor Right &
Parts List on PL 7.0 BM-Q50 Stapler Home Position Sensor Left
Purposes Parts List on PL 7.0
• Ensure proper staple function, the stapler head bracket assembly can be adjusted
both along with and across the paper travelling direction. Removal
• There is no need to adjust each stapler head individually. 1. The home position sensors is built into the stapler assembly.
Each staple head is factory mounted to an adapter plate and then sealed with red paint. Replace the stapler (REP 4.0 Stapler Heads, Stapler Assy and Clincher).
Replacement staple heads comes with adapter plate factory mounted.
The adapter plate can only be installed to the stapler head bracket one way and
is not adjustable.
Replacement

1. Reverse removal procedure.

x y x y
Staple head not centered. Staple head centered.
Distance x and y is not equal. Distance x and y is equal.

Correctly formed staples.

1. Check that stapler head is centered.

If not centered, proceed to adjustment described in ADJ 4.1 Staple Quality.
2. Check the staple quality.
If staples are correctly formed, no adjustment is needed.
Else proceed with adjustment described in ADJ 4.1 Staple Quality.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 4.3 BM-M5 Set Transport Motor & [D]
BM-Q40 Set Transport Motor Sensor
Parts List on PL 5.0
Removal
1. Set the machine to A4.
2. Turn off the main power and disconnect the power cord.
3. Remove Front and Rear Cover (REP 1.1 Front and Rear Cove).
4. Remove Infeed Cover (REP 1.2 Lower Infeed Cover and Infeeder).
[C]
5. Remove infeed module. This is not required but it will be easier to gain access.
6. Remove R-pin [A] and unhooked steel belt [B].
7. Remove screw and bushing [C].
8. Remove screws (x3) [D], loosen screws (x2) [E] and tilt down the bracket [F]. [E]
9. Loosen screws [G], unhooked the timing belt [H] and remove the motor [I] (x2).
10. Disconnect connectors [J] (x2). [H]

[I] [G]

[J]

[B]

[F]

Replacement

1. Check that the timing belt do not have too much tension.
(Too much belt tension will affect the motor speed negatively)
[A]
2. Reverse Removal procedure.
3. Check adjustment according to (ADJ 4.3 Set Transport Drive).

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 4.4 BM-M22 Stop Gate Stapler Motor
[E]
Parts List on PL 5.0
[F]
Removal
1. Select the machine to A4.
2. Turn off the main power and disconnect the power cord.
3. Remove Front and Rear Cover (REP 1.1 Front and Rear Cover).
4. Remove Infeed cover (REP 1.2 Lower Infeed Cover and Infeeder).
5. Remove infeed module.
This is not required but it will be easier to gain access to the motor.
6. Remove R-pin [A] and unhooked steel belt [B].
7. Remove screw and bushing [C].
8. Loosen screw and nut. Remove crank wheel [D]. [G]

9. Remove screws [E].

10. Disconnect connectors [F] (x2) and remove motors [G].

[D]

Replacement

1. Mount motor and connectors (x2).

2. Ensure there is 1 mm spacing between crank and sensor.
[B]
3. Reverse Removal procedure from Step 4.
4. Check adjustment (BQ 9 Staple and Fold Position).

[C]

[A]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 4.5 BM-Q41 Stop Gate (M22) Motor Sensor [D]
Parts List on PL 5.0

Removal

1. Turn off the main power and disconnect the power cord.
2. Remove Front and Rear Cover (REP 1.1 Front and Rear Cover).
3. Select the machine to A4.
4. Remove Infeed cover (REP 1.2 Lower Infeed Cover and Infeeder).
[C]
5. Remove infeed module.
This is not required but it will be easier to gain access to the motor. [H]

6. Remove R-pin [A] and unhooked steel belt [B].

7. Remove screw and bushing [C].
[E]
8. Remove screws (x3) [D], loosen screws (x2) [E] and tilt down the bracket [F].
9. Disconnect connectors [G] (x2) and remove sensor BM-Q41 [H].
10. Loosen screw (x1) [I] and nut [J] (x1).
11. Remove the crank [K] from the motor shaft.
12. Remove screws(x3) [L].

Replacement [F]

NOTE:
Make sure that the screw [I] is positioned against the flat of the motor shaft.
Make also sure that the crank is 1 mm from the bottom of the sensor.
Mount sensor and connectors (x2).
1. Reverse Removal procedure from Step 4.

[ I, J ]
[B]

[G] [L]

[K]

[A]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 4.6 BM-Q42 Home Position Stop Gate Stapler (M22) sensor

Parts List on PL 5.0

Removal
1. Follow REP 4.5 BM-Q41 Stop Gate (M22) Motor Sensor,, step 1-8.
2. Loosen screw (x1) [A].
3. Disconnect connector (x1] [B].
4. Remove sensor BM-Q42 [C].

[C] [B] [A]

Replacement

1. Reverse Removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 5.0 BM-Q4 Start Sensor Saddle Stapling Sensor
Parts List on PL 5.1
[D]
Removal
1. Set machine to A3 to facilitate access to nuts.
2. Turn off the main power and disconnect the power cord.
[C]
3. Open Top Cover.
4. Remove nuts [A] (x4).
5. Remove screw [B].
6. Disconnect connector [C] (x1) and remove sensor [D].

[B]

Replacement

1. Reverse Removal procedure.

NOTE:
Make sure that the sleeve of the wire, do not interfere with the paper path.

[A]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 5.1 BM-M9 Staple Fold Positioning Motor &
BM-Q10 Stapler Fold Positioning Motor Sensor
Parts List on PL 6.2 [C]

Removal
1. Set the machine up for A4 / 8.5 x 11”.
2. Turn off the main power and disconnect the power cord.
3. If system is equipped with a SQF, undock it (REP 1.0 Undocking BM / TR / SQF).
[A]
4. Remove Front Cover (REP 1.1 Front and Rear Cover).
5. Remove Cover Exit Lower (REP 1.3 Upper and Lower Exit Cover).
6. Disconnect connectors (x2) [A].
7. Remove screws from the motor bracket (x3) [B].

NOTE:
The sensor BM-Q10 is located on the motor.
8. Remove motor [C] with bracket.

[B]

Replacement

1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 6.0 Length Transmission Shaft & Lubrication of Length Transmission Shaft
BM-Q11 Staple Fold Home positioning Sensor 1. Remove Front and Rear Cover (REP 1.1 Front and Rear Cover).
2. Remove Infeed Cover (REP 1.2 Lower Infeed Cover and Infeeder).
Parts List on PL 4.0 3. Lubricate with grease on the Length transmission shaft [A],
and the nut of the Length transmission shaft.
Removal BM-Q11 Sensor
1. Turn off the main power and disconnect the power cord. NOTE:
You should be able to turn the length adjustment shaft by hand.
2. Remove Front and Rear Cover (REP 1.1 Front and Rear Cover).
3. Remove Infeed Cover (REP 1.2 Lower Infeed Cover and Infeeder).
4. Disconnect Connector (x1) [A]. [A]

5. Loosen screw (x1) [B].

6. Remove Sensor BM-Q11 [C].

[B]

[C]

[A]

Replacement BM-Q11 Sensor

1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 6.1 BM-M8 Stop Gate Folder Motor, Removal Motor BM-M8 / Sensor BM-Q43
BM-Q7 Stop Gate Folder Sensor & 1. Set the machine up for 12 x 18”.
BM- Q48 Clinch Trigger Sensor Right 2. Turn off the main power and disconnect the power cord.
3. If system is equipped with a TR, undock it (REP 1.0 Undocking BM / TR / SQF).
Parts List on PL 6.2 and 7.0 4. Remove nuts(x2) and washers (x2) [A].
5. Remove Paper guide [B].
6. Remove screws (x2), bushing (x2), nuts (x2) [C] on both sides.
[D] [A] [B]
7. Remove Stop gate [D].
8. Loosen allen screw [E] and remove the crank [F].
9. Remove screws (x3) [G] and remove the motor M8 ( with BM-Q43) [H].

Replacement Motor BM-M8 / Sensor BM-Q43

[C]

1. Reverse removal procedure.

2. Check adjustment according to:
(ADJ 6.1 BM-M8 Stop Gate Folder Motor,
BM-Q7Stop Gate Folder sensor &
BM-Q48 Clinch Trigger Sensor Right).
[F]
[E]
[C]
Removal Sensor BM-Q7

1. Disconnect connector [K] (x1).

[G]
2. Remove screw [L] (x2).
[H] 3. Remove sensor BM-Q7 [M].

Replacement Sensor BM-Q7

1. Reverse removal procedure.

2. Check adjustment according to:
(ADJ 6.1 BM-M8 Stop Gate Folder Motor,
BM-Q7Stop Gate Folder sensor &
[L] [M] [K] BM-Q48 Clinch Trigger Sensor Right)

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 6.2 Fold Stop Gate
Parts List on PL 6.2

Removal
1. Set the machine up for 12 x 18”.
2. Turn off the main power and disconnect the power cord.
3. If system is equipped with a TR, undock it (REP 1.0 Undocking BM / TR / SQF).
4. Remove nuts (x2) and washers (x2) [A].
5. Remove Paper guide [B].
6. Remove screws (x2), bushing (x2), nuts (x2) [C] on both sides.
7. Remove Stop gate [D].

max. 0.2 mm
[D] [A] [B]

[C]
Replacement
NOTE:
Make sure that the shaft on the Fold stop gate, is positioned in the linkage.

1. Reverse removal procedure.

2. Place a ruler as in figure above.

[C]
3. Ensure that the stop gate is parallel with the ruler (i.e the curvature of the gate is zero)
or slightly concave with a maximum curvature less or equal +0.2mm.

The curve should never be convex, i.e. the curvature of the gate should never be less
than zero (negative).

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 6.3 BM-M7 Fold Knife Motor & [B] [C]
BM-Q15 Fold Knife Home Position Sensor
Parts List on PL 6.2
Removal sensor BM-Q15

1. Set the machine up for 8.5 x 11 ”.

2. Enter service mode, start up and stop M7 in its upper position.
3. Turn off the main power and disconnect the power cord.
4. Remove Front and Rear Cover (REP 1.1 Front and Rear Cover).
5. Remove Infeed cover (REP 1.2 Lower Infeed Cover and Infeeder).
6. Disconnect connector [A] to sensor BM-Q15 (x1).
7. Remove sensor through the opening,
if it is hard to access sensor, proceed to next step.
[D] [A]
8. Loosen screw [B] and remove the set collar [C].
9. Disconnect connector (x1) [D].
10. Remove screws (x 2+2) and nuts (x 2+2) on both side [E].
11. Remove sensor BM-Q15 [A].

Removal motor BM-M7

1. Follow the procedure for removing sensor BM-Q15, step 1-10.

2. Remove screw and washer [F].
3. Remove crank [G].
4. Remove screws (x3) [H].
5. Remove motor.
[E]
Replacement
NOTE:
Install the Motor on the Motor Assembly but do not tighten the screws [G]
[F] [A]
until the Crank Wheel is fasten with the screw and washer.

1. Reinstall screws [H] to the motor (x3).

NOTE: Do not tighten the screws.
2. Reinstall the Crank [G].
3. Reinstall screw (x1) and washer (x1) [F].
4. Tighten screws [H] to the motor (x3).
5. Reverse the rest of the removal procedure.
[H]
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 6.4 Fold Transmission Module, BM-M6 Fold Roller Motor,
BM-Q9 Fold roller sensor & fold transmission chain.
Parts List on PL 3.0 and 6.0 Removal BM-M6 Fold Roller Motor

Removal Transmission module 1. Remove transmission module (see previous section).

2. Loosen screw [E] and nut [F] for the chain tensioner.
1. Turn off the main power and disconnect the power cord.
3. Remove screws (x3) [G] and washers (x6) [H].
2. Remove Cover (REP 1.1 Front and Rear Cover).
4. Remove BM-M6 Motor.
3. Disconnect connector [A] to BM-M6 Fold roller motor (x1).
[G] [E]
4. Disconnect connector [B] to BM-Q9 Fold roller sensor (x1).
5. Remove nuts [C] to the Fold transmission module (x3).
6. Remove transmission module w/M6 motor assembly.

[C] [A]

[H]

[F]

Removal BM-Q9 Fold roller sensor

1. Remove screw [I] and nut [J] for the sensor bracket.
2. Remove sensor bracket and shaft [K].

[I]

[K]

[J]

[B]

Continued on next page

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 Removal Transmission chain Replacement Transmission module

1. Run the BM-M6 Fold Roller Motor in service mode, 1. Reverse the removal procedure.
and stop when the master link is accessable.
2. Make sure there is grease in the couplers.
2. Remove screw [A] and nut for the chain tensioner.
3. Remove chain tensioner [B]. Replacement BM-M6 Fold Roller Motor
4. Remove master link and chain. 1. Reverse the removal procedure.
[B]
2. Adjust chain according to ADJ 6.4 Fold Transmission Chain.

[A]
Replacement BM-Q9 Fold Roller sensor

1. Reverse the removal procedure.

Replacement transmission chain

1. Reverse the removal procedure.

2. Adjust the chain until the tension is almost tense.

NOTE:
The route of the chain [A] should be mounted according to figure.

[B] [A]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 6.5 Spring Support Replacement

1. Reverse removal procedure.

Parts List on PL 6.1
2. Check/Adjust spring tension according to ADJ 6.7 Lower Fold Roller.
Removal Front Spring Support
Lubricate Spring Support
1. Turn off the main power and disconnect the power cord.
2. Remove Rear Cover (REP 1.1 Front and Rear Cover). 1. Without removing parts, add oil from care pack kit behind Spring Support [B] and wedge [C].
3. Remove Fold Transmission Module 2. Perform the same lubrication on both sides of the Booklet Maker.
(REP 6.4 Fold Transmission Module, BM-M6 Fold Roller Motor,
BM-Q9 Fold roller sensor & fold transmission chain).
4. Remove nut and the bracket [A].
Lubricate Fold roller bearings
5. Remove nuts and bushings (x5) and Spring Support [B].
1. If necessary, apply grease to metal surfaces between bracket and bearings
(where the bearings move) and between the excenter and the wedge [C].
Areas are marked in red.
2. Perform the same on both sides of the Booklet Maker.

[C]

[A]

NOTE:
Picture shows front side.
Rear side looks similar,
but is mirrored.
[B]

Removal Rear Spring Support

1. Turn off the main power and disconnect the power cord.
2. Remove Rear Cover (REP 1.1 Front and Rear Cover).
3. Remove nut and the bracket [A].
4. Remove nuts and bushings (x5) and Spring Support [B].

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-50
 REP 6.6 Upper Fold Rollers [H] [I]

Parts List on PL 6.1

Removal
1. Set machine to A3 or 8.5x14”. [F]
[G]
2. Turn off the main power and disconnect the power cord.
3. Remove Front and Rear Cover (REP 1.1 Front and Rear Cover).
4. Remove User Interface (REP 7.6 User assembly).
5. Remove Upper Exit Cover (REP 1.3 Upper and Lower Exit Cover).
6. Remove nuts (x2) [C] for the cam cover on both sides.
[H]
7. Remove nuts (x2) [D] for the leaf springs (x2) [E] on both sides.
8. Remove the paper guide [F] by loosening/removing the spacers (x2) [G] on both sides.
9. Remove the nuts (x4) [H] for the locking brackets (x2) [I] on both sides.
10. Remove screws (x2) [J] and the plastic guides (x2) [K] holding the wires.
11. Unhook the wires from the springs [L] and place the springs on the screws [M].
12. Loosen the nuts (x2) [N] in order to release the tension of the fold roller springs [O].
[J]

[L]

[C]

[M]
[D]

[E]

Continued on next page

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 13. Remove the nut [P] for the bracket [Q] on both sides.
[S]
14. Press the bracket [Q] from inside and remove the spring assemblies on both sides.

Note:
The Upper and lower spring is not align resulting in a distance [R]
greater than zero.

[T]
15. Remove the nuts (x4) [S] for the fold roller holders [T] on both sides.
16. Remove screws, washers and bearings from the fold rollers [U].
17. Gently remove the Upper folder rollers.

[O]
[U]

[N]

Replacement

1. Reverse removal procedure.

2. Check Fold roller adjustment according to (ADJ 6.6 Upper Fold Roller).
3. When re-mounting the spring assemblies, push the bracket
in the direction of the arrow [V] with a screwdriver [W].
4. Ensure the springs are placed in the correct and recorded positions.
5. Adjust the spring tension according to ADJ 6.7 Lower Fold Roller.

[Q] [P] [V]

Upper
spring [R] Lower spring

[W]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 6.7 Lower Fold Rollers
Parts List on PL 6.1

Removal
[F]
1. Remove Upper fold rollers (REP 6.6 Upper Fold Rollers).
2. Remove nuts (x2) [A] and the bearing support [B].
3. Remove lower fold roller (1 of 2) [C].
4. Remove screws (x3) [D] and the paper guide [E].
5. Remove lower exit cover (REP 1.3 Upper and Lower Exit Cover).
6. Remove screw (x1) [F] and tilt out the frame [G].
7. Remove the lower fold roller (2 of 2) [H].

[A]

[B]
[C]

[E]

[H] [G]

Replacement

1. Reverse the removal procedure.

NOTE:
Make sure to lubricate, with Molybdenum grease.
PerformADJ 6.7 Lower Fold Roller.
[D]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 6.8 BM-Q44 Home Position Stop Gate Folder Sensor REP 6.9 BM-Q8 Exit Sensor
Parts List on PL 2.1
Parts List on PL 6.2
Removal
Removal
1. Set machine to 12 x 18”.
1. Enter Service mode and run M9, press cycle 1 and then press cycle out 2. Turn off the main power and disconnect the power cord.
until the motor reaches its outermost porsition.
3. Undock the Booklet Maker and Trimmer (REP 1.0 Undocking BM / TR / SQF).
2. Turn off the main power and disconnect the power cord.
4. Remove Front and Rear Cover (REP 1.1 Front and Rear Cover).
3. Undock the Booklet Maker and Trimmer (REP 1.0 Undocking BM / TR / SQF).
5. Remove Exit Cover (REP 1.3 Upper and Lower Exit Cover).
4. Replace the sensor [A].
6. Remove screw [A] (x1).
7. Disconnect connector [B] (x1).

[B]

[A] [A]

Replacement Replacement

1. Reverse removal procedure. 1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 7.0 MD6DC PCB ”H” (upper)
Parts List on PL 4.0 Replacement

Removal 1. Ensure DIP Switches are set according to below schematic figure.
2. If installing a new MD6DC PCB you must load new S/W.
CAUTION: Refer to GP 19 Update Software.
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, data and/or communica-
3. Reverse removal procedure.
tions problems. Failure to use proper ESD procedures will cause damage to electronic components
(example: PCBs). ESD problems can be minimized by maintaining all machine ground connections,
ensuring the proper handling of circuit boards/ sensors. Use ESD protection when working near PCBs.
Failure to use ESD protection is likely to result in a PCB failure.

1. Turn off the main power and disconnect the power cord.
2. Undock the Booklet Maker and Trimmer (REP 1.0 Undocking BM / TR / SQF).
3. Remove the Front Cover (REP 1.1 Front and Rear Cover).
4. Remove all connectors from the PCB ”H” (x8).
5. Pinch the barbs of the pins and remove PCB ”H”.

H.P4 H.P5 J51

ON

1 2 3 4
H.P11

H.P13
H.P3

OFF / CLOSED
H.P2 H.P14 ON / OPEN
1 2 3 4
DIP Switch settings

H.P16

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 REP 7.1 MD6DC PCB ”B” (middle)
Parts List on PL 4.0 Replacement

Removal 1. Ensure DIP Switches are set according to below schematic figure.
2. If installing a new MD6DC PCB you must load new S/W.
CAUTION: Refer to GP 19 Update Software.
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, data and/or 3. Reverse removal procedure.
communications problems. Failure to use proper ESD procedures will cause damage to
electronic components (example: PCBs). ESD problems can be minimized by maintaining
all machine ground connections, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to
result in a PCB failure.

1. Turn off the main power and disconnect the power cord.
2. Undock the Booklet Maker and Trimmer (REP 1.0 Undocking BM / TR / SQF).
3. Remove the Front Cover (REP 1.1 Front and Rear Cover).
4. Remove all connectors from the PCB ”B” (x9).
5. Pinch the barbs of the pins and remove PCB ”B”.

B.P4 B.P5

ON

1 2 3 4
B.P12

B.P13
B.P11

B.P3
B.P14 OFF / CLOSED

B.P2
ON / OPEN
1 2 3 4
DIP Switch settings

B.P16
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 REP 7.2 MD6DC PCB ”C” (lower)
Replacement
Parts List on PL 4.0
1. Ensure DIP Switches are set according to schematic (Figure 2).
Removal 2. If installing a new MD6DC PCB you must load new S/W.
Refer to GP 19 Update Software.
CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, data and/or 3. Reverse removal procedure.
communications problems. Failure to use proper ESD procedures will cause damage to
electronic components (example: PCBs). ESD problems can be minimized by maintaining
all machine ground connections, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to
result in a PCB failure.

1. Turn off the main power and disconnect the power cord.
2. Undock the Booklet Maker and Trimmer (REP 1.0 Undocking BM / TR / SQF).
3. Remove the Front Cover (REP 1.1 Front and Rear Cover).
4. Remove all connectors from the PCB ”C” (x9).
5. Pinch the barbs of the pins and remove PCB ”C”.

C.P4 C.P5

ON

1 2 3 4

C.P12

C.P11
C.P13

C.P3
OFF / CLOSED
C.P14
ON / OPEN
C.P2
1 2 3 4
DIP Switch settings

C.P16
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 REP 7.3 PCB Controller, PCB ”A”
Parts List on PL 3.1
Removal

CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, data and/or com-
munications problems. Failure to use proper ESD procedures will cause damage to electronic
components (example: PCBs). ESD problems can be minimized by maintaining all machine
ground connections, ensuring the proper handling of circuit boards/ sensors. Use ESD protec-
tion when working near PCBs. Failure to use ESD protection is likely to result in a PCB failure.

1. Record NVM values: BM: Index 2-7 and 11, see GP 20 NVM reset
NOTE: GP 20 also covers problems in retieving NVM values.
2. Turn off the main power and disconnect the power cord.
3. Undock the Booklet Maker and Trimmer (REP 1.0 Undocking BM / TR / SQF).
4. Remove the Front Cover (REP 1.1 Front and Rear Cover).
5. Remove all connectors from the PCB Controller, PCB “A” PCB (x10).
6. Pinch the barbs of the pins and remove PCB Controller, PCB “A”.
Replacement

1. Reverse removal procedure.

2. Enter recorded NVM values: BM: Index 2-7 and 11, see GP 20 NVM reset.

P11 P7 A.P5 A.P4 A.P3 A.P2

A.P13 A.P10 A.P8 A.P1

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 7.4 Addon PCB ”F”
Parts List on PL 3.1 Adjustment

Removal 1. Check perform calibration of trim potentiomenters according to table below.

2. Use an Ohm meter or a Multi meter with appropriate sensitivity.
3. After Calibration is performed and a Cover Feeder is installed perform DSD calibration
CAUTION: (ADJ 9.9)
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, data and/or com-
munications problems. Failure to use proper ESD procedures will cause damage to electronic
components (example: PCBs). ESD problems can be minimized by maintaining all machine
ground connections, ensuring the proper handling of circuit boards/ sensors. Use ESD
protection when working near PCBs. Failure to use ESD protection is likely to result in a PCB Pot Value Measure Component Module
failure.
R1 2.2 - 2.3KΩ J1, pin 1 Q30 DSD sensor Cover Feeder
1. Turn off the main power and disconnect the power cord. &3
2. Undock the Booklet Maker and Trimmer (REP 1.0 Undocking BM / TR / SQF). R2 Not in use
3. Remove the Front Cover (REP 1.1 Front and Rear Cover).
R3 2.2 - 2.3KΩ J3, pin 1 Q37 Hall sensor M23 BM Thickness
4. Remove all connectors from the PCB ”F” (x5). &3 thickness motor sensor
5. Pinch the barbs of the pins and remove PCB ”F”. R4 9.5 - 10.5KΩ J4, pin 1 Q38 Cover width sensor Cover Feeder
&3

F.P1

F.P6 F.P2

F.P3

F.P4

F.P5

Replacement

1. Reverse removal procedure.

Perform next section, Adjustment, before connecting
NOTE:
If the Addon PCB F is replaced and the Booklet Maker is equipped with a
Cover Feeder, perform a DSD Calibration.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 7.5 Expansion PCB ”J” 4 In 4 Out REP 7.6 User Interface assembly
Parts List on PL 3.1 Parts List on PL 2.0

Removal Removal UI assembly

CAUTION: CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, data and/or com- ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, data and/or com-
munications problems. Failure to use proper ESD procedures will cause damage to electronic munications problems. Failure to use proper ESD procedures will cause damage to electronic
components (example: PCBs). ESD problems can be minimized by maintaining all machine components (example: PCBs). ESD problems can be minimized by maintaining all machine
ground connections, ensuring the proper handling of circuit boards/ sensors. Use ESD ground connections, ensuring the proper handling of circuit boards/ sensors. Use ESD
protection when working near PCBs. Failure to use ESD protection is likely to result in a PCB protection when working near PCBs. Failure to use ESD protection is likely to result in a PCB
failure. failure.
1. Turn off the main power and disconnect the power cord.
1. Turn off the main power and disconnect the power cord.
2. Undock the Booklet Maker and Trimmer (REP 1.0 Undocking BM / TR / SQF).
2. Remove the Front Cover (REP 1.1 Front and Rear Cover).
3. Remove the Front Cover (REP 1.1 Front and Rear Cover).
3. Remove screws (x4) [A].
4. Remove all connectors from the PCB (x3).
4. Disconnect connectors P107 and ethernet [B].
5. Pinch the barbs of the pins and remove PCB.
5. Remove the UI assy.

J.P2

J.P1

[B]
J.P3 [A]

Replacement

1. Reverse removal procedure.

NOTE:
Replacement If the User Interface assembly on the BM500 is to be replaced,
the BM500 upgrade kit should be transferred from the old User Interface assembly to the new one.
1. Reverse removal procedure. See installation instruction for how to install the upgrade kit.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 7.7 BM-M23 Thick Sensor Motor
BM-Q37 Thick Set Motor Sensor &
BM-Q36 Thick Set Motor Home Sensor [G]
Parts List on PL 7.1
[D]
Removal
[F]
1. Set machine to 12 x 18 “.
2. Turn off the main power and disconnect the power cord. [C]

3. Loosen nut (x1) [A] and remove cover.

4. Remove nuts (x4) [B] for the left stapler, and move stapler on the operator side. [E]

5. Remove screw, lock nut (x1) [C] and spring [D].

6. Remove arm sensor [E].
7. Loosen screw and nut [F].
8. Remove crank [G].
9. Disconnect connectors M23 and Q37 [H].
[I]
10. Remove screws (x3) [I] and remove motor BM-M23.

Replacement

1. Reverse removal procedure.

2. When tightening the screw and nut [F] for the crank [G],
ensure that the distance [J] is between 1-1.5 mm.
3. Adjust the lock nut [C], so that the distance [K] is 1 mm.

1-1.5 mm [J]

[H]
1 mm [K]
[B]

[A]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 7.8 Removing Power Supply unit
[D]
Parts List on PL 3.0

Removal

CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, data and/or com-
munications problems. Failure to use proper ESD procedures will cause damage to electronic
components (example: PCBs). ESD problems can be minimized by maintaining all machine
ground connections, ensuring the proper handling of circuit boards/ sensors. Use ESD
protection when working near PCBs. Failure to use ESD protection is likely to result in a PCB
failure.

1. Turn off the main power and disconnect the power cord.
2. Undock the Booklet Maker and Trimmer (REP 1.0 Undocking BM / TR / SQF).
3. Remove the Front Cover (REP 1.1 Front and Rear Cover).
4. Loosen screws [A] and remove cover [B] (x2).
5. Disconnect connectors P45, G.P2, F.P2 [C] (x3).
6. Loosen nuts [D] and remove PSU (x3).

[B] [C]

[A]

Positions of G.P2 and F.P2

Replacement
1. Reverse the removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 7.9 Accessing Rear Side of Connection Bracket REP 7.10 BM-M19 Infeed module motor M19 &
Parts List on PL 4.0 BM-Q34 Infeed motor sensor
Removal Parts List on PL 4.0

CAUTION: Removal
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, data and/or communica- 1. Turn off the main power and disconnect the power cord
tions problems. Failure to use proper ESD procedures will cause damage to electronic components
2. Undock the BM from upstream device
(example: PCBs). ESD problems can be minimized by maintaining all machine ground connections,
ensuring the proper handling of circuit boards/ sensors. Use ESD protection when working near 3. Remove Rear Cover (REP 1.1)
PCBs. Failure to use ESD protection is likely to result in a PCB failure.
4. Remove Hand feed cover (REP 1.4)
1. Turn off the main power and disconnect the power cord. 5. Disconnect motor [A]
6. Remove E-clip (B) and remove Shaft [C]
2. Undock the BM, TR and SQF (REP 1.0 Undocking BM / TR / SQF).
7. Losen screws (x3), rotate and remove motor.
3. Remove Rear Cover (REP 1.1 Front and Rear Cover).
4. Note position of ground wires and loosen nuts [A] (x2).
5. Tilt out Connection bracket [B] for access.

[A]
[B] [B] [B]
[A]

[B]

Replacement
1. Reverse the removal procedure.
NOTE:
Replacement
Remember to position ground wires correctly. 1. Reverse the removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 8.0 Stacker Module Replacement
Parts List on PL 8.0
1. Check ADJ 8.0 Stacker Module.
Removal 2. Reverse removal procedure.
1. Turn off the main power and disconnect the power cord.
2. Disconnect connector [A].
NOTE:
Depending on system configuration, the Connector can be located on
either the back of the BM, TR or SQF module.
The picture shows the connector connected to the TR module.
3. Loosen screws (x2) [B]
4. Lift and remove Stacker [C].

[A]
NOTE:
Depending on system configuration,
the Connector can be located on either the back of
the BM, TR or SQF module.
The picture shows the connector connected to the TR module.

[C]

NOTE:
If the Stacker is to be re-installed on a different unit,
fasten the 2 lower screws so that they do not interfere
with Covers on other modules.

[B]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 8.1 ST-M1 Stacker Motor
Parts List on PL 8.0

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Stacker Module (REP 8.0 Stacker Module).
3. Loosen nuts [A] (x3).
[C]
4. Slide the motor bracket [B] and remove.
5. Disconnect connector [C] (x1).
6. Remove screws [D] (x3).

[D]

[B] [A]

Replacement

1. Reverse removal procedure.

NOTE: Stacker motor pulley is D-shaped.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 10.0 Front and Rear Cover Removal Rear Cover
Parts List on PL 11.0 and 11.1
1. Turn off the main power and disconnect the power cord.
Removal Front Cover
2. Undock from BM and SQF (REP 1.0 Undocking BM / TR / SQF).
1. Turn off the main power and disconnect the power cord. 3. Loosen screws [B] (x2).
2. Open the Top Cover. 4. Remove screw [C] (x1).
3. Remove screws [A] (x4). 5. Remove rear cover.
4. Remove front cover.

[A]

[B]

[C]

Replacement

1. Reverse removal procedure.

Replacement

1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 10.1 Top Cover [D]

Parts List on PL 11.0

Removal

1. Turn off the main power and disconnect the power cord.
2. Remove Rear Cover (REP 10.0 Front and Rear Cover) and open Top Cover.
3. Disconnect connector [A].
4. Remove Top cover gas spring lower end from joint [B].
NOTE: Press plastic stud from pivot point.
5. Mark the position for the hinges [C].
6. Loosen screws (x4) [D]. Replacement
1. Reverse removal procedure.
2. Check the adjustment of the Top Cover according to ADJ 10.1 Top Cover.

[A]

[B]

[C]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 10.2 Infeed Cover
Parts List on PL 11.1

Removal

1. Turn off the main power and disconnect the power cord.
2. Undock from BM and SQF (REP 1.0 Undocking BM / TR / SQF).
3. Remove Front and Rear Cover (REP 10.0 Front and Rear Cover).
4. In the front, remove screws (x3) [A].
5. In the rear, remove screws (x3) [B].
6. Remove Infeed Cover.

[B]
[A]

Replacement

1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 10.3 TR-M5 / M6 Blower Motor (Blower Assembly) REP 10.4 Upper Exit Cover
Parts List on PL 11.2 Parts List on PL 11.0

Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.

2. Undock from BM and SQF (REP 1.0 Undocking BM / TR / SQF). 2. Undock from BM and SQF (REP 1.0 Undocking BM / TR / SQF or
remove Stacker (REP 8.0 Stacker Module).
3. Remove Front and Rear Cover (REP 10.0 Front and Rear Cover).
3. Remove Front and Rear Cover (REP 10.0 Front and Rear Cover).
4. Remove Infeed Cover (REP 10.2 Infeed cover).
4. Loosen front screws (x3) and rear screws (x3) [A].
5. Open Top Cover.
5. Remove Upper Exit Cover [B].
6. Loosen screws (x2) [A] three turns.
7. Turn crank until the knife beam reach its lowest position [B].
8. Disconnect connectors (x2) and remove the screws (x2) and the nuts (x2) [C].
9. Lift out Fan Assembly [D].

[A]
[A]
[B]

[C] [D]

[B]

Replacement
Replacement
1. Reverse removal procedure. 1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 10.5 TR-SW10 Interlock Switch & TR-Q1 Interlock Replacement
sensor
1. Reverse removal procedure.
Parts List on PL 11.2
2. Install Interlock in its upper most position.
Removal 3. Check ADJ 10.5 TR-SW10 Interlock Switch & TR-Q1 Interlock Sensor.
1. Turn off the main power and disconnect the power cord.
2. Remove Front cover ( REP 10.0 Front and Rear Cover).
3. Note position and remove connectors [A] (x5).
4. Remove screws [B] to remove interlock box (x4).

[A]

[B]

TR-Q1 TR-SW1.2 TR-SW1.4 TR-SW1.3 TR-SW1.1

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 REP 10.6 Protection Cover
Parts List 11.2

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove Waste Bin [A].
3. Loosen screws (x4) [B]. [D]
4. Protection cover consists of two parts [C] and [D]. Unhook and remove [C] from [D].
[D] remains in the Trimmer.

[A]

[C]

[C]

Replacement

1. Reverse removal procedure.

[B] 2. Make sure that [C] and [D] latches properly.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 10.7 TR-Q8 Trim Bin Full Sensor REP 10.8 TR-Q13 Infeed Sensor
Parts List on PL 11.1 Parts List on PL 11.1

Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.

2. Undock Trimmer (REP 1.0 Undocking BM / TR / SQF). 2. Undock Trimmer (REP 1.0 Undocking BM / TR / SQF).

3. Remove screw and sensor TR-Q8 [A]. 3. Loosen screws (x2) [A] holding the Sensor bracket.
4. Disconnect connector P31 and sensor [B].
5. Lift out the Trim waste chute.
6. Replace sensor TR-Q13 [C].

[C]

[B]

[A]

Replacement
[A]
1. Reverse removal procedure.
Replacement
1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 10.9 TR-Q2 Infeed Shaft Sensor REP 10.10 TR-Q3 Exit Belt Sensor
Parts List on PL 11.4 Parts List on PL 11.4

Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.
2. Undock TR from BM and SQF (REP 1.0 Undocking BM / TR / SQF). 2. Undock TR from BM and SQF (REP 1.0 Undocking BM / TR / SQF).
3. Remove Rear Cover (REP 10.0 Front and Rear Cover). 3. Remove Rear Cover (REP 10.0 Front and Rear Cover).
4. Remove screw (x1) and sensor TR-Q2 [A]. 4. Remove screw (x1) and sensor TR-Q3 [A] .

[A]

[A]

Replacement Replacement
1. Reverse removal procedure. 1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 10.11 TR-M1 Transport / Knife Motor REP 10.12 TR-Q4 Transport Belt Sensor
Parts List on PL 11.2 Parts List on PL 11.4

Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.
2. Undock TR from BM and SQF (REP 1.0 Undocking BM / TR / SQF). 2. Undock TR from BM and SQF (REP 1.0 Undocking BM / TR / SQF).
3. Remove Rear Cover (REP 10.0 Front and Rear Cover). 3. Remove Front Cover (REP 10.0 Front and Rear Cover).
4. Loosen nuts (x2) [A]. 4. Remove nut (x1) and screw (x1) [A].
5. Disconnect connector (x1) [B]. 5. Remove bracket [B].
6. Remove screws [D] holding the motor (x3) [C] through the slots in the support bracket. 6. Loosen the screw for the sensor clamp.
7. Remove motor [D]. 7. Remove the sensor [C].
NOTE:
Remove spacers (x3) [E] and mount them on the new motor.

[B]
[C]

[B]

[E]
[A]

[C]

[D]
[A]

Replacement
Replacement
1. Reverse removal procedure.
1. Reverse removal procedure.
2. Check adjustment according to ADJ 10.13 TR-Q4 Transport Belt Sensor.
2. Tension the support chain so there is no slack when tightening the screws (x3) [C].

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 10.13 TR-M2 Trim Knife Motor
Parts List on PL 11.2
[C]
Removal
1. Turn off the main power and disconnect the power cord.
2. Undock TR from BM and SQF (REP 1.0 Undocking BM / TR / SQF).
3. Remove Rear Cover (REP 10.0 Front and Rear Cover).
WARNING:
Place the safety block between lower knife and upper knife beam.
When removing the chain nothing holds upper knife beam and knife in position.
Failure to insert the Safety Block could result in serious injuries.
Safety Block is located behind the Front Cover.

4. Insert the Safety Block between upper knife beam and lower knife [A].
5. Use a Wrench and turn the crank until the knife assembly is stopped by the safety
block [B].
6. Remove the clamp ring.
7. Remove screws (x3) [C] holding the motor.
8. Remove the motor and the sprocket.

Replacement

1. If it is difficult to mount sprocket remove master link [D].

2. Reverse the removal procedure.
[A] 3. Tension the chain so there is no slack when tightening screws.

[D]

[B]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 10.14 TR-Q5 Trim Knife Home Position Sensor Replacement
Parts List on PL 11.4 1. Reverse removal procedure.
Removal 2. Enter service program mode to check that sensor TR-Q5 changes state
1. Turn off the main power and disconnect the power cord. when blocked/unblocked (GP1).

2. Undock TR from BM and SQF (REP 1.0 Undocking BM / TR / SQF). NOTE:

Do not cheat the interlock.
3. Remove Rear Cover (REP 10.0 Front and Rear Cover).
4. Note the position of the encoder disc [A].
3. Move the Upper knife by turning crank [C] using a 13 mm wrench.
Use a 7 mm wrench to remove the two nuts securing the encoder disc.
Remove disc. 4. Check on the LCD that sensor TR-Q5 changes state when blocked/unblocked by
actuators on the encoder disc.
5. Remove sensor TR-Q5 [B].

[A]

[B]

[C]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 10.15 Knife guard Replacement
Parts List on PL 11.5 1. Reverse removal procedure.
NOTE:
Removal Ensure the edge [A] fits in the slot [B] and above the Ball bearing [C].
1. Turn off the main power and disconnect the power cord.
2. Undock TR (REP 1.0 Undocking BM / TR / SQF) or
remove Stacker (REP 8.0 Stacker Module).
3. Remove Rear Cover (REP 10.0 Front and Rear Cover).
4. Remove Infeed Cover (REP 10.2 Infeed cover).
5. Loosen the screw [A] and simultaneously keep the spacer [B] in position,
until the knife protection plate come loose.
6. Lift out and remove the knife guard [C].

[A]

[A] [B]

[C]

[B]

[C]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 10.16 Upper Trim Knife
Parts List on PL 11.10

WARNING:
When removing the chain nothing holds upper knife beam and lower knife in position.
Extreme caution should be taken when working with knife removal or replacement.

Removal Upper Knife

1. Turn off the main power and disconnect the power cord.
2. Undock BM and SQF (REP 1.0 Undocking BM / TR / SQF) or
remove Stacker (REP 8.0 Stacker Module). [B]
3. Remove Front and Rear Cover (REP 10.0 Front and Rear Cover).
4. Remove Infeed Cover (REP 10.2 Infeed cover).
5. Remove Fan assembly (REP 10.3 TR-M5 / M6 Blower Motor (Blower Assembly). Replacement Upper Knife
6. Remove Upper knife protection plate. 1. First tighten the screws (x6) [A] completely, and then loosen them
counter clockwise half a revolution.
7. Assemble the transport protection plate by tighten the screws (x2) [A].

8. Remove the upper knife by removing the screws (x6) [B].

[A]

[A]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 10.17 Lower Trim Knife Replacement of Lower Knife
Parts List on PL 11.10
1. Reverse removal procedure.
WARNING: 2. Ensure the exit belts are in upper position.
When removing the chain nothing holds upper knife beam and lower knife in position.
Extreme caution should be taken when working with knife removal or replacement. 3. On both side, loosen the check nuts on the adjustments screws (x2) [A].
4. Turn the adjustment screws (x2) [A] counter clockwise a few turns,
Removal Lower Knife however ensure clearance between the upper and lower knife.
1. Undock TR (REP 1.0 Undocking BM / TR / SQF). 5. Lubricate the lower side of the lower trim knife with a thin layer of oil or grease.
2. Loosen screws [A] (x2) holding the sensor bracket. 6. Place lower trim knife on the beam.
3. Disconnect connector P31 [B]. Make sure that the two compression springs are facing the back side of the knife.

4. Lift out the Trim waste chute [C]. 7. Mount the mounting screws (x6) [C] loosly so the lower knife can be moved by the compres-
sion springs.
5. Remove lower knife by loosen the mounting screws (x6) [D].
8. Push the lower knife against the two adjustment screws and tighten the two outer screws [E]
[A] enough to hold the lower knife in the position.
9. Latch the plungers (x5) [D] in upper position by pressing them up.
Tilt the plungers so they remain in the upper positions.
CAUTION:
Slowly hand crank the knife motor clockwise and check that
the upper knife does not interfere with the lower knife (to avoid damage of the knives).
10. When the lowest position is reach by the upper knife, then loosen the two outer screws [E].
Make sure that the springs are able to move the lower knife against the upper knife.

[C] [B]
[D]

[B]

[A]

Continued on next page

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 10.17 Lower Trim Knife, continued 11. Gently turn the two adjustment screws by hand against the lower knife.
12. Tighten the screws(x6).
13. Hand crank clockwise the knife motor to its uppermost position [F].
[C]
14. Reset the plungers (x5) to its default position.
15. Hand crank slowly and carefully without paper.
Check that the upper knife does not come in contact with the lower knife.
If knives are in contact, return the upper knife to its upper position by
inserting a screwdriver or similar into one of the holes in the camshaft and repeat from step 1.
If knives are not in contact, move a full rotation.
16. Place a A4 / 8.5” x 11 “ booklet of two A3 / 11” x 17” sheets in trim position and hand crank
one cycle [G].
Inspect the trim result on the lower sheet. The cut shall be clean throughout the length.
17. If the set is not correctly trimmed on one of the ends.
Loosen the five screws on the bad end and keep the one screw tightened at the good end.
Turn the adjustment screw 1/24 revolution (15°) clockwise.
Torque the loose screws (5x).
18. Repeat previous step for following number of sheets:
If it begins to be heavy to hand crank it is better to run the trim knife motors in service mode.

10 (5 sheets booklet) ,
26 (13 sheets booklet) ,
74 (37 sheets booklet) ,
[E] 100 ( 50 sheets booklet)

[D]

[F] [G]

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 REP 10.18 TR-Q14 Paper Path & TR-Q6 Exit Sensor
Parts List on PL 11.11

Removal Paper Path

1. Turn off the main power and disconnect the power cord.
2. Open Top Cover.
3. Disconnect connector J21 [A].
4. Loosen screws (x2) [B].
5. Remove screws (x4) [C].
6. Pull out the Paper path bracket [D].
7. Remove sensor TR-Q14 and/ or TR-Q6.
[A]

[D]
Q14

[C]

Q6
Replacement

1. Reverse removal procedure.

[B]

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 REP 10.19 Stop Gate Carriage 8. Remove connector, labeled TR-M3 (x1) [C].
Parts List on PL 11.9 9. On both sides loosen screws (x2) [D].
10. On both sides remove screws (x2) [E].
Removal
1. Set the Trimmer (Paper size) to A4 / 8.5x11” and Trimming to off.
2. Turn off the main power and disconnect the power cord.
3. Undock Square Folder (REP 1.0 Undocking BM / TR / SQF)
or remove Stacker (REP 8.0 Stacker Module).
4. Remove Front and Rear cover (REP 10.0 Front and Rear Cover).
5. Remove Protective cover (REP 10.6 Protection Cover).
6. Remove connectors J20 and J21 [A].
7. Remove connectors, labeled TR-M4 and TR-Q12 (x2) [B]. [D]

[E]
[A]

[B]

[F]

[C]

Continued on next page

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 10.19 Stop Gate Carriage, continued REP 10.20 TR-M3 Stop Gate Motor,
11. Loosen screws (x2) [F] and (x4) [G].
TR-Q7 Stop Gate Home Position sensor &
12. Pull out the Stop Gate Carriage [G] gently so the motor connectors (x2)
TR-Q11 length adjustment home position sensor
will not be damaged. Parts List on PL 11.9
Removal Motor
CAUTION:
When removing the Carriage, watch out so the motor connectors (2)
do not get damaged by the side frame cut-outs. 1. Remove Stop Gate Carriage (REP 10.19 Stop Gate Carriage).
2. Loosen the motor screws (x2) and turn the motor [A] and lift it out.

[G] Removal Sensors

1. Remove Stop Gate Carriage (REP 10.19 Stop Gate Carriage).
2. Remove sensors TR-Q7 and TR-Q11.

Sensor TR-Q11
[A]

Replacement

1. Reverse the removal procedure.

2. Check adjustment according to (ADJ 10.21 TR-Q11 Length Adjustment Home Position
Sensor) and (BQ20).

Replacement
1. When positioning the carriage in place, make sure the two sliding rods and the gear rack
enters their holes and slots.
Sensor
2. Reverse removal procedure (BQ 21 Stop Gate Carriage). TR-Q7

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 REP 10.21 TR-M4 Length Adjustment Motor &
TR-Q12 (M4) Motor Encoder
Parts List on PL 11.9
Replacement
Removal
1. Remove Stop Gate Carriage (REP 10.19 Stop Gate Carriage). 1. Reverse the removal procedure.
2. Loosen the motor screws (x3) and turn the motor and lift it out. NOTE:
If trimming is skew, then the screw [C] need to be turned until the trim result is satisfactory.
3. Remove Motor TR-M4 [A] and Sensor TR-Q12 [B].
Sensor TR-Q12 is included in the motor TR-M4 .

[A]

[B]

[C]

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 REP 10.22 Lower Exit Belts and foam rollers
Parts List on PL 11.8
Removal lower exit belts [D]
1. Set machine up for A4 / 8.5 x 11, no trim.
2. Turn off the main power and disconnect the power cord.
3. Remove Rear and Front Cover.
4. Remove Stop Gate carriage (REP 10.19 Stop Gate Carriage).
5. Remove Paper Path Exit (REP 10.18 TR-Q14 Paper Path & TR-Q6 Exit Sensor).
6. Remove Paper guides [A].
7. Unhook tension spring and transmission chain [B].
8. Remove e-clips [C] (x2) from the shaft and
move the bushing towards the center of the machine [D].
[C]
9. Unhook the belts [F].
10. Pull out the shaft through the cut-outs in the side frame.
[F]

Removal lower foam rollers

1. Remove lower exit belts according to previos section.
2. Remove the pulleys and e-clips.
[A] 3. Remove the foam rollers [A].

[A]

[B]

Continued on next page

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 10.22 Lower Exit Belts and foam rollers,
continued
Replacement
1. Adjust belt tension by adjusting the lower pulleys up or down (totally 4 screws) [A],
until belts have no slack and even tension.

NOTE:
Belt tension must be checked when Trimmer knife is in the upper position.

2. Mount and ensure the Paper guides are placed under the belt and not above [B].

[A]

Ensure the Paper guides are placed

under the belt and not above [B].

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 10.23 Upper Exit Belts and foam rollers 9. Pull out the upper exit belts assembly.
Parts List on PL 11.7 10. Loosen belt tension by loosening the screws [F].
Removal Upper Exit Belts 11. Remove the belts.
1. Set machine to A4 / 8.5 x 11, no trim.
2. Turn off the main power and disconnect the power cord.
3. Remove Rear and Front cover (REP 10.0 Front and Rear Cover).
4. Remove Upper Exit Cover (REP 10.4 Upper Exit Cover).
5. Unhook tension spring and transmission chain [A] (REP 10.24 Transmission Chain).
6. Remove the screw and linkage arm [B].
Note the position of the washers and spacers.
7. Remove e-clips (x2) and move the bushings [C] towards the center of the shaft.
8. Remove e-clips (x2) [D]. (One on each side of the machine),
unhook the linkage arms (x2) [E] and remove needle bearing (x2).

[E]

[D]

[A]

[F]

[B]

[C] Continued on next page

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 10.23 Upper Exit Belts and foam rollers, Replacement
continued
1. Reverse the removal procedure.
Removal Foam Rollers 2. Ensure the belts have no slack.
1. Pull out the linkage arm assembly [A] according to previous section. The belt tension can be adjusted by tighten the tension roller and screws (x2) [A].
2. Remove e-clips (x6) and sprocket [B]. NOTE:
Ensure correct position of the linkage arm [B].
3. Remove foam rollers [C].

[A]
[A]

[B]
[B] [C] [B]

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REP 10.24 Transmission Chain REP 10.25 Knife Support Chain
Parts List on PL 11.3 Parts List on PL 11.3
Removal
Removal 1. Turn off the main power and disconnect the power cord.
1. Turn off the main power and disconnect the power cord. 2. Remove Front Cover (REP 10.0 Front and Rear Cover).
2. Remove Front Cover (REP 10.0 Front and Rear Cover). 3. Loosen nuts (x2) [A].
3. Remove screws and nuts (x3) [A] and the support bracket [B]. 4. Remove screws and nuts (x3) [B] and the support bracket [C].
4. Unhook spring [C]. 5. Unhook spring [D].
5. Remove transmission chain [D]. 6. Remove transmission chain [E].

[A] 7. Loosen motor screws (x3) [F].

[B] [D]
8. Remove support chain [G].

[B] [C]

[E]

[D]

[A]

[F]

[G]

[C]

Replacement
Continued on next page
1. Reverse removal procedure.
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REP 10.25 Knife Support Chain continued REP 10.26 Knife Chain
Parts List on PL 11.4
Replacement Removal
1. Turn off the main power and disconnect the power cord.
1. Reverse the removal procedure.
2. Remove Rear Cover (REP 10.0 Front and Rear Cover).
2. Tension the chain so there is no slack when tightening the screws (x3).
3. Remove Transmission Chain (REP 10.24 Transmission Chain).
3. Reassemble the support bracket [C].
WARNING:
4. Tighten nuts (x2) [A]. Place the safety block between lower knife and upper knife beam. When removing the
chain nothing holds upper knife beam and knife in position. Failure to insert the Safety
Block could result in serious injuries. Safety Block is located behind the Front Cover.

[B] [C] 4. Insert Safety Block between upper knife beam and lower knife [A].
5. Lower the knife by turning the shaft [B] clockwise with a 13 mm wrench,
until it reaches the safety block.
[E]
6. Loosen motor screws (x3) [C].
7. Unhook the chain [D].
[D] 8. Remove support chain.

[A]

[B] [D]

[C]

[A] [E]

Replacement
1. Reverse the removal procedure. If it is difficult to mount sprocket remove master link [E].
2. Tension the chain so there is no slack when tightening screws.
3.
Remove the safety block by turning the camshaft in reversed direction.
Use the holes in the camshaft.
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 REP 10.27 Infeed Belts
Parts List on PL 11.5

Removal
1. Turn off the main power and disconnect the power cord. Undock TR.
2. Remove Front and Rear Cover (REP 10.0 Front and Rear Cover).
3. Remove Infeed Cover (REP 10.2 Infeed cover).
4. Remove protective cover. [E]

5. Unhook tension spring [A] and transmission chain [B] from sprockets [C].
6. Remove Idler [D].
Note: Unhooking chain from exit shaft sprockets first to gain more slack.
7. Unhook Spring [E] (x1).
8. Remove screws [F] (x4) and linkage arms (x4) [G] on both ends of the shafts.
9. Remove e-clips (x4) and bushings (x4) on both side of shafts,
and slide the bushings (x2) towards the center of the shafts [H].
10. Tilt the shafts out through the cut-outs in the side frames.
11. Remove the infeed belts.

[F]
[A]

[G]

[H]

[C]

[D]

[B]
Continued on next page

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 REP 10.27 Infeed Belts, continued

Replacement
1. Reverse the removal procedure.
Make sure that the D-shaped bushings fit into the D-shaped links [G]
properly before tightening the screws. When tightening the screws on the upper shaft,
the shaft should be on its uppermost vertical position to ensure parallelity.
2. Install the spring to the upper shaft [E]. [G]

3. When tighten the screws on the lower shaft, place two paper strips (80 gsm) between
the outer belts.
4. Pull the strips, the applied forces, F1 and F2 between belts should be approximately
equal [I]. If the applied forces is not equal,
adjust screws (x2) [E] until equality is obtained.

[E]

[H]

[F]

[I]

F F
1 2

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3-92
 REP 10.28 MD6DC PCB ”A” Replacement
Parts List on PL 11.4 1. Ensure DIP Switches are set according to switch setup schematic.

Removal
1 2 3 4

CAUTION: ON SWITCH SETUP

ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, data and/or
communications problems. Failure to use proper ESD procedures will cause damage to OFF
electronic components (example: PCBs). ESD problems can be minimized by maintaining
all machine ground connections, ensuring the proper handling of circuit boards/ sensors. 2. If installing a new MD6DC PCB you must load new S/W.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to Refer to GP 19 Update Software.
result in a PCB failure.
3. Reverse removal procedure.

1. Turn off the main power and disconnect the power cord.
2. Remove Rear Cover (REP 10.0 Front and Rear Cover.
3. Remove all connectors from the PCB (x8).
4. Pinch the barbs of the four pins [A] and lift out the PCB.
ON

A.P4 A.P7 A.P6

A.P11
A.P13

A.P3

A.P14

A.P2

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 REP 10.29 Latch, Docking REP 10.30 TR-M8 Lifter Motor &
TR-Q15 Lift Motor Home Pos. Sensor
Parts List on PL 11.5 Parts List on PL 11.6

Removal Removal
1. Loosen screws [A] (x4) nuts [B] (x2).
2. Locking bracket will fall down. 1. Turn off the main power and disconnect the power cord.
2. Undock from BM and SQF (REP 1.0 Undocking BM / TR / SQF) or
remove Stacker (REP 8.0 Stacker Module).
Replacement 3. Remove screws and washers to free linkage.

1. Push Trimmer against Bookletmaker. 4. Remove Crank by loosening set screw.

2. Push up Locking bracket so it latches studs [C]. 5. Disconnect motor. Remove screws and motor.

3. Tighten screws [A] (x4) and nuts [B] (x2). 6. Revers removing procedure

Replacement

1. Reverse removal procedure.

[A] [B] [C] [A]
Note! At replacing, position set screw so point is hitting hole on the flat side of the shaft.

[B]
[A]

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 REP 10.31 Plunger, upper knife beam Replacement

1. If installing ordered spare part, it contains all components to replace the removed.
Parts List on PL 11.10 2. Mount the two plungers with stronger springs, washers and retaining rings [C].
3. Mount the three plungers with weaker springs, washers and retaining rings [D].
Removal
NOTE!
If replacing with spare part a full set of five plungers is delivered.
You must then replace all five plungers.

Note that there are two types of springs. For location see below.

1. Turn off the main power and disconnect the power cord.
2. Undock from BM and SQF (REP 1.0 Undocking BM / TR / SQF) or
remove Stacker (REP 8.0 Stacker Module).
3. Remove Blower assembly (REP 10.3 TR-M5 / M6 Blower Motor (Blower Assembly).
4. Fold up exit drive belts.
[C]
5. Lift up plunger and remove retaining ring and Nylon washers (2x) [A]. Stronger spring
6. Drop down plunger with spring and remove [B].
7. For the rest of replacement reverse removal procedure.

[A]

[D]
Weaker spring

[B]

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 REP 11.0 Front and Rear Cover REP 11.1 Infeed Cover
Parts List on PL 10.0
Parts List on PL 10.0
Removal
Removal Front and Rear Cover
1. Turn off the main power and disconnect the power cord.
1. Turn off the main power and disconnect the power cord.
2. Undock SQF (REP 1.0 Undocking BM / TR / SQF).
2. Undock SQF (REP 1.0 Undocking BM / TR / SQF).
3. Remove front and rear cover (REP 11.0 Front and Rear Cover)
3. Open Top Cover.
4. Remove nuts [A] (x2).
4. Remove Front Cover by loosen screws (x4) [A].
5. Disconnect connector P32.
5. Remove Rear Cover by loosen screws (x2) [B].
6. Loosen nuts [B] (x2).
7. Tilt machine (REP 11.4 Tilt the Machine).
8. Loosen nuts [C] (x2). [A]

[B]

[A]

[C]

[B]

Replacement

1. Reverse removal procedure. Replacement

1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 11.2 Exit Cover Assembly Removal lower cover
1. Remove Belt Stacker hangers (x2) and washers [C] (x2).
Parts List on PL 10.2
2. Remove screws [D] (x2).
Removal upper cover 3. Remove screws (x2) and washers [E] (x2).
4. Disconnect connector P27 [F] (x1).
1. Turn off the main power and disconnect the power cord.
5. Lift out cover carefully and disconnect LED P29 [G].
2. Undock SQF.
3. Loosen screws [A] (x2).
4. Remove screws [B] (x2).
5. Remove upper part of exit cover (continue to remove lower cover).

[A]

[F]

[B]

[D] [G]

[C]

[E]

Replacement Replacement
1. Reverse removal procedure. 1. Reverse removal procedure.

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 REP 11.3 Top Cover
Parts List on PL 10.0

Removal
1. Turn off the main power and disconnect the power cord. [C]
2. Remove Rear cover and open Top Cover.
3. Disconnect connector [A].
4. Remove Top cover gas spring lower end from joint [B].
NOTE: Press plastic stud from pivot point.
5. Mark the position for the hinges [C].
6. Loosen screws [D] (x4).

[D]

[A]

[B]

Replacement

1. Reverse removal procedure (ADJ 11.3 Top Cover).

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 REP 11.4 Tilt the Machine

WARNING:
When tilting the SQF, the machine will be heavy on one side and the Service Bracket must be installed.
Failure to install the Service Bracket will cause machine damage and could cause severe injuries.

NOTE:
The Service Bracket is available in two models, A and B.

Removal

1. Turn off the main power and disconnect the power cord.
2. Undock the SQF. Removal Service Bracket model B
3. Remove Front and Rear Cover (REP 11.0 Front and Rear Cover). 1. Remove nuts (x2) [G] to dismount Service bracket [H] from resting position.
4. Install Service Bracket model A or model B. 2. Remove two upper nuts [I].
5. Loosen nut [L] a few turns. 3. Place the Service bracket [H] at the base [J] as illustrated.
6. Grab the machine at [M] and lift it. 4. Secure Service Bracket with two nuts [I].
7. Remove the Service Bracket. 5. Turn foot screw [K] on Service bracket,
until it firmly contacts the floor.

Removal Service Bracket model A

1. Remove the Service bracket [A] by removing nuts (x2) [B].
[G]
2. Remove the foot screw [C] and mount it in the hole on the opposite side of the
Service bracket [D] turned up-side-down.
3. Place the Service bracket [A] at the base [E].
4. Turn foot screw on the Service bracket, until the Service bracket firmly contacts the floor
[F].
[I]
[A]

[E] [H]

[J]

[K]
[C] [B] [D] [F]
Continued on next page

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 8. Secure the machine with the latch (x1) [N].
9. The latch should fit into the slot [O].
10. If latch looks like [P], secure it with screw from removing from front and rear cover.

[L]

View from Below

[P]

[M]

Replacement

1. Reverse removal procedure.

[N]

[O]

WARNING:
Carefully observe that latch [N] does not come out of slot [O] during repair.

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 REP 11.5 Antistatic Brushes REP 11.6 SQF-M1 Transport Belt Motor
Parts List on PL 10.0 Parts List on PL 10.7

Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.

2. Undock SQF. 2. Tilt the Machine (REP 11.4 Tilt the Machine).

3. Remove screws [A] (x4). 3. Remove R-pin [A] (x1).

4. Remove antistatic brush bracket [B]. 4. Remove gear [B].

5. Disconnect the motor connectors (x4) [C].
6. Remove screws [D] (x4).
7. Remove Motor SQF-M1.

[B] [C]
M1

[A]

[B]

[A]
[D]

Replacement
1. Reinstall the motor, and secure it by tighten screws [D] (x4).
2. Connect the motor connectors (x 2).
Replacement NOTE: The Orange wire on ”+” (or 1), and the Violet wire on ”-” (or 0).

1. Reverse removal procedure. 3. Reverse the rest of the removal procedure.

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 REP 11.7 SQF-M2 Stop Gate Motor Replacement
Parts List on PL 10.7 1. Reverse the rest of the removal procedure.
Removal 2. Stop Gate Adjustment (BQ 12 Square Fold Stop Gate Adjustment A) is only required
1. Turn off the main power and disconnect the power cord. if screws (x4) [F] have been removed.

2. Tilt the Machine (REP 11.4 Tilt the Machine).

3. Remove cam by loosening allen screw [A] (x1).
4. Remove needle bearing [B].
5. Disconnect connectors labeled SQF-M2 and SQF-Q10 [C].
6. Remove screws [D] (x3) and remove the bearing support [E] from the motor SQF-M2.

[A]

[C]

M2

[B]

[D]

[F]

[B]

[E]

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REP 11.8 SQF-M3 Clamp Motor Replacement
Parts List on PL 10.5 1. Insert the motor assembly.Make sure the shaft [G] fits into the hubs [H].
2. Tighten the nuts (x4) [D].
Removal
3. Connect the motor connectors (x2).
1. Turn off the main power and disconnect the power cord. NOTE: Make sure that the allen screw [C] fits into the groove of the shaft [G].
2. Remove Upper Exit Cover (REP 11.2 Exit Cover Assembly). The end of the shaft should extend (at minimum) 1 mm beyond the plane of the hub [I].

3. Remove screws (x2) and protective cover [A].

4. Disconnect the connector (x1) [B].
5. Loosen the allen screw (x1) four turns [C].
6. Remove nuts (x4) [D].
7. Pull out the motor assembly.
[A]
8. Remove the screw, washer and
the gear/bearing assembly [E]. M3
[B]
9. Remove the screws (x3) [F].

[D]

[C]

[F]

[H]
m [I]
[E] min. 1 m
[G]

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 REP 11.9 SQF-M4 Roll Motor [H]
[A] [G]
Parts List on PL 10.6
Removal
1. Turn off the main power and disconnect the power cord.
2. Remove Front and Rear Cover (REP 11.0 Front and Rear Cover). [I]

3. Remove Upper and Lower Exit Cover (REP 11.2 Exit Cover Assembly).
4. Remove the gas spring at the lower end point.
5. Remove the protective cover [A].
6. Move the upper clamp to its lowest position [B] manually or in service mode,
according to figure.
7. Move the roller motor assembly according to below figure.
8. Loosen the screws (x2) [C] for the timing belt, and grab the belt and
pull it away from frame until it come loose.
[D]
9. Remove the idlers (x2) [D].
[C]
10. Remove the allen screw [E] and remove the bearing with the shaft [F].
11. Loosen the screws (x2) [G] and remove the cover [H].
12. Remove encoder disc [I].
13. Disonnect the motor connectors (x2).
NOTE: The Green wire on ”+” (or 1), and the Brown wire on ”-” (or 0).
14. Tilt the machine (REP 11.4 Tilt the Machine).
15. Remove screws (x2) [J] and the bearings with the shafts.
16. Loosen screws (x2) [K].
[B]
[K]

[E]

[F]

[J]

Continued on next page

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 REP 11.8 SQF-M3 Clamp Motor, continued Replacement
17. Pull out the motor and remove the pin [L]. NOTE:
Ensure that the spring is fitted into the groove of the plastic bearing [N],
18. Remove motor screws (x3) [M].
and record the mounting direction of the bearing.
Note the postion of the motor so the connectors can be re-assembled properly.
1. Apply grease at the surface [O].
2. Ensure the distance [P] is approximately 2 mm.
3. Reverse removal procedure.
NOTE:
[L]
Ensure that the encoder disc is not in contact with the motor connectors,
minimum distance approximately 2 mm [Q]. If not possible, bend the connectors.
4. Tighten the timing belt until no slack. Tighten screw (x1) [P] when belt tension is good.
5. Adjust bearings according to ADJ 11.9.

[O]

[P]

[N]

[M] [Q]

≈ 2 mm Continued on next page

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 REP 11.8 SQF-M3 Clamp Motor, continued REP 11.10 SQF-Q1 (M2) Stop Gate Sensor
Parts List on PL 10.1

Removal
1. Turn off the main power and disconnect the power cord.
2. Tilt the Machine (REP 11.4 Tilt the Machine).
[Q] 3. Disconnect connector [A] (x1).
4. Remove screw [B] and sensor [C].

min. 2 mm

[A]

[C]

[B]

Replacement
1. Reverse removal procedure.
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REP 11.11 SQF-M4 Roll Motor, REP 11.12 SQF-Q4 Clamp Motor (M3) Encoder
SQF-Q2 (M4) Right sensor & SQF-Q3 (M4) Left Sensor
Parts List on PL 10.5
Parts List on PL 10.5
Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.
2. Remove Upper Exit Cover (REP 11.2 Exit Cover Assembly). 2. Remove Exit Cover (REP 11.2 Exit Cover Assembly).
3. Manually move the M4 motor [A] towards the center. 3. Disconnect connector [A] (x1).
4. Disconnect connector to sensor SQF-Q2 / SQF-Q3 . 4. Remove screw [B] (x1).
5. Remove screw [B] (x1).
[B] [A]

[B] Sensor Q2 [A] Sensor Q3 [B]

Replacement Replacement

1. Reverse removal procedure. 1. Reverse removal procedure.

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 REP 11.13 SQF-Q5 Infeed Sensors REP 11.14 SQF-Q7 Exit Sensors
Parts List on PL 10.4 Parts List on PL 10.5
[B]
Removal SQF-Q5, LED Removal SQF-Q7, LED [A]

1. Turn off the main power and disconnect the power cord.
1. Turn off the main power and disconnect the power cord.
2. Remove Lower Exit cover (REP 11.2 Exit Cover Assembly).
2. Disconnect connector [A].
3. Remove screw and nut [A].
3. Remove nut [B] (x1).
4. Remove cover [B]
4. Remove LED.
[A] [B] 5. Remove screws (x2) [C].
Infeed Sensor
LED 6. Remove bracket [D].
7. Remove LED [E].
[D]
[C]

Black Red Red Black

Removal SQF-Q5, Phototransistor

1. Turn off the main power and disconnect the power cord.
2. Tilt the machine (REP 11.4 Tilt the Machine).
3. Disconnect connector [A].
4. Remove nut [B] (x1). [E]
[F] LED
[B] [A]
5. Remove Phototransistor.
Infeed Sensor
Phototransistor Removal SQF-Q7, Phototransistor Exit Sensor
Phototransistor
1. Turn off the main power and disconnect the power cord.
2. Remove Lower Exit cover (REP 11.2 Exit Cover Assembly).
3. Remove cable ties [F].

4. Remove Phototransistor.

White Black White Black

Replacement Replacement

1. Reverse removal procedure. 1. Reverse removal procedure.

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 REP 11.15 SQF-Q6 Clamp Sensor REP 11.16 SQF-M4 Roll Motor & SQF-Q8 (M4) Motor Sensor
Parts List on PL 10.7 Parts List on PL 10.6 [B] [C]

Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.

2. Tilt the Machine (REP 11.4 Tilt the Machine). 2. Remove upper part of the Exit Cover
(REP 11.2 Exit Cover Assembly).
3. Disconnect connector [A] (x1). [A]
3. Loosen screw [A] (x1).
4. Remove screw [B] (x1).
4. Loosen screw [B] (x1).
5. Remove sensor [C].
5. Remove safety cover [C].
6. Loosen allen screw [D] and remove Encoder Disc [E] (x1).
7. Disconnect connector [F] (x1).
8. Remove sensor [G].
[H]

[E]
min. 2 mm

Bottom view
[G]
[D] [F]
[B] [C] [A]
Replacement
1. Reverse removal procedure.
NOTE:
Replacement Ensure that the encoder disc is not in contact with the motor connectors,
minimum distance approximately 2 mm [ H ]. If not possible, bend the connectors.
1. Reverse removal procedure.

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 REP 11.17 Upper Transport Belt Assembly
Parts List on PL 10.3
Removal Fig 1. Springs in upper positions (default setting)
1. Turn off the main power and disconnect the power cord.
2. Remove Front and Rear Cover (REP 11.0 Front and Rear Cover).
3. Record the positions of the springs (either in upper or lower position, see figures 1-2).
4. Remove the Infeed cover (REP 11.1 Infeed Cover).
5. Tilt the machine back to standard position.
6. Remove R-pin [A] and remove upper gear [B] (x1).
7. Remove E-Clip and bearing (located behind the gear) (x1).
8. Remove E-Clip and bearing [C] (x1). [D]
9. Disconnect connectors to clutches [D] by releasing the plastic hatches [E].
10. Slide out the Upper Transport Belt Assembly.
[A] Ensure that one end of the spring
is into the upper or lower position,
[B] and the other end centered on the
infeed cover.

Fig 2. Springs in lower positions

[C]
[E]

Replacement
1. Reverse removal procedure.
Ensure the springs are mounted as the recorded position (fig 1 or 2).

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 REP 11.18 SQF-SW2 Interlock Switches REP 11.19 Upper Transport Belt, SQF-SOL1/3 Clutches &
Foam Rollers
Parts List on PL 10.0
Parts List on PL 10.3
Removal
Initial actions
1. Turn off the main power and disconnect the power cord.
1. Remove Upper Transport Belts Assembly (REP 11.17 Upper Transport Belt Assembly).
2. Remove Front cover (REP 11.0 Front and Rear Cover).
Removal of belts
3. Note position and remove connectors [A] (x4). 1. Remove belts (x2) [A].
4. Remove screws [B] to remove interlock box (x4). NOTE: Do not switch the position of the right and left pulleys/shaft assemblies [B] when re-assemble.

Removal of cluthes
1. Remove belts (x2), loosen screws (x2) and unfold the brackets (x2) [C].
[A]
2. Remove E-clip [D], plastic spacer, bearings, springs, R-clips and slide the clutches [E] off.
NOTE: Clutch with blue label on left side, and yellow label on right side.

Removal of foam rollers

1. Remove clutches (x2), R-clips [F] and foam rollers.
NOTE: Do not switch the position of the right and left pulleys/shaft assemblies [B] when re-assemble.

[B] [B]
[C]

SW2.2 SW2.4 SW2.3 SW2.1

[A]

[D]

Replacement
1. Reverse removal procedure.
2. Check adjustment according to (ADJ 11.18 SQF-SW1 Interlock Switch).

[F] [E] Continued on next page

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3-111
REP 11.19 Upper Transport Belt, SQF-SOL1/3 Clutches &
Foam Rollers, continued
Replacement

1. Turn the gear [A] clockwise, and check that the belts are moving.
Movement should not be possible if turning counter clockwise.
Fig 2: Springs in lower positions
2. Re-assemble infeed cover (REP 11.1 Infeed Cover).
3. Ensure that the springs are mounted as the recorded position (fig 1 or 2). Ensure that one end of the spring
is into the upper or lower position,
and the other end centered on the
infeed cover.
[A]

Fig 1: Springs in upper positions (default setting)

Ensure that one end of the spring

is into the upper or lower position,
and the other end centered on the
infeed cover.

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REP 11.20 Lower Transport Belt, SQF-SOL2/4 Clutches &
Foam rollers
Q5
Parts List on PL 10.4 [B]

Initial actions
1. Remove Infeed cover (REP 11.1 Infeed Cover). [F]
2. Remove R-clip [A] and the gear.
3. Remove e-clips, one on each side of the shaft, and remove the bearings.
4. Loosen the nuts [B] and unfold the brackets. [C]
5. Disconnect connectors to clutches [C] by releasing the plastic hatches [D].
Note: Clutch with blue label on left side, and yellow label on right side.
6. Disconnect connector SQF-Q5 (Record: white on short leg, black on long leg).
7. Unhhok the belts and remove the roller shaft assembly [E].
Note the direction of the roller shaft.
8. Slide out the lower transport belt shaft [F].
[E]

[A]

[D]

Continued on next page

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Removal of clutches Removal of belts
1. Remove R-clips [G]. 1. Remove nuts (x2) [M].
2. Disconnect SQF-Q6 [N], and plug P20 and P21 [O], and remove jack J20 and J21.
3. Loosen wire harness label J29 from the tie wraps [P].

Removal of foam rollers 4. Slide out the belts between the paper path [Q] and the paper path support [R].
1. Remove clutches and E-clips [H].
2. Knock out the pin [I] gently with a hammer.
3. Remove R-clips [J]. [O]
[Q]
4. Remove ball bearing [K].
5. Knock out the pin [L] gently with a hammer.
6. Remove washer, spring and pulley. [M]
[R]

[P]

Q6

Replacement
1. Turn the gear [A] clockwise, and check that the belts are moving.
Movement should not be possible if turning counter clockwise.
[H] [ I ] [J] [L] [K] [G]
2. Check that SQF-Q5 is correctly connected (white on short leg, black on long leg).
3. Re-assemble infeed cover (REP 11.1 Infeed Cover).

[A]

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REP 11.21 Teflon Tape Lower Transport Belt
Parts List on PL 10.8
Removal
1. Turn off the main power and disconnect the power cord.
2. Open the Top cover.
3. Lift the upper Feed belt assembly.
4. Lift the lower Feed belt and remove Teflon tape.

Replacement
1. Mount the new teflon tape straps between the cut-outs for the rollers.

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 [A]
REP 11.22 Set Clamps
Parts List on PL 10.1 and 10.2

Removal Upper Set Clamps

1. Turn off the main power and disconnect the power cord.
2. Remove Exit cover (REP 11.2 Exit Cover Assembly).
3. Remove allen screws [A] for upper Paper guides (x4).
4. Remove the upper paper guide.
5. Tilt machine (REP 11.4 Tilt the Machine).
[I]
6. Remove linkage shafts [B] holding the upper clamp on front and rear side,
by removing E-clips [C] (x2). [D] [H] [F] [G]
[B]
7. Pull out the upper set clamp.
[J]

Removal Lower Set Clamps

1. Turn off the main power and disconnect the power cord.
2. Remove Exit cover (REP 11.2 Exit Cover Assembly). [C]

3. Loosen allen screws [D] for lower Paper guides (x4).

4. Tilt machine (REP 11.4 Tilt the Machine).
5. Remove the screws (x2) [E] for the timing belt brackets on front and rear side. [E]
6. Remove the idlers (x2) for the timing belts.
7. NOTE: Measure the distances between spring seats and brackets,
on front and rear side [F].
8. Decrease the spring tension by loosening the lock nut [G] ,
and remove the screws and springs (x2) [H] on both sides.
[N]
9. Remove the screws (x4) [I] on both sides, and remove the brackets [J].
10. Loosen screws (x2) [K] on the side according to figure,
move the plastic guides apart [L] and lock them by tighten the screws (x2) [K].
11. Move the roller motor assembly towards the center.
12. Remove the springs (x2) on both sides [M].
13. Remove the pins (x2) [N] (attached to the lower set clamp),
when pulling out the lower set clamp.

[K] [L] [M] Continued on next page

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 REP 11.22 Set Clamps, continued [H] [F] [G]

Replacement upper paper guides

[I]
1. Reverse the removal procedure.
[B]
[J]
Replacement lower paper guides

1. Insert lower set clamp and springs [M] in the machine.

2. Untilt the machine.
3. Insert the pins [N], and slide the lower set clamp into position. [C]
4. Tilt the machine (REP 11.4 Tilt the Machine).
5. Re-position the plastic guides [L] to its normal positions.
6. Mount the brackets [J] with screws (x4) [I]. [E]
7. Mount the springs (x2) [H] with the screws.
8. Tighten the screws, and ensure the distances between spring seats and brackets,
on front and rear side [F] is according to the recorded values.
9. Mount the idlers (x2) for the timing belts.
10. Mount the brackets (to initial positions) for the timing belts (on front and rear side)
with the screws (x4) [E].
11. Mount lower Paper guides with screws (x4) [D].
12. Un-tilt the machine. [N]

13. Mount Exit cover (REP 11.2 Exit Cover Assembly).

14. Check REP 11.23 Stop Gate. [A]

[K] [L] [M]

[D]
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 REP 11.23 Stop Gate
Parts List 10.7

1. Set up the Square Folder to Mode 1.

2. Run 6 sheet booklets of 80 gsm (20lb bond), from the Copier.
3. Check appearance of booklets according to pictures below.
If results are not good, proceed to BQ 12.

Not Good Good Not Good

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 REP 11.24 MD6DC PCB ”D”
Replacement
Parts List on PL 10.2
1. Ensure DIP Switches are set according to schematic below.
Removal
2. If installing a new MD6DC PCB you must load new S/W. Refer to GP 20 NVM Reset.

CAUTION: 3. Reverse removal procedure.

ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, data and/or
communications problems. Failure to use proper ESD procedures will cause damage to
electronic components (example: PCBs). ESD problems can be minimized by maintaining
all machine ground connections, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to
result in a PCB failure.

1. Turn off the main power and disconnect the power cord.
1 2 3 4
2. Remove Cover (REP 11.0 Front and Rear Cover). ON/OPEN
3. Remove all connectors from PCB [A] (x8).
OFF/CLOSED
4. Remove PCB by squeezing barbs [B] on the standoffs (x4) securing PCB.
DIP Switch settings

[A] [B]
ON

[C]

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 REP 11.25 Accessing Rear Side of Connection Bracket
Parts List N/A

Removal

CAUTION:
Turn off the power and disconnect the power plug.

1. Remove Belt stacker.

2. Remove the connector cover by removing nuts [A] ( x 4).

[A]

Replacement
1. Reverse the removal procedure.

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 REP 12.0 Front and Rear Cover
Removal Front Cover
Parts List on PL 12.0 and 12.1
1. Remove screws (x2) [C].
Removal Rear Cover
2. Open Slide Door slightly and remove Front Cover by lifting [D].
1. Turn off the main power and disconnect the power cord.
2. Remove screws (x2) [A].
3. Remove Rear Cover by lifting [B].

[C]

[A]
[D]

[B]

Replacement
1. Reverse removal procedure.

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 REP 12.1 Infeed and Exit Cover Removal Exit Cover
1. Turn off the main power and disconnect the power cord.
Parts List on PL 12.1
2. Remove screws (x4) [C].
Removal Infeed Cover 3. Remove Exit Cover [D].
1. Turn off the main power and disconnect the power cord.
2. Remove screws (x4) [A].
3. Remove Infeed Cover [B].

[D]
[C]

[B]

[A]

Replacement
1. Reverse removal procedure.

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 REP 12.2 Top Cover
Parts List on PL 12.4
Removal
1. Turn off the main power and disconnect the power cord.
2. Open Top Cover. [B]
3. Loosen nuts (x6) [A]
4. Remove Top Cover [B].

[A]

Replacement
1. Reverse removal procedure.

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REP 12.3 Top Cover Assembly
Parts List on PL 12.5
[F]
Removal
1. Turn off the main power and disconnect the power cord.
2. Open Top Cover.
3. Remove Top Cover (REP 12.2 Top cover).
4. Remove screws (x2) [A].
5. Remove Interlock actuator [B].
6. Loosen screws (x2) [C] and relieve spring tension.
7. Remove lock nuts and screws (x4) [D].
8. Remove counter balance springs (x3) [E].
9. Remove screws (x4) [F].

[A] [C]

[B] [E] [D]

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REP 12.3 Top Cover Assembly (continued)

[I]

[G]

[H]
Intentionally blank

10. Remove screw [G] and fold out the mounting plate [H].
11. Remove screws (x2) [I] on rear side.
12. Remove Top Cover Assembly.

Replacement
1. Reverse removal procedure.

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 REP 12.4 Interlock Switch Assy Top Cover CT-SW3 (CT-Q9)
& Main power switch CT-SW1
Parts List on PL 12.6

Removal [D]
[B] [F]
1. Turn off the main power and disconnect the power cord.
2. Open Top Cover.
3. Remove screw [A]. Lift up Interlock Switch Assembly
4. Remove Interlock Switch Assembly Top Cover [B].
5. Disconnect connectors (x4) (Note position of leads) [C].
6. Pinch locking tabs and remove Power Switch [D].
(Note orientation of 1 and 0)
7. Disconnect connectors (x4) [E].
(Note position of leads)
8. Pinch locking tabs and remove Interlock Switch [F].

[A]

[E] [C]

Replacement
1. Reverse removal procedure (ADJ 12.6 Interlock Switch Slide Door).

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 REP 12.5 Interlock Switch Slide Door CT-SW2 (CT-Q8) REP 12.6 Entrance Sensor (CT-Q1)
Parts List on PL 12.7 Parts List on PL 12.19
Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.
2. Remove the Front Cover (REP 12.0 Front and rear cover). 2. Open Top Cover.
3. For easier access you may remove Infeed Cover (REP 12.1 Infeed and Exit cover). 3. Remove screw [A].
4. Unlatch and pull out the Slide. 4. Disconnect connector [B].
5. Pinch locking tabs and move Interlock Switch [A] out. 5. Remove Entrance Sensor (CT-Q1) [C].
6. Note position of leads and disconnect connectors [B] (x4).
7. Remove Interlock Switch, Slide Door.

[B] [A]

[B] [C] [A]

Replacement
Replacement
1. Reverse removal procedure (ADJ 12.6 Interlock Switch Slide Door).
1. Reverse removal procedure.

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 REP 12.7 Exit Sensor (CT-Q7) Replacement
Parts List on PL 12.46 1. Reverse removal procedure.
Removal
1. Turn off the main power and disconnect the power cord.
2. Open Top Cover.
3. Remove the screw [A].
4. Disconnect the connector [B] .
5. Remove the Exit Sensor (CT-Q7) [C].

[B]

[C]

[A]

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REP 12.8 Drive Motor (CT-M1)
Parts List on PL 12.8
[B]
Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Remove the Drive Motor (M1) Primary Timing Belt
(REP 12.9 Drive Motor (CT-M1) Primary Timing Belt).
4. Disconnect motor plug E.P2 on Stepper Motor Driver (M1) PCB “E” [A].
5. Pull the slide out to get better access to the motor.
6. Remove screws (x4), nuts (x4) and washers (x4) [B].
7. Remove Drive Motor [C].

[C]
Replacement
1. Reverse removal procedure.

[A]

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REP 12.9 Drive Motor (CT-M1) Primary Timing Belt [B]

Parts List on PL 12.8

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Loosen screw, relieve tension and tighten screw [A].
4. Remove Drive Motor (CT-M1) Primary Timing Belt [B].
Note Routing.

[ A]

Replacement
1. Reverse removal procedure (ADJ 12.10 Drive Motor (M1) Primary Timing Belt).

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REP 12.10 Drive Motor (M1) Secondary Timing Belt
Parts List on PL 12.9

Removal Replacement
1. Turn off the main power and disconnect the power cord. 1. Reverse removal procedure (ADJ 12.10 Drive Motor (M1) Primary Timing Belt).
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Relieve Timing Belt tension by loosening screw [A]. Tighten screw [A].
4. Remove Drive Motor (M1) Secondary Timing Belt [B].

[A] [B]

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 REP 12.11 Infeed Drive Shaft REP 12.12 Infeed Idler Roller
Parts List on PL 12.14 Parts List on PL 12.19

Removal Removal
1. Turn off the main power and disconnect the power cord.
1. Turn off the main power and disconnect the power cord.
2. Remove the Front and Rear Cover (REP 12.0 Front and rear cover).
2. Open Top Cover.
3. Remove Drive Motor (CT-M1) Secondary Timing Belt
3. Remove spring [A].
(REP 12.10 Drive Motor (M1) Secondary Timing Belt).
4. Remove E-clips and bearings [B] .
4. Remove screw [A].
5. Remove Infeed Idler Roller [C].
5. Remove Infeed Drive Shaft [B].

[B]

[A]

[A] [C] [B]

Replacement Replacement
1. Reverse removal procedure. 1. Reverse removal procedure.
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 REP 12.13 Infeed Baffle REP 12.14 Exit Drive Shaft
Parts List on PL 12.18 Parts List on PL 12.14 and 12.45

Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.

2. Remove the Front and Rear Cover (REP 12.0 Front and rear cover). Open Top Cover. 2. Remove the Front and Rear Cover (REP 12.0 Front and rear cover).

3. On front and back side, remove screws [A] (x4) and cams [B] (x2). 3. Remove Secondary Timing Belt (REP 12.10 Drive Motor (M1) Secondary Timing Belt).

4. Remove screws, washers and spacers [C] (x2) and remove Infeed Baffle [D]. 4. Remove O-ring [A].
5. Loosen set screw [B] and remove O-ring pulley [C].
6. Remove retaining screw [D]
7. Remove Exit Drive Shaft [E].

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

[C]

[B]

[D]

Replacement Replacement
1. Reverse removal procedure. 1. Reverse removal procedure.
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 12.15 Exit Idler Roller
Parts List on PL 12.46

Removal
1. Turn off the main power and disconnect the power cord.
2. Open the Top Cover.
3. Remove Exit Idler Roller [A].

[A]

Replacement
1. Reverse removal procedure.

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 REP 12.16 Exit Baffle
Parts List on PL 12.45

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Front and Rear Cover (REP 12.0 Front and rear cover).
3. Remove screws (x2), washers (x2), and spacers (x2) on front and rear side [A].
4. Remove Exit Baffle [B].

[A]

[B]

Replacement
1. Reverse removal procedure.

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 REP 12.17 Pre Trimmer Fixing Roller
1. Remove screw and bearing retainer [C] on front side (x1).
Parts List on PL 12.15
Removal CAUTION:
Ensure that Idler Roller does not slide out from the frame supports and is dropped down. If
CAUTION: one or both ends of these shafts is unsupported, damage to the frame is likely to occur.
Ensure that Idler Roller and Fixing Roller do not slide out from the frame supports and are
dropped down. If one or both ends of these shafts is unsupported, damage to the frame is 2. Reach in through where the Infeed Cover was installed and remove the Idler Roller [D].
likely to occur. 3. Remove screw [E] on the rear side.
4. Remove screw and bearing retainer [F] and Guide Plate [G] on the rear side.
1. Switch off the main power Switch and disconnect the Power Cord.
CAUTION:
2. Remove the Front and Rear Cover (REP 12.0 Front and rear cover). Ensure that Fixing Roller does not slide out from the frame supports and is dropped down. If
3. Remove Infeed Cover (REP 12.1 Infeed and Exit cover). one or both ends of these shafts is unsupported, damage to the frame is likely to occur.

4. Unlatch and pull out the Slide. 5. Reach in through where the Infeed Cover was installed and remove Pre Trimming Fixing
Roller [H].
5. Remove Drive Dog Shaft (REP 12.25).
6. Remove screws and bearing retainers [A] (x2) on both front and rear side.
7. Remove springs [B] on front and rear side (x2). [E] [G] [F] [A]
[A] [D] [C] [H]

[B]

[H] [D] [B] rear side

Replacement
front side 1. Reverse removal procedure.

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 REP 12.18 Post Trimmer Fixing Roller 10. Remove screws [E] (x2) on front and rear side to widen waste channel as much as
possible.
Parts List on PL 12.9 and 12.16 11. Remove screws [F] (x2), screw and rear side bearing retainer [G] and guide plate [H].
CAUTION:
12. Remove Idler Roller [ I ] through waste channel [J].
Ensure that Idler Roller and Fixing Roller do not slide out from the frame supports and are
dropped down. If one or both ends of these shafts is unsupported, damage to the frame is [F] [H] [G] [I] [E]
likely to occur.
[J]
Removal
1. Turn off the main power and disconnect the power cord.
2. Undock CST.
3. Remove the Front and Rear Cover (REP 12.0 Front and rear cover).
4. Remove Timing Belt (REP 12.10 Drive Motor (M1) Secondary Timing Belt).
5. Open Top Cover and latch ”D” baffle in Open position.
6. Remove springs on operator and non-operator side [A].
7. Remove Timing Belt Pulley [B].
8. Remove screws (x4) on operator and non-operator side [C].
9. Loosen screws (x2) [D] on operator and non-operator side and
13. Slide the Fixing Roller [K] to the front side.
lift up Exit Paper Path as much as possible. Tighten screws (x2) [D] again.
14. Remove screws [L] (x2), screw and front side bearing retainer [M] and Guide Plate [N].
[C]
15. Remove Post Trimmer Fixing Roller [K].

[N] [K]

[B]
[L] [M]

[A] [D]

Replacement
1. Reverse removal procedure.
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 REP 12.19 Transmission Shaft
Parts List on PL 12.8
Replacement
Removal 1. Reverse removal procedure.
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Remove Primary Timing Belt (REP 12.9 Drive Motor (CT-M1) Primary Timing Belt).
4. Remove Secondary Timing Belt (REP 12.10 Drive Motor (M1) Secondary Timing Belt).
5. Remove screw [A].
6. Remove Transmission Shaft.

[A]

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 REP 12.20 Lower Drive Shaft
Parts List on PL 12.8

Removal
1. Turn off the main power and disconnect the power cord.
[B]
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Remove Drive Motor (M1) Primary Timing Belt
(REP 12.9 Drive Motor (CT-M1) Primary Timing Belt). [C]
4. Unlatch and pull out the Slide to disengage the Drive Dog.
5. Loosen set screw, remove pulley and spacer [A].
6. Remove screws (x2) [B]. Replacement, Drive Shaft
7. Remove Lower Drive Shaft [C]. 1. Reverse removal procedure.

Removal of Drive Dog

1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Unlatch and pull out the Slide to disengage the Drive Dog.
4. Loosen allen screw [D].
5. Remove Drive Dog [E]

[D]
[A]

[E]

Replacement
1. Reverse removal procedure (ADJ 12.23 Lower Drive Shaft).

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 REP 12.21 Chassis Counter
Parts List on PL 12.13

Removal
[D]
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Removing screw [A] and folding out mounting plate [B] facilitates access.
4. Disconnect connector [C].
5. Pinch locking tabs and remove Chassis Counter [D].

[B] [A] [C]

[B]

Replacement
1. Reverse removal procedure.

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 REP 12.22 Waste Transport Belt
Parts List on PL 12.14

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Front and Rear Cover REP 12.0 Front and rear cover). [C]
NOTE:
Observe how the O-ring is twisted before removal.
Failure to do so may result in wrong transport direction.

3. Remove the O-ring [A].

4. Remove the Drive Shaft [B] by pulling out and up.
5. On the rear side, remove the indler Shaft [C].
6. Remove the Waste Transport Belt [D].

[A]

[D]

[B] Replacement
1. Reverse removal procedure.

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 REP 12.23 Waste Bin Full Sensor (CT-Q11)
Parts List on PL 12.10

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove screw [A].
3. Remove Sensor Cover [B].
4. Disconnect connector [C].
5. Remove screw [D].
6. Remove the Waste Transport Sensor (CT-Q11) [E].

[D]

[C]

[A]

[E]

[B]
Replacement
1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 12.24 Waste Transport Sensor (CT-Q14)
Parts List on PL 12.10

Removal Replacement
1. Turn off the main power and disconnect the power cord. 1. Reverse removal procedure.

2. Undock the Booklet Maker (REP 1.0 Undocking BM / TR / SQF).

3. Remove the Exit Cover (REP 12.1 Infeed and Exit cover).
4. Disconnect connector [A].
5. Remove screw [B].
6. Remove screw [C].
7. Remove the Waste Transport Sensor (Q14).

[A] [C] [B]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 12.25 Upper Drive Shaft 7. Remove screws [D] (x2).
[D]
Parts List on PL 12.8

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Remove Drive Motor (CT-M1) Primary Timing Belt
(REP 12.9 Drive Motor (CT-M1) Primary Timing Belt).
4. Unlatch and pull out the Slide to disengage all Drive Dogs.
8. Loosen Allen screws [E] (x2) and slide the Flex Coupling [F] towards the frame [G].
5. Loosen screws (x4) [A]. This allows plate [B] to be moved out slightly to facilitate re-
moval of Upper Drive Shaft later on.

[E] [G]

[F]

[B]
[A] 9. Remove Upper Drive Shaft [H] by tilting Drive Shaft and moving plate [B] a bit outwards

[H]

[B]

10. Slide the Flex Coupling off the Fixing Roller shaft [I]
[I]
6. Loosen set screw, remove pulley and spacer [C].

[F]

[C] Replacement
1. Reverse removal procedure (ADJ 12.28).

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 12.26 Rotator Sensor (CT-Q2) REP 12.27 Rotator Timing Belt

Parts List on PL 12.28 Parts List on PL 12.29

Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.
2. Unlatch and pull out the Slide. 2. Remove the Front and Rear Cover (REP 12.0 Front and rear cover).
3. Remove screw [A]. 3. Unlatch and pull out the Slide.
4. Disconnect connector [B]. 4. Remove the upper slide guide (REP 13.9 Slide guide).
5. Remove Rotator Sensor (CT-Q2). 5. Loosen Timing Belt tension by loosening the idler pulley screw [A].
6. Remove Rotator Timing Belt.
[A] [B]

[A]

Replacement Replacement
1. Reverse removal procedure. 1. Reverse removal procedure.

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 REP 12.28 Rotator Disengage Solenoid (CT-SOL1)
Parts List on PL 12.28
Replacement
Removal
1. Reverse removal procedure.
1. Turn off the main power and disconnect the power cord.
2. Unlatch and pull out the Slide. CAUTION:
3. Remove screw to detach Solenoid plunger linkage from mechanism [A]. Ensure that Orange lead is connected to terminal marked with orange dot.
4. Remove screws (x4) [B]. 2. Perform ADJ 12.31 Rotator Disengage Solenoid (CT-SOL1)
5. Note position of wiring. Remove Rotator Disengage Solenoid (CT-SOL1).

CAUTION:
The Solenoid connectors must be correctly connected during the replacement procedure.
Refer to Step 1 in the Replacement process. Failure to re-connect properly might cause
Solenoid and PCB to fail.
orange connector

[A]

Ensure the orange connector is

mounted on the indicated side.
Same side as line on the Diode.

Indicated side Line on Diode

[B]

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 REP 12.29 Rotator Disengage Solenoid (CT-SOL1) Idler REP 12.30 Rotator Disengage Solenoid (CT-SOL1)
Shaft Mechanism
Parts List on PL 12.28 Parts List on PL 12.28

Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.
2. Unlatch and pull out the Slide. 2. Unlatch and pull out the Slide.
3. Remove tension spring [A]. 3. Remove Rotator Disengage Solenoid (SOL1) Idler Shaft
(REP 12.29 Rotator Disengage Solenoid (CT-SOL1) Idler Shaft).
4. Remove screw [B].
4. Remove screw to release solenoid linkage [A].
5. Remove Rotator Disengage Solenoid (SOL1) Idler Shaft [C].
5. Remove screws (x2) [B] at Rotator Disengage Solenoid (CT-SOL1) mechanism
pivot points on both sides.
Note the position of the shims between ball bearing and press nuts.
6. Remove Rotator Disengage Solenoid (SOL1) Mechanism [C].

[A]
[B] [A]

[C]

[B]

[C]

Replacement Replacement
1. Reverse removal procedure.
1. Reverse removal procedure.

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 REP 12.31 Rotator Disengage Solenoid (CT-SOL2)
Parts List on PL 12.28
Replacement
Removal 1. Reverse removal procedure.
1. Turn off the main power and disconnect the power cord.
CAUTION:
2. Unlatch and pull out the Slide. Ensure that Orange lead is connected to terminal marked with orange dot.
3. Remove screw to detach Solenoid plunger linkage from mechanism [A]. 2. Perform ADJ 12.34 Rotator Disengage Solenoid (CT-SOL2).
4. Remove screws (x4) [B].
5. Note position of wiring. Remove Rotator Disengage Solenoid (CT-SOL2) [C].

CAUTION:
The Solenoid connectors must be correctly connected during the replacement procedure.
Refer to Step 1 in the Replacement process. Failure to re-connect properly might cause
Solenoid and PCB to fail. orange connector

[B]

Ensure the orange connector is

[A] mounted on the indicated side.
Same side as line on the Diode.

Indicated side Line on Diode

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 REP 12.32 Rotator Disengage Solenoid (CT-SOL2) Idler REP 12.33 Rotator Disengage Solenoid (CT-SOL2)
Shaft Mechanism
Parts List on PL 12.28 Parts List on PL 12.28

Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.
2. Unlatch and pull out the Slide. 2. Unlatch and pull out the Slide.
3. Remove tension spring [A]. 3. Remove Rotator Disengage Solenoid (CT-SOL2) Idler Shaft
(REP 12.32 Rotator Disengage Solenoid (CT-SOL2) Idler Shaft).
4. Remove E-clip (2) [B].
4. Remove screw to release solenoid linkage [A].
5. Remove Rotator Disengage Solenoid (CT-SOL2) Idler Shaft [C].
5. Remove screws (x2) [B].
[B] Note position of shims between ball bearing and press nuts.
6. Remove Rotator Disengage Solenoid (CT-SOL2) Mechanism [C].

[C]

[A] [C]

[A] [B]

Replacement Replacement
1. Reverse removal procedure. 1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 12.34 Rotator Upper Drive Shaft REP 12.35 Rotator Lower Drive Shaft
Parts List on PL 12.29 Parts List on PL 12.29
Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.
2. Remove the Front and Rear Cover (REP 12.0 Front and rear cover). 2. Remove the Front and Rear Cover (REP 12.0 Front and rear cover).
3. Unlatch and pull out the Slide. 3. Unlatch and pull out the slide.
4. Remove the upper slide guide (REP 13.9 Slide guide). 4. Remove the upper slide guide (REP 13.9 Slide guide).
5. Remove Rotator Timing Belt (REP 12.27 Rotator Timing Belt). 5. Remove Rotator Timing Belt (REP 12.27 Rotator Timing Belt).
6. Remove screw [A]. 6. Remove Tension Spring on the non-operator side [A].
7. Remove Rotator Upper Drive Shaft [B]. 7. Remove nuts (x2) [B].
8. Remove Lower Drive Shaft and Bracket [C].
9. Remove screw and retainer [D].
10. Remove Lower Drive Shaft from bracket [E].
11. Remove Lower Drive Shaft.
[B]
[A] [C] [B]

[A]

Replacement Replacement [E] [D]

1. Reverse removal procedure. 1. Reverse removal procedure.
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 12.36 Rotator Motor (CT-M3)
Parts List on PL 12.29

Removal Replacement
1. Turn off the main power and disconnect the power cord.
1. Reverse removal procedure.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Unlatch and pull out the slide.
4. Remove the upper slide guide (REP 13.9 Slide guide).
5. Disconnect motor plug J.P2 on Stepper motor driver PCB “J” [A].
6. Free harness from cable ties [B].
7. Remove nuts (x2) [C] and remove bracket with motor.
8. Remove screws (x4) [D].
9. Remove Motor (CT-M3) from bracket [E].

[C] [A]

[D] [E] [B]

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 REP 12.37 Rotator Motor (CT-M3) Drive Shaft REP 12.38 Registration Lead Screw
Parts List on PL 12.29 Parts List on PL 12.21

Removal Removal
1. Remove motor and bracket (REP 12.36 Rotator Motor (CT-M3). 1. Turn off the main power and disconnect the power cord.
2. Remove screw and bearing retainer [A]. 2. Remove the Front and Rear Cover (REP 12.0 Front and rear cover).
3. Remove Rotator Motor (CT-M3) Drive Shaft [B]. 3. Unlatch and pull out the Slide.
4. Remove screw [A].
[B]
5. Remove the lead screw by turning [B].
[A]

[A]

[B]

Replacement Replacement
1. Reverse removal procedure. 1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 12.39 Registration Width Adjustment Motor (CT-M4)
Parts List on PL 12.8

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Unlatch and pull out the Slide.
4. Remove screw and fold out PCB plate [A].
5. Disconnect motor plug D.P2 on Stepper motor driver PCB “D” [B]. [D]
[C]
6. Free harness from tie wraps [C].
7. Remove motor screws (x4) [D] .
8. Remove Registration Width Adjustment Motor (CT-M4) [E].

[E]

Replacement
1. Reverse removal procedure.

[A]

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 REP 12.40 Registration M4 Home Sensor (CT-Q3)
Parts List on PL 12.21

Removal Replacement
1. Turn off the main power and disconnect the power cord. 1. Reverse removal procedure (ADJ 12.43 Registration M4 Home Sensor (CT-Q3).

2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Unlatch and pull out the Slide.
4. Disconnect connector [A].
5. Remove screws and lock nuts (x2) [B].
6. Remove Registration M4 Home Sensor (CT-Q3).

[A] [B]

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 REP 12.41 Registration Cross Rolls Drive Shaft
Parts List on PL 12.21

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Front and Rear Cover (REP 12.0 Front and rear cover).
3. Unlatch and pull out the Slide.
4. Loosen screw to Timing Belt Tensioner [A] and decrease timing belt tension by pivoting [C]
the Timing Belt Tensioner [B] to the left. Re-tighten screw when tension is decreased
5. Remove screw retaining bearing to shaft [C].
6. Loosen screw retaining bearing to frame member [D].
7. Pull out shaft to the rear side of the CT and be careful not to loose the Timing Belt Pul-
ley [E].
[D]
[B]

[A] [B]

[E]

rear side of slide

Replacement
1. Reverse removal procedure.
2. Timing Belt Tension is set according to ADJ 12.44
3. For routing Timing Belt, see REP 12.45.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 12.42 Registration Cross Rollers Timing Belt
Parts List on PL 12.29

Removal
1. Turn off the main power and disconnect the power cord. Replacement
2. Remove the Front and Rear Cover (REP 12.0 Front and rear cover). 1. Reverse removal procedure.

3. Unlatch and pull out the Slide. 2. Route timing belt as illustrated.

4. Remove the Registration Cross Rollers Drive Shaft

(REP 12.41 Registration Cross Rolls Drive Shaft).
5. Remove the Registration Cross Rollers Timing Belt pulley [A]
6. Remove the Registration Cross Rollers Timing Belt [B].

[A] [B]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 12.43 Registration Cross Rollers
Parts List on PL 12.29 Adjustment
Purpose is to ensure proper adjustment of the flexibel part in the middle of the shaft assy.

Removal 1. Unlatch and pull out the Slide.

1. Turn off the main power and disconnect the power cord. 2. Loosen the Set Screws [C]. Two different type of shafts illustrated below.

2. Unlatch and pull out the Slide. 3. Hold the outermost Guide Wheel [D] to prevent the outermost part of the Registration
Flexibel Shaft assy from turning.
3. Remove the Registration Cross Rollers Drive Shaft (REP 12.44).
4. Rotate the Registration Cross Rolls Drive Shaft [E] so that the innermost part of the
4. Remove the Registration Cross Rollers Timing Belt and the Registration Cross Rollers Registration Flexibel Shaft assy turns 2-3 revolutions.
Timing Belt Pulley (REP 12.45).
5. Tighten the Set Screws [C].
5. Depending on which Cross Roller(s) to remove, remove Registration Primary and/or
Secondary Alignment Rail (REP 12.48 and REP 12.49). 6. Push the Slide in and latch it.

6. Remove screws (x4) [A].

7. Remove Flexible Shaft Assemblys with Cross Rollers [B].

[A]

[D] [C] [D]

[E]

[B]

Replacement
1. Reverse removal procedure.

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REP 12.44 Registration Cross Rollers Idler Rollers Secondary side

Primary side Parts List on PL 12.32

Parts List on PL 12.31

Removal
1. Disconnect plastic links from Idler rollers [A]. Note position of Washers and bearings. (Picture
Removal below).
1. Turn off the main power and disconnect the power cord. 2. Remove the nuts [B] (8x) and the brackets [C] (2x)
2. Unlatch and pull out the Slide. 3. Remove the Registration Cross Rollers Idler Rollers.
3. Remove nuts (x2) [A]. [B]
4. Remove Registration Cross Roller Idler Roller Spring Assembly [B].
5. Remove the Registration Cross Rollers Idler Rollers [C].

[C]

[B]
[C]

[A] [A]

Replacement Replacement
1. Reverse removal procedure. Adjustments according to (ADJ 12.47 Registration Cross Rollers 1. Reverse removal procedure. Adjustments according to (ADJ 12.47 Registration Cross Rollers
Idler Roller). Idler Roller).

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 12.45 Registration Primary Alignment Rail REP 12.46 Registration Secondary Alignment Rail
Parts List on PL 12.32 Parts List on PL 12.32

Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.
2. Unlatch and pull out the Slide. 2. Unlatch and pull out the Slide.
3. Remove nuts (x2) and plastic washers (x2) from within the Registration Sub Frame [A]. 3. Disconnect solenoid [A]. Note cable position. Orange cable at orange dot [B].
Poinnter shows approximate position inside.
4. Remove nuts and plastic washers [C] (2+2) from within the Registration Sub Frame.
4. Remove the spring [B].
5. Remove the spring [D].
5. Remove the Registration Primary Alignment Rail [C].
6. Remove the Registration Secondary Alignment Rail [C].
[B]
[A]

[A]

[C]

[D]

[B] [C]

Replacement Replacement
1. Reverse removal procedure. Adjustments according to 1. Reverse removal procedure. Adjustments according to
ADJ 12.48 Registration Primary Alignment Rail. ADJ 12.49 Registration Secondary Alignment Rail.

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 REP 12.47 Registration Disengage Solenoid (CT-SOL5)
Parts List on PL 12.32
Removal
1. Turn off the main power and disconnect the power cord.
2. Unlatch and pull out the Slide.
3. Note position and disconnect the Registration Disengage Solenoid (CT-SOL5) Leads [A].
CAUTION:
The Solenoid connectors must be correctly connected during the replacement procedure.
Refer to Step 1 in the Replacement process.
Failure to re-connect properly might cause Solenoid and PCB to fail.
4. Remove locknut, Washers (x2), Spacers (x4) to detach the Solenoid plunger from the mechanism
linkage [B].
5. Remove nuts (x2) [C] and the Bracket.
6. Remove screws (x4) [D] and the Disengage Solenoid (CT-SOL5) from the Bracket.
[D]
[C] [A]

[B]

Continued on next page.

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 REP 12.47 Registration Disengage Solenoid (CT-SOL5), REP 12.48 Registration Disengage Solenoid (SOL5)
continued Linkage
Parts List on PL 12.32
Replacement
1. Reverse removal procedure. Removal
1. 1. Turn off the main power and disconnect the power cord.
CAUTION:
2. Unlatch and pull out the Slide.
Ensure that Orange lead is connected to terminal marked with orange dot.
3. Remove the Registration Disengage Solenoid (CT-SOL5)
2. Perform ADJ 12.50 Registration Disengage Solenoid (CT-SOL5). (REP 12.47 Registration Disengage Solenoid (CT-SOL5).
4. Remove screws (x2), Washers (x4), Spacers (x4) [A] and remove the Linkage [B] from
the Idler Rollers [C].

orange connector

[A]

[B]
[C]

Ensure the orange connector is

mounted on the indicated side. [A]
Same side as line on the Diode.

Indicated side Line on Diode

Replacement
1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 12.49 Creaser Assembly [C] [D]

Parts List on PL 12.33

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Front Cover (REP 12.0 Front and rear cover).
3. Unlatch and pull out the Slide.
4. Remove the upper slide guide (REP 13.9 Slide guide).
5. Disconnect Creaser Trigger Sensor (CT-Q4) LED [A].
6. Open cable holders (x3) and free harness [B].
7. Disconnect Creaser Trigger Sensor (CT-Q4) Photo Transistor [C].
8. Open cable holders (x3) and free harness [D].
9. Disconnect sensor [E].
10. Open cable holders (x3) and free harness [F].

[A] [B]

[E]

[F]

Continued on next page.

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REP 12.49 Creaser Assembly, continued
11. Disconnet Creaser Motor (CT-M6) by
disconnecting motor plug H, P2 Stepper motor driver PCB-”H” [G].
[J]
12. Remove the star shaped knob and the excenter [H].
13. Pull the slide out and remove the orange e-clip [I] at the rear of the Creaser Assembly in order
to move the Creaser Assembly rearwards.
14. Support the Creaser Assembly [J] and remove it by moving it rearwards. Creaser Assembly
can be lifted when the key-hole in the rear frame is the same position as the orange e-clip
was.
[H]

[I]

[G]

Replacement
1. Reverse removal procedure ADJ 12.52 Creaser Assembly.

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 REP 12.50 Creaser Trigger Sensor (CT-Q4) LED REP 12.51 Creaser Trigger Sensor (CT-Q4)
Parts List on PL 12.33 Phototransistor
Parts List on PL 12.33
Removal
1. Turn off the main power and disconnect the power cord. Removal
2. Remove the Front and Rear Cover (REP 12.0 Front and rear cover). 1. Turn off the main power and disconnect the power cord.
3. Unlatch and pull out the Slide. 2. Unlatch and pull out the Slide.
4. Remove the upper slide guide (REP 13.9 Slide guide). 3. Disconnect connector [A].
5. Disconnect connector [A]. 4. Loosen screw [B].
6. Loosen nut and remove Trigger Sensor (CT-Q4) LED [B]. 5. Remove Creaser Trigger Sensor (CT-Q4) Phototransistor.

[B] [A]

[A] [B]

Replacement Replacement
1. Reverse removal procedure 1. Reverse removal procedure
ADJ 12.54 Creaser Trigger Sensor (CT-Q4) Phototransistor. ADJ 12.54 Creaser Trigger Sensor (CT-Q4) Phototransistor.

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 REP 12.52 Creaser Tools Home Sensor (CT-Q5) REP 12.53 Creaser Timing Belt
Parts List on PL 12.33 Parts List on PL 12.33

Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.
2. Unlatch and pull out the Slide. 2. Unlatch and pul out the Slide.
3. Disconnect connector [A]. 3. Loosen Timing Belt Tensioner Screw [A].
4. Remove screws (x2) [B]. 4. Remove the Creaser Timing Belt [B].
5. Remove Creaser Tools Home Sensor (CT-Q5).

[B] [A]

[B]
[A]

Replacement Replacement
1. Reverse removal procedure ADJ 12.55 Creaser Tools M6 Home Sensor (CT-Q5). 1. Perform ADJ 12.56 Creaser Timing Belt.
2. Reverse removal procedure.
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REP 12.54 Creaser Tools
[C] [D] [E]
Parts List on PL 12.36

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Front Cover (REP 12.0 Front and rear cover).
3. Unlatch and pull out the Slide.
4. Remove Creaser Tools Home Sensor (Q5) (REP 12.52).
5. Remove Creaser Timing Belt (REP 12.53).
6. Loosen screws (x2) and remove Pulleys [A].
7. Remove screw and Timing Belt Tensioner [B].
8. Remove screws (x2) and remove eccentrics (x2) [C].
9. Remove screws (x4) and remove brackets (x2) [D].
10. Loosen set screws (x2) to retract plungers (x2) [E].
11. Remove plunger mechanism [F].
[H] [F]
12. Remove screws (x8) and remove guide brackets (x2) [G]. [A]
13. Remove Creaser Tools [H].

[G]

[B]

Replacement
1. Reverse removal procedureADJ 12.57 Creaser Tools.

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 REP 12.55 Creaser Motor (CT-M6) Replacement
1. Reverse removal procedure.
Parts List on PL 12.36

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Front Cover (REP 12.0 Front and rear cover).
3. Unlatch and pull out the Slide.
4. Remove Creaser Assembly (REP 12.49).
5. Remove Creaser Timing Belt (REP 12.53).
6. Loosen screw and remove Pulley [A].
7. Remove screws (x4) [B].
8. Remove Creaser Motor (CT-M6).

[B] [A]

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 REP 12.56 Creaser Baffle
Parts List on PL 12.33 and 12.37

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Front Cover (REP 12.0 Front and rear cover). [E] [C]
3. Unlatch and pull out the Slide.
4. Disconnect sensor (CT-Q4) Phototransistor [A].
5. Open cable holders (x3) and free harness [B].
6. Remove springs (x2) [C].
7. Remove stand offs [D].
8. Remove screws (x2) [E].
[D]
9. Remove Creaser Baffle [F].

[B] [A] [F]

Replacement
1. Reverse removal procedure ADJ 12.59 Creaser Baffle.

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 REP 13.0 Bleed Trimmer Drive Shaft
Parts List on PL 12.39
Replacement
Removal
1. Reverse removal procedure.
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Remove Timing Belt [A].
4. Remove screw and Bearing Retainer [B].
5. Pull out the Bleed Trimmer Drive Shaft [C].

[B] [A]

[C]

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 REP 13.1 Bleed Trimmer Upper Knives [B] [C] [D]
Parts List on PL 12.41, 12.42 and 12.44
Removal
WARNING:
Use the Knife Handling Protection when the Protective Plate is removed.
Failure to do so may result in serious injury.

1. Turn off the main power and disconnect the power cord.
2. Remove Front and Rear Covers (REP 12.0 Front and rear cover).
3. Compress and lock Upper Gratings with R-pin [A].
4. Remove screw [B].
5. Remove bearing [C].
6. Prevent the axle [D] from rotating by holding it with an open end wrench. Compress
Knife Spring and loosen Knife Bolt [E].
7. Remove screws (x2) [F].
8. Remove Protective Plate [G].
9. Attache Knife handling protection [H]. [F] [H] [E]
10. Remove Knife Bolt [E].
11. Remove Upper Knife [ I ].
12. Repeat on other side.
NOTE:
Upper and Lower Trimmer Knives form a pair that wears against each other.
If replament is required for one of the blades, the other must be replaced simultaneosly.

[A]

[E] [G] [I]

Replacement
1. Reverse removal procedure.
2. Ensure that the mating surfaces between the knife and knife shaft are thoroughly wiped
clean before reassembly. Any wobble of the blades cutting edge will have impact on
cutting accuracy.
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 13.1 Bleed Trimmer Upper Knives, continued

Removal of Waste Guides

1. Remove screws [J] (x2).

2. Remove Waste guide [K] and bracket.
[L]
3. Repeat on other side.

[J] 2-3m
m (49
/64”-5
3/64”

[K]

[K]

Replacement [M]
[N]
1. Reverse removal procedure.

Adjustment
Loosen screws [J] to adjust Waste guide position.
1. Adjust the position of the Waste Guide so that:
- The distance between Waste Guide and Lower Knife is 2-3mm (49/64”-53/64” [L].
- The Waste Guide is positioned above the cutting point [M].
- The curved part ot the Waste Guide is inside the circumference of the lower knife [N].

rear side (non operator side)

knives viewed from rear side
paper travelling
direction
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 13.2 Bleed Trimmer Lower Knives [F] [G] [D] [E]
Parts List on PL 12.43 and 12.44

Removal
WARNING:
Use the Knife Handling Protection when the Protective Plate is removed.
Failure to do so may result in serious injury.

1. Turn off the main power and disconnect the power cord.
2. Remove the Front and Rear Cover (REP 12.0 Front and rear cover).
3. Remove Bleed Trimmer Drive Shaft (REP 13.0).
4. Remove Upper Bleed Trimmer Knives (REP 13.1).
5. Compress and lock Lower Gratings with R-pin [A].
6. On both front and rear side, remove screws (x4) [B].
7. On both front and rear side, remove Lower Spring bracket [C]. [H]
8. On both front and rear side, insert a lever (screw driver, rod) [D] into the hole in the
knife hub [E] to be able to hold the hub while loosening the screws [F]. Removal of the
Waste Guides is not necessary but will facilitate accessing the knife hub (REP 13.1). Replacement
9. On both front and rear side, remove screws (x4) [F]. 1. Reverse removal procedure.
10. On both front and rear side, remove Bleed Trimmer Lower Knives [G]. 2. Ensure that the mating sur-
faces between the knife and
knife shaft are thoroughly
11. On both front and rear side, ensure that drive dog stays in correct position [H].
wiped clean before reas-
NOTE: sembly.
Upper and Lower Trimmer Knives form a pair that wears against each other. Any wobble of the blades
If replament is required for one of the blades, the other must be replaced simultaneosly. cutting edge will have impact
on cutting accuracy.
3. Ensure that the Waste Guide
is correctly adjusted,
should the Waste Guide
accidentaly have been loose-
ned and moved out of adjustment.

The straigth entry portion of the Waste Guide should line up tangentially with the circum-
ference of the lower knife to avoid bending the waste strip before it is cut loose.
[B]
The curved part of the Waste Guide should be adjusted to create a (axial) clearence to
[A] the lower knife less than 2mm (5/64”),
to prevent narrow 5mm (13/64”) waste strips to pass in-between the lower knife and the
Waste Guide.

[C] Also check that there is some clearance between the arc of the Waste Guide and the
Gills Guide Shaft.
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 REP 13.3 Bleed Trimmer CT-M7 Home Sensor (CT-Q6)
Parts List on PL 12.39

Removal Replacement
1. Turn off the main power and disconnect the power cord. 1. Reverse removal procedure ADJ 13.4 Bleed Trimmer Home Sensor (CT-Q6).
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Disconnect connector [A].
4. Remove screws and lock nuts (x2) [B].
5. Remove Bleed Trimmer CT-M7 Home Sensor (CT-Q6).

[B]

[A]

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 REP 13.4 Bleed Trimmer Width Adjustment Motor (CT-M7) [B]
Parts List on PL 12.39

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Remove screw and fold out PCB [A].
4. Disconnect motor by disconnecting motor plug C.P2 on
Stepper motor driver PCB “C” [B].
5. Free harness from cable holders [C].
6. Remove screws fastening motor (x4) [D].
7. Remove Timing Belt [E].
8. Remove Bleed Trimmer Width Adjustment Motor (CT-M7) [F].

[A]

[C]

[E]

[F]

[D]

Replacement
1. Reverse removal procedure.

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 REP 13.5 Bleed Trimmer Disengage Solenoid (CT-SOL3)
Parts List on PL 12.40

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Remove screw [A] and fold out PCB mounting plate.
4. Note wiring position and disconnect Bleed Trimmer Disengage Solenoid (CT-SOL3)
connectors (x2) [B].

CAUTION:
The Solenoid connectors must be correctly connected during the replacement procedure.
Refer to Step 1 in the Replacement process. Failure to re-connect properly might cause
Solenoid and PCB to fail.
5. Remove screw (linkage from lever) [C].

[A]

[C]

[B]

Continued on next page.

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REP 13.5 Bleed Trimmer Disengage Solenoid (CT- REP 13.6 Bleed Trimmer Disengage Shaft
SOL3), continued Parts List on PL 12.40

6. Remove screws (x4) [D].

Removal
7. Remove Bleed Trimmer Disengage Solenoid (CT-SOL3).
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear and Front Cover (REP 12.0 Front and rear cover).
3. Remove spring [A].
4. On both front and rear side, remove screws (x2) [B].
5. On both front and rear side, remove screws (x2) [C].
6. On both front and rear side, remove bearings (x2) [D].
7. Remove Bleed Trimmer Disengage Shaft [E].

[D]

[E]

[C]
Replacement
1. Ensure the solenoid is correctly connected according to below figure.
Reverse removal procedure (ADJ 13.6).

orange connector [B]

[A]
[D]

Ensure the orange connector is

mounted on the indicated side.
Same side as line on the Diode. Replacement
1. Reverse removal procedure ADJ 13.7 Bleed Trimmer Disengage Shaft.
Indicated side Line on Diode

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 REP 13.7 Bleed Trimmer Gratings Upper REP 13.8 Bleed Trimmer Gratings Lower
Parts List on PL 12.44 Parts List on PL 12.44

Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.
2. Remove the Rear and Front Cover (REP 12.0 Front and rear cover). 2. Remove the Rear and Front Cover (REP 12.0 Front and rear cover).
3. Remove screws (x2) and guide shaft [A]. 3. Remove Bleed Trimmer Gratings Upper (REP 13.7).
4. Remove screws (x2), compress gratings and remove guide shaft [B]. 4. Remove screws (x2) and guide shaft [A].
5. Remove Bleed Trimmer Gratings Upper. 5. Remove screws (x2), compress gratings and remove guide shaft [B].
6. Remove Bleed Trimmer Gratings Lower.

[B]

[A] [B]

[A]

Replacement Replacement
1. Reverse removal procedure. 1. Reverse removal procedure.
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 REP 13.9 Slide Guide
Parts List on PL 12.21
CAUTION:
Ensure that Idler Roller and Fixing Roller do not slide out from the frame supports
and are dropped down. If one or both ends of these shafts is unsupported,
damage to the frame is likely to occur.
Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear and Front Cover (REP 12.0 Front and rear cover).
3. Remove Slide Guide screws on non-operator side (x4) [A].
4. Unlatch and pull out the Slide.
5. Remove screws (x4) [B], pull out the slide.
6. Remove the Slide Guide.

[A]
Intentionally blank

PCB mounting plate folded down for clarity

[B]
[B]

Replacement
1. Reverse removal procedure.

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 REP 13.10 Slide Drive Shaft Transportation
Parts List on PL 12.26

Removal
[I] [J]
1. Turn off the main power and disconnect the power cord.
2. Loosen idler pulley screw [A] to relieve tension in belt [B] and remove timing belt.
3. Remove spring [C].
4. Remove screw [D].
5. Remove Slide Drive Shaft Transportation [E] through the larger cut-out [F] in slide frame.
6. Remove screw [G].
7. Remove Slide Drive Shaft Transportation [H] through the larger cut-out [F] in slide frame.

[A]

[L] [K]
[D]
8. Remove timing pulley [I]. Note position of washers and spacers. One washer is located
inside the slide frame. Four washers and a spacer on the outside of the slide frame.
[F] 9. Remove screw [J].
10. Move Slide Drive Shaft Transportation [K] slightly to the front to release bearing from
[E] slide front frame. Move [K] up to larger cut-out [L] to clear registration solenoid trig
sensor CT-Q10. Continue moving [K] to the front until the rear end of the shaft clears the
[C] cut-out in the slide rear frame. Position the rear end of [K] into the cut-out in the slide
rear frame that corresponds to cut out [F]. Remove the Slide Drive Shaft Transportation
[K] through the larger cut-out [F] in slide frame.

[H] [G] [B]

Replacement
1. Reverse removal procedure.
2. Tension the Timing Belt so that there is no slack and tighten idler pulley screw [A]. In order
to make sure the belt is in correct position, turn pulleys so that the belt will rotate two
revolutions. If necessary, tension the belt so that there is no slack.

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 REP 13.11 Transportation Disengage Solenoid (CT-SOL4)
Parts List on PL 12.27

Removal Replacement
1. Turn off the main power and disconnect the power cord. 1. Ensure the solenoid is correctly connected according to below figure.
Reverse removal procedure (ADJ 13.12).
2. Unlatch and pull out the Slide.
3. Note wiring position and disconnect Transportation Disengage Solenoid (CT-SOL4)
connectors (x2) [A].

CAUTION:
The Solenoid connectors must be correctly connected during the replacement procedure.
Refer to Step 1 in the Replacement process. Failure to re-connect properly might cause
Solenoid and PCB to fail.
4. Remove screw (linkage from lever) [B].
5. Disconnect Transportation Disengage Solenoid (CT-SOL4).
6. Remove screws (x2) [C].
7. Remove Transportation Disengage Solenoid (CT-SOL4).

Ensure the ORN connector is

mounted on the indicated side.
Same side as line on the Diode. orange connector

[A]

Indicated side Line on Diode

[B] [C]
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 REP 13.12 Transportation Disengage Solenoid (CT-SOL4) REP 13.13 Transportation Disengage Solenoid (SOL4)
Idler Shaft Mechanism
Parts List on PL 12.27 Parts List on PL 12.27

Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.

2. Unlatch and pull out the Slide. 2. Unlatch and pull out the Slide.

3. Remove tension spring [A]. 3. Remove Idler Shaft (REP 13.12).

4. Remove E-clips (x2) [B]. 4. Remove screw to release solenoid linkage [A].

5. Remove Idler Shaft [C]. 5. Remove screws (x2) [B]. Note position of shims between ball bearing and press nuts.
6. Remove Transportation Disengage Solenoid (SOL4) Mechanism [C].

[B]

[A] [C]

[B] [C] [A]

Replacement Replacement
1. Reverse removal procedure. 1. Reverse removal procedure.
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 13.14 Slide Latch Mechanism
Parts List on PL 12.25
Removal
1. Turn off the main power and disconnect the power cord.
2. Unlatch and pull out the Slide.
3. Remove screw and handle [A].
4. Remove E-clip [B].
5. Loosen set screw and remove stop collar and washer [C].
6. Remove Slide Latch Mechanism.
7. Pull out the shaft towards the rear.

[A] [C] [B]

Intentionally blank

Replacement
1. Reverse removal procedure (ADJ 13.15 Slide Latch Mechanism).

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 REP 13.15 Slide Fixing Roller 10. Remove screw [F], screw and bearing retainer [G] and Guide Plate [H] from the slide rear
frame.
Parts List on PL 12.25
Removal

CAUTION: [H]
Ensure that Idler Roller and Fixing Roller not slide out from the frame supports and are [F]
dropped down. If one or both ends of these shafts is unsupported, damage to the frame is
likely to occur.

1. Turn off the main power and disconnect the power cord. [G]
2. Remove the Front Cover (REP 12.0 Front and rear cover).
3. Unlatch and pull out the Slide.
4. Remove screws and bearing retainers [A] on front and rear side.
5. Remove springs [B] on front and rear side (x2).

CAUTION:
Idler Roller is now loose and can fall out of place.
11. Move Fixing Roller to the rear until it is free from slide front frame. Lift up front end
6. Remove Idler Roller [C]. of Fixing Roller and remove through cut-out [I] on the slide front frame.
7. Remove the Drive Dog (REP 12.25).
8. Remove screw and bearing retainer [D] on the front side.
9. Move the Fixing Roller [E] slightly to the front side.

[A]

[E]
[I]
[C]

[B] [D]

Replacement
1. Reverse removal procedure.

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 REP 13.16 Slide “B” Baffle REP 13.17 Slide “B” Paper Path
Parts List on PL 12.23 Parts List on PL 12.23

Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.
2. Remove the Front Cover (REP 12.0 Front and rear cover). 2. Remove the Front Cover (REP 12.0 Front and rear cover).
3. Unlatch and pull out the Slide. 3. Remove the ”B” Baffle (REP 13.16).
4. Remove E-clip [A]. 4. Unlatch and pull out the Slide.
5. Remove nuts (x2) [B]. 5. From rear side, remove screws (x2) [A].
6. Remove Slide ”B” Baffle. 6. Remove Slide ”B” Paper [B].

[B]

[A]

[A] [B]

Replacement Replacement
1. Reverse removal procedure. 1. Reverse removal procedure.

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 REP 13.18 Slide “C” Baffle REP 13.19 Slide “C” Paper Path
Parts List on PL 12.24 and 12.32 Parts List on PL 12.24 and 12.32

Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.

2. Remove the Front Cover (REP 12.0 Front and rear cover). 2. Remove the Front Cover (REP 12.0 Front and rear cover).

3. Unlatch and pull out the Slide. 3. Remove the ”C” Baffle (REP 13.18).

4. Remove E-clip [A]. 4. Unlatch and pull out the Slide.

5. Remove nuts (x2) and Baffle [B]. 5. Remove screws (x2) [A].
6. Remove Slide ”C” Paper Path [B].

[A] [B]
[B] [A]

Replacement Replacement
1. Reverse removal procedure. 1. Reverse removal procedure.

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 REP 13.20 Slide L/H Lower (CT-SOL4) Baffle
Parts List on PL 12.26 [C]

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Front Cover (REP 12.0 Front and rear cover).
3. Unlatch and pull out the Slide.
4. Open tie wraps [A] and free harness [B].
5. Note wiring position and disconnect CT-SOL4 connectors (x2) [C]
(REP 13.12 Transportation Disengage Solenoid (CT-SOL4) Idler Shaft ).
6. On the front and rear side, remove springs (x2) [D].
7. On the front and rear side, remove screws (x2), washer (x2) and spacer (x2) [E]. [D]
8. Remove Slide L/H Lower (CT-SOL4) Baffle assembly [F].

[B] [A]

[E] [D] [F]

Replacement
1. Reverse removal procedure Connecting SOL4 connectors
(REP 13.12 Transportation Disengage Solenoid (CT-SOL4) Idler Shaft ).
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 REP 13.21 Slide R/H Lower Baffle REP 13.22 Registration Solenoid SOL5 Trigger Sensor
Parts List on PL 12.26 (CT-Q10)
Parts List on PL 12.20
Removal
Removal
1. Turn off the main power and disconnect the power cord.
1. Select size SR4T to improve access to CT-Q10 connector.
2. Remove the Front Cover (REP 12.0 Front and rear cover).
2. Turn off the main power and disconnect the power cord.
3. Unlatch and pull out the Slide.
3. Open Top Cover.
4. Remove screws (x2) and handle [A].
4. Disconnect connector [A].
5. Remove screws (x2) and springs (x2) [B].
5. Remove screw [B].
6. Remove screws (x2), washer (x2), hinge (x2) and Baffle [C].
6. Remove Registration Solenoid SOL5 Trigger Sensor (CT-Q10).
7. Remove Slide R/H Lower Baffle [D].
[D] [A]

[B] [A] [B]

[C]

Replacement
Replacement
1. Reverse removal procedure Connecting SOL4 connectors
(ADJ 13.21 Slide R/H Lower Baffle). 1. Reverse removal procedure.

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 REP 13.23 CPU / Controller PCB “A”
Parts List on PL 12.12
CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause
damage to electronic components (eg: PCBs). ESD problems can be minimized by main-
taining all machine ground connections, ensuring the proper handling of circuit boards/
sensors. [C]
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to
result in a PCB failure.
Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. If possible, retrieve data stored in the EEProm memory (addresses 2, 3 and 4)
prior to disconnecting the PCB.

If not possible to retrieve data before changing the PCB, replace the EEProm chip from
new PCB with EEProm chip from the old PCB to retrive these data after installation of
the new PCB.

If not possible to retrive any data from the old EEProm, go to section 5 (CT EEProm
reset), when the new PCB is installed.
[B]
4. Remove screw and fold out PCB [A].
5. Disconnect connectors (x6) [B].
6. Release PCB from plastic studs (x4) [C].
7. Remove CPU Controller PCB ”A”.

[A]

[C]
Replacement
1. Reverse removal procedure.
2. A new CPU / Controller PCB ”A” must be loaded with S/W. Refer to section 5.

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 REP 13.24 Solenoid Driver PCB “B”
Parts List on PL 12.13
CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause
damage to electronic components (eg: PCBs). ESD problems can be minimized by main-
taining all machine ground connections, ensuring the proper handling of circuit boards/
sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to
result in a PCB failure.
Removal [B]
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Disconnect connectors (x5) [A].
4. Release PCB from plastic studs (x4) [B].
5. Remove Solenoid Driver PCB ”B”.

Replacement

1. Ensure DIP switches are set according to below schematic figure.

2. Reverse removal procedure.
3. A new Solenoid Driver PCB ”B” must be loaded with S/W. Refer to section 5. [A]

[B]

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 REP 13.25 Stepper Motor Driver (M7) PCB “C”
Parts List on PL 12.12
CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause
damage to electronic components (eg: PCBs). ESD problems can be minimized by maintain- [C]
ing all machine ground connections, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to result
in a PCB failure.
Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Remove screw and fold out PCB [A]
4. Disconnect connectors (x6) [B]
5. Release PCB from plastic studs (x4) [C].
6. Remove Stepper Motor Driver (M7) PCB ”C” .

[A]
[B]

[C]

[C]

Replacement
1. Ensure DIP switches are set according to below schematic
figure.
2. Reverse removal procedure.
3. A new “C” Stepper Motor Driver PCB must be loaded with
S/W. Refer to section 5.

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 REP 13.26 Stepper Motor Driver (M4) PCB “D”
Parts List on PL 12.13
CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause
damage to electronic components (eg: PCBs). ESD problems can be minimized by maintain-
ing all machine ground connections, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to result
in a PCB failure.
Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
[B] [A] [B]
3. Disconnect connectors (x7) [A].
4. Release PCB from plastic studs (x4) [B].
5. Remove Stepper Motor Driver (M4) PCB ”D”.

Replacement
1. Ensure DIP switches are set according to below schematic figure.
2. Reverse removal procedure.
3. A new “D” Stepper Motor Driver PCB must be loaded with S/W. Refer to section 5.

[B]

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 REP 13.27 Stepper Motor Driver (M1) PCB “E”
Parts List on PL 12.13
CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause
damage to electronic components (eg: PCBs). ESD problems can be minimized by main-
taining all machine ground connections, ensuring the proper handling of circuit boards/
sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to
result in a PCB failure.
Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover). [B] [A] [B]
3. Disconnect connectors (x4) [A].
4. Release PCB from plastic studs (x4) [B].
5. Remove Stepper Motor Driver (M1) PCB ”E” .
6. Remove the End Termination plug from E.J6.and ensure that is transferred to the new
PCB ”E”. J6.

Replacement
1. Ensure DIP switches are set according to below
schematic figure.
2. Reverse removal procedure.
3. A new “E” Stepper Motor Driver PCB must be
loaded with S/W. Refer to section 5.

[B]

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REP 13.28 PCB Printer Interface PCB “F”
Parts List on PL 12.11
CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause
damage to electronic components (eg: PCBs). ESD problems can be minimized by maintain-
ing all machine ground connections, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to result
in a PCB failure.
Removal
1. Turn off the main power and disconnect the power cord. [D]
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Remove nut [A] and remove ground wire [B].
4. Disconnect ribbon cable [C].
5. Remove screws [D] (x4).
6. Remove PCB Printer Interface PCB ”F” from CT.
7. Remove remaining nuts and stand-off’s from PCB.

Replacement
1. Reverse Removal Procedure.
2 Ensure that all eight positions of SW1 are set to OFF (pointing away from J1) before install.
3. Perform a NVM reset (GP 20) to download S/W into the PCB Printer Interface PCB ”F”.

[A]

J1
[C]
SW1

[B]

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REP 13.29 I/O Extension PCB “G”
Parts List on PL 12.12
CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause
damage to electronic components (eg: PCBs). ESD problems can be minimized by maintain-
ing all machine ground connections, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to result
in a PCB failure.
[C] [B] [C]
Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Remove screw and fold out PCB [A]
4. Disconnect connectors (x3) [B].
5. Release PCB from plastic studs (x4) [C].
[A]
6. Remove I/O Extension PCB ”G”.

[C]

Replacement
1. Reverse Removal Procedure.

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 REP 13.30 Stepper Motor Driver (M6) PCB “H”
Parts List on PL 12.21
CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause
damage to electronic components (eg: PCBs). ESD problems can be minimized by maintain-
ing all machine ground connections, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to result
in a PCB failure.
Removal [B]
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Unlatch and pull out the slide about 200 mm to get some work space to disconnect PCB.
4. Disconnect connectors (x6) [A].
5. Release PCB from plastic studs (x4) [B].
6. Remove Stepper Motor Driver (M6) PCB ”H” .

Replacement
1. Ensure DIP switches are set according to below schematic figure.
2. Reverse removal procedure.
3. A new “H” Stepper Motor Driver PCB must be loaded with S/W. Refer to section 5.

[A]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 [C]
REP 13.31 Stepper Motor Driver (M3) PCB “J”
Parts List on PL 12.29
CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause
damage to electronic components (eg: PCBs). ESD problems can be minimized by maintain-
ing all machine ground connections, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to result
in a PCB failure. [D]

Removal
1. Turn off the main power and disconnect the power cord.
2. Remove the Rear Cover (REP 12.0 Front and rear cover).
3. Remove the upper slide guide (REP 13.9 Slide guide).
4. Disconnect connectors (x3) [A].
5. Remove nuts (x3) [B].
6. Remove Protective Cover.
7. Remove stand-offs (x3) [C]. Replacement
8. Release PCB from plastic studs (x4). 1. Ensure DIP switches are set according to below schematic figure.
9. Remove Stepper Motor Driver (M3) PCB ”J”. 2. Reverse removal procedure.
10. If PCB has to be replaced then also remove the End Termination plug from J.J6. 3. A new “J” Stepper Motor Driver PCB must be loaded with S/W. Refer to section 5.
4. Ensure that the CAN End Termination plug is transferred to the new PCB J.J6.

[B]

[A]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 13.32 SCP (Short Circuit Protection) PCB “K” REP 13.33 SCP (Short Circuit Protection) PCB “L”
Parts List on PL 12.17 Parts List on PL 12.17
CAUTION: CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause data and/or communications problems. Failure to use proper ESD procedures will cause
damage to electronic components (eg: PCBs). ESD problems can be minimized by maintain- damage to electronic components (eg: PCBs). ESD problems can be minimized by maintain-
ing all machine ground connections, ensuring the proper handling of circuit boards/ sensors. ing all machine ground connections, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to result Use ESD protection when working near PCBs. Failure to use ESD protection is likely to result
in a PCB failure. in a PCB failure.
Removal Removal
1. Turn off the main power and disconnect the power cord. 1. Turn off the main power and disconnect the power cord.

2. Undock the Booklet Maker (REP 1.0 Undocking BM / TR / SQF). 2. Undock the Booklet Maker (REP 1.0 Undocking BM / TR / SQF).

3. Remove the Exit Cover (REP 12.1 Infeed and Exit cover). 3. Remove the Exit Cover (REP 12.1 Infeed and Exit cover).

4. Disconnect connectors (x2) [A]. 4. Disconnect connectors (x2) [A].

5. Release PCB from plastic studs (x2) [B]. 5. Release PCB from plastic studs (x2) [B].

6. Remove SCP (Short Circuit Protection) PCB ”K”. 6. Remove SCP (Short Circuit Protection) PCB ”L”.
[B] [A]
[B]

[A]

Replacement Replacement
1. Reverse removal procedure. 1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 13.34 SCP (Short Circuit Protection) PCB “M”
Parts List on PL 12.17 6. Disconnect connectors (x2) [C].
CAUTION: 7. Release PCB from plastic studs (x4) [D].
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
8. Remove SCP (Short Circuit Protection) PCB ”M”.
data and/or communications problems. Failure to use proper ESD procedures will cause
damage to electronic components (eg: PCBs). ESD problems can be minimized by maintain-
ing all machine ground connections, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to result
in a PCB failure.
Removal [C]
1. Turn off the main power and disconnect the power cord.
2. Undock the Booklet Maker (REP 1.0 Undocking BM / TR / SQF).
3. Remove the Exit Cover (REP 12.1 Infeed and Exit cover).
4. Remove the Front Cover (REP 12.0 Front and rear cover).
5. Remove screws [A] [x4) and remove cover [B].

[A]

[D]

[B] Replacement
1. Reverse removal procedure.
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 13.35 SCP (Short Circuit Protection) PCB “N”
Parts List on PL 12.17
CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause
damage to electronic components (eg: PCBs). ESD problems can be minimized by maintain-
ing all machine ground connections, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to result
in a PCB failure.
Removal
1. Turn off the main power and disconnect the power cord.
2. Undock the Booklet Maker (REP 1.0 Undocking BM / TR / SQF).
3. Remove the Exit Cover (REP 12.1 Infeed and Exit cover).
4. Disconnect connectors (x2) [A].
5. Release PCB from plastic studs (x4) [B].
6. Remove SCP (Short Circuit Protection) PCB ”N”.
Intentionally blank

[B]

[A]

Replacement
1. Reverse removal procedure.
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 13.36 12V Power Supply Unit
Parts List on PL 12.17
CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause
damage to electronic components (eg: PCBs). ESD problems can be minimized by maintain-
ing all machine ground connections, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to result
in a PCB failure.
Removal
1. Turn off the main power and disconnect the power cord.
2. Undock the Booklet Maker (REP 1.0 Undocking BM / TR / SQF).
3. Remove the Exit Cover (REP 12.1 Infeed and Exit cover).
4. Remove the High Voltage Power Supply Unit (REP 13.39). [C]
[B]
5. Remove the Front Cover (REP 12.0 Front and rear cover).
6. Remove screws (x2) [A].
7. Open cable holders and free harness.
8. Loosen screws (x2) [B] and tilt PSU package [C].
9. Disconnect leads from 24 V PSU terminal [D].
10. Remove the 12V PSU Power Supply Unit.

[D]
[A]

Replacement
1. Reverse removal procedure (ADJ 13.36).

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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 REP 13.37 24V Power Supply Unit (1)
Parts List on PL 12.17
CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause
damage to electronic components (eg: PCBs). ESD problems can be minimized by maintain-
ing all machine ground connections, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to result
in a PCB failure.
Removal
1. Turn off the main power and disconnect the power cord.
2. Undock the Booklet Maker (REP 1.0 Undocking BM / TR / SQF).
3. Remove the Exit Cover (REP 12.1 Infeed and Exit cover).
[C]
4. Remove the High Voltage Power Supply Unit (REP 13.39).
[B]
5. Remove the Front Cover (REP 12.0 Front and rear cover).
6. Remove screws (x2) [A].
7. Open cable holders and free harness.
[D]
8. Loosen screws (x2) [B] , pull out PSU to gain access to the terminal.
9. Remove the plastic protection cover.
10. Disconnect leads from 24 V PSU terminal [D].
11. Remove the 24V PSU 1 (Power Supply Unit 1) from Support bracket.

[A]

Replacement
1. Reverse removal procedure (ADJ 13.37 24V Power Supply Unit (1).

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-201
 REP 13.38 24V (48V) Power Supply Unit (2)
[C]
Parts List on PL 12.17
CAUTION:
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause
damage to electronic components (eg: PCBs). ESD problems can be minimized by maintain-
ing all machine ground connections, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to result
in a PCB failure.
Removal
[D]
1. Turn off the main power and disconnect the power cord.
2. Undock the Booklet Maker (REP 1.1 Front and Rear Cover).
3. Remove the Exit Cover (REP 12.1 Infeed and Exit cover).
4. Remove the High Voltage Power Supply Unit (REP 13.39).
5. Remove the Rear Cover (REP 12.0 Front and rear cover).
6. Remove screws (x3) [A].
7. Open cable holders and free harness [B].
8. Loosen screws (x2) [C] , pull out PSU to gain access to the terminal [D].
9. Disconnect leads from 48 V PSU terminal [E].
10. Remove the 24V (48 V) PSU 2 (Power Supply Unit 2) from Support bracket.

[A]

[E]

[B]
Replacement
1. Reverse removal procedure (ADJ 13.38 24V (48V) Power Supply Unit (2)).

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 13.39 High Voltage Power Supply Unit Removal High Voltage Power Supply Unit
(Optional, For Antistatic Bars) 1. Remove screws (x2) [A].
Parts List on PL 12.50
2. Disconnect antistatic bars (x4) [B].
CAUTION:
3. Disconnect harness (x2) and slide out the High Voltage PSU [C].
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to
electronic components (eg: PCBs). ESD problems can be minimized by maintaining all machine ground
connections, ensuring the proper handling of circuit boards/ sensors. [B]
Use ESD protection when working near PCBs.
Failure to use ESD protection is likely to result in a PCB failure.
Removal
1. Turn off the main power and disconnect the power cord.
2. Undock the Booklet Maker (REP 1.0 Undocking BM / TR / SQF).
3. Remove the Exit Cover (REP 12.1 Infeed and Exit Cover).
4. Remove applicable component(s):

- Remove the High Voltage Power Supply Unit (Figure 1).

- Remove Antistatic Bars Exit (Figure 2).
- Remove Antistatic Bars Waste Transport (Figure 3).
- Remove component(s) from the High Voltage Power Supply Unit (Figure 4).

[C] [A]

Figure 1: Removal High Voltage Power Supply Unit

Continued on next page.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 13.39 High Voltage Power Supply Unit (Optional, For Antistatic Bars), continued

Removal Antistatic Bars Exit Removal Antistatic Bars Waste Transport

BAR 1A BAR 1B
BAR 2B BAR 2A

Figure 2: Removing Antistatic Bars Exit

Figure 3: Removing Antistatic Bars Waste Transport

BAR 1A: BAR2 A:

1. Remove nuts (x2). 1. Remove nuts (x2).
2. Open tie wraps and free harness. 2. Open tie wraps and free harness.

BAR 1B:
BAR 2B:
1. Open tie wraps and free harness. 1. Remove nuts (x2).

2. Remove nuts (x2). 2. Open tie wraps and free harness.

Continued on next page.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-204
REP 13.39 High Voltage Power Supply Unit
(Optional, For Antistatic Bars), continued TR2
TR1

Removal component(s) from the high voltage Power Supply unit

REL2:
1. Disconnect connectors (x6).
2. Remove screws (x2).
REL3

REL3:
1. Disconnect connectors (x6).
2. Remove screws (x2).

TR1
1. Disconnect connector.
REL2
2. Remove screws (x4).

Figure 4: Removing component(s) from the High Voltage Power Supply Unit
TR2:
1. Disconnect connector.
2. Remove screws (x4).

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-205
REP 13.40 Interlock Relay (CT-REL1)
Parts List on PL 12.17
CAUTION:
[C]
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to
electronic components (eg: PCBs). ESD problems can be minimized by maintaining all machine ground [E]
connections, ensuring the proper handling of circuit boards/ sensors.
Use ESD protection when working near PCBs.
Failure to use ESD protection is likely to result in a PCB failure.
Removal
[D]
1. Turn off the main power and disconnect the power cord.
2. Undock the Booklet Maker (REP 1.0 Undocking BM / TR / SQF).
3. Remove the Exit Cover (REP 12.1 Infeed and Exit cover).
4. Remove the High Voltage Power Supply Unit (REP 13.39), if fitted.
5. Remove the Front Cover (REP 12.0 Front and rear cover).
6. Remove screws (x3) [A].
7. Open tie wraps and free harness [B].
8. Remove screws [C] and remove cover [D].
9. Loosen screws (x2) [E], tilt the PSU unit and remove it from frame. [F]
10. Disconnect connectors (x6) [F].
11. Remove the Interlock Relay (CT-REL1) [G].

[B]
[G]

Replacement
[A] 1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-206
 REP 13.41 Temp Sensor (CT-Q13) REP 13.42 Cooling Fan (CT-FAN1)
Parts List on PL 12.12 Parts List on PL 12.12
CAUTION:
Removal
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, 1. Turn off the main power and disconnect the power cord.
data and/or communications problems. Failure to use proper ESD procedures will cause
damage to electronic components (eg: PCBs). ESD problems can be minimized by maintain- 2. Remove the Rear Cover (REP 12.0 Front and rear cover).
ing all machine ground connections, ensuring the proper handling of circuit boards/ sensors. 3. Remove screw and fold out the mounting plate [A].
Use ESD protection when working near PCBs. Failure to use ESD protection is likely to result
in a PCB failure. 4. Disconnect connector (x1) [B].

Removal 5. Remove screws (x2) [C].

1. Turn off the main power and disconnect the power cord. 6. Remove the Cooling Fan (CT-FAN1).

2. Remove ”E” Stepper Motor Driver PCB (REP 13.27).

3. Disconnect connector [A].
4. Remove nuts (x2) [B].
[A]
5. Remove Temp Sensor (CT-Q13).

[B]

[B]

[A]

Replacement [C]
1. Reverse removal procedure.
Replacement
1. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 14.0 Cover, Rear REP 14.1 Cover, Front
(AF602 Spare Parts Manual, Section 1.0 Item 13) (AF602 Spare Parts Manual, Section 1.0 Item 1)

CAUTION CAUTION
There is a risk of tilting the machine with the back cover off and paper in the bins. There is a risk of tilting the machine with the back cover off and paper in the bins.
Make sure that there is no paper in the bins before fully sliding them out. Make sure that there is no paper in the bins before fully sliding them out.

Rear Cover Front Cover

[C]

[B]

[D]

[E]

[A]

1. Loosen screw [A]

2. Lift up cover [B]
1. Lift the latch [D] (x2) and push in the bins
3. Tilt out top [C]
2. Open the front door [E]
4. Remove cover
3. Lift and remove front cover
Replacement
Replacement
Reverse removal procedure
Reverse removal procedure

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-208
REP 14.2 Cover, Bin REP 14.3 Door
(AF602 Spare Parts Manual, PL1.0 Item 3) (AF602 Spare Parts Manual, PL1.0 Item 5)

1. Remove screws, [A] (x6 total, x3 on either side) 1. Lift off Front Cover (REP 14.1) and place it on a flat surface
2. Remove cover 2. Remove nuts [A] (x2) and remove door
3. Remove the remaining parts [B] from the door

A A

B
Replacement
Reverse removal procedure:
1. Mount cover but do not tighten screws
2. Close bin
3. Adjust position of cover to flush with front cover
Replacement
4. Open bin and tighten screws
Reverse removal procedure.
When tightening nuts for door, push door in the direction shown. Ensure
that the door closes properly and has even gaps around the edges.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 14.4 Cover, Upper Exit REP 14.5 Cover, Top
(AF602 Spare Parts Manual, PL1.0 Item 9) (AF602 Spare Parts Manual, PL1.0 Item 11)

1. Loosen screw [A] (x2) 1. Remove Cover, Upper Exit (REP 14.4)
2. Slide cover [B] upwards 2. Press Cover, Top in arrow direction and remove

Replacement Replacement
Reverse removal procedure Reverse removal procedure

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-210
REP 14.6 Cover, Side REP 14.7 Timing Belt
(AF602 Spare Parts Manual, PL1.0 Item 12) (AF602 Spare Parts Manual, PL2.0 Item 4)

1. Loosen screws [A] (x2)

2. Lift cover up and out CAUTION
There is a risk of tilting the machine with the back
cover off and paper in the bins. Make sure that there
is no paper in the bins before fully sliding them out.

1. Turn off system and disconnect power

2. Remove Cover, Rear (REP 14.0)
3. Lift the locking latch and push out bin
4. Remove Cover, Bin (REP 14.2)
5. Loosen screw [B] to release belt tension
6. Remove the belt [A] A

B A

Replacement
Replacement Reverse removal procedure. After replacing the belt, ensure that the
Reverse removal procedure tray table is level (REP 14.8 Replacement Section). Make sure that the
belt tensioner is tensioning the belt correctly and then torque the screw
[B].

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 14.8 Tray Table

1. Move the paper guides [A] towards the middle of the tray, as far in- Replacement
wards as possible Reverse removal procedure. Ensure that the tray table is level (with
2. Remove the countersunk screws [B] (x4) respect to the tray). Put a ruler between the sides of the bin (in loca-
3. Lift out the tray table [C] tions marked [C]). Release timing belt tension (REP 14.7). Finely
adjust the tray table until it is level by manually rotating the lead screw
assemblies [D] until the bin tray is flush against the rulers. When the
tray table is level, tension the timing belt.
A D

D C

A D
D

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-212
REP 14.9 Solenoid SOL101/201 REP 14.10 Blower Fans, FAN101 - FAN204
(AF602 Spare Parts Manual, PL2.0 Item 10) (AF602 Spare Parts Manual, PL2.1a/2.1b Item 1)

1. Remove Cover, Rear (REP 14.0) 1. Disconnect connector [A]

2. Lift the locking latch and push out bin half way to gain access 2. Unhook harness from cable holders [B]
to solenoid from the back 3. Remove nuts [C] (x2)
3. Disconnect connectors from solenoid 4. Remove fan
4. Remove screw [A]
5. Remove screw [B] (x3) and remove solenoid assembly
6. Replace solenoid in reverse order
7. Adjust position of solenoid so that the tray locking latch engagement
distance is 1-2mm when the solenoid is activated

B C
1-2mm

A
A
B

Replacement
Reverse removal procedure

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-213
REP 14.11 Torsion Spring, Paper Stop Upper, Side Guides REP 14.12 Lead Screw Assembly
(AF602 Spare Parts Manual, PL2.1a/2.1b Items 2-4) (AF602 Spare Parts Manual, PL2.2 Item 15)

1. Remove nuts [A] (x3) Before starting find something to keep Elevator Yoke [red] in place after
2. Fold out the fan assy disassembly (ex. a piece of string or some tape)
3. Move the pin half way out [B]
4. Remove the spring [C]

B
1. Move tray table to its lower position, either in service menu or by hand
2. Remove Tray Table (REP 14.8)
3. If lead screw is on front side, remove Cover, Bin (REP 14.2)
C 4. Remove Timing Belt (REP 14.7)
5. Loosen set screw [A] and remove timing wheel and spacer
6. Remove screws [B]
Replacement
Reverse removal procedure
Apply pre-tension of 70° - 120° to spring before mounting

Continued on next page....

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-214
REP 14.12 Continued

7. Remove screws [C] and screw cover [D] (on relevant screw assy)
8. Remove Lead Screw Assembly [E] E

Replacement
Reverse removal procedure. Adjust/reinstall timing belt using REP 14.7
Level Tray Table using REP 14.8 (Replacement Section)

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-215
REP 14.13 Stepper Motor M101 / M201
(AF602 Spare Parts Manual, PL2.2 Item 3)

Check Motor
1. Enter service mode and run motor between end positions
2. Check that set screw is firmly torqued in sprocket and against the D-
surface of the shaft

Replace motor
1. Remove Tray Table (REP 14.8)
2. Remove Timing Belt (REP 14.7)
3. Disconnect connector M101/M201 [B]
D
4. Unhook harness from cable holders [C]
5. Remove nuts [D] (x4) and remove motor F
6. Measure position of pulley for later replacement [E]
7. Move screws [F], spacers [G] and timing pulley (H) over to new motor.

E
G
H

Replacement
Reverse removal procedure
Make sure to mount timing pulley using measured position [E]
Note!
Torque the set screw against flat surface [I] on motor shaft.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 14.14 Side Guide Adjustment Cable REP 14.15 Pivot Bracket OB (AF602 V1)
(AF602 Spare Parts Manual, PL2.2 Item 8) (AF602 Spare Parts Manual, PL2.3a Item 2)
See REP 14.25 for V2
1. Remove Tray Table (REP 14.8) 1. Open tray
2. Remove screws [A] 2. Remove feed roller [A]
3. Loosen screws [B] 3. Unhook spring [B]
4. Remove cable [C] 4. Remove screws [C]
5. Lift out bracket
For visibility, these figures are shown with parts removed and with cables 6. Remove plates [D] by removing screws [E]
painted red.

B A
B

C C
D D
D

A
A B

C E

AF602-V1/V2 AF602-V3

Replacement Replacement
Reverse removal procedure Reverse removal procedure
Note!
Before torquing screws [B], move the sleds [D] as far inwards as possible
Continued on next page....
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-217
REP 14.15 Continued
Adjustment
1. Remove the reinforcement bracket, loosen screws [A]
2. Loosen the screws [B]
3. Place the tool [C] (located inside the front hatch)
4. Tighten the screws [B]
5. Check that the mechanism moves easily up and down on both ends of
the shaft
6. Repeat this at the other end of the shaft if necessary (REP 14.16)

A C

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-218
REP 14.16 Pivot Bracket IB (AF602 V1)
(AF602 Spare Parts Manual, PL2.3a Item 9)
See REP 14.25 for V2 7. Remove plates [I] by removing screws [J]

1. Open tray I
2. Remove feed roller [A] J
3. Unhook spring [B]
4. Remove pulleys and timing belt [C]
5. Pull out R-clip [D] and remove clutch wheel [E]
6. Remove screws [F], unhook belt [G] and remove timing pulley [H]

Replacement
1. Reverse removal procedure
2. Mount plate [K] in upper position
A
Adjustment
See Adjustment Instructions, Section 14.15 - Same procedure but mirrored

F
E
D

H G

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-219
REP 14.17 Timing Belt Long, Feed Roller REP 14.18 PCB LED (Q101LED, Q201LED) (Optical DSD)
(AF602 Spare Parts Manual, PL2.3a/2.3b Items 10, 21) (AF602 Spare Parts Manual, PL2.3a/2.3b Item 3)

1. Open tray 1. Open tray

2. Remove feed roller [A] 2. Disconnect connector [A]
3. Disconnect connector and remove clutch [B] 3. Remove screws [B]
4. Remove screws [C] 4. Remove PCB LED
5. Tilt shaft and remove belt [D]

B A

B D

Replacement Replacement
Reverse removal procedure 1. Reverse removal procedure
2. Perform Calibration Optical DSD according to BM500 Operator
Manual, AF602 Feeder Settings

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-220
REP 14.19 PCB Sensor (Q101PHT, Q201PHT) (Optical DSD) REP 14.20 Ultrasound DSD Sensor (Matched Pair)
(AF602 Spare Parts Manual, PL2.3a/2.3b Item 4) (AF602 Spare Parts Manual, PL2.3a/2.3b Item 5)
1. Open tray 1. Open tray
2. Disconnect connector [A] 2. Disconnect connector [A]
3. Remove nuts [B] and unhook the grounding cable [C] 3. Remove nuts and washers [B]
4. Remove PCB photo transistor 4. Remove the US DSD receiver box [C]
5. Disconnect connector [D]
6. Remove nuts and washers [E] C A
7. Remove the US DSD transmitter box [F]
B
A C

E B

Replacement
1. Reverse removal procedure
2. Perform Calibration Optical DSD according to BM500 Operator
Manual, AF602 Feeder Settings
F

Replacement
D
1. Reverse removal procedure
2. Perform Calibration US DSD BM500 Operator Manual, AF602 Feeder
Settings

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-221
 REP 14.21 PCB White LED Lamp (LAMP101, LAMP201)
(AF602 Spare Parts Manual, PL2.3a/2.3b Item 1)

1. Remove Cover tray (3.3.3)

2. Remove screw [A]
3. Unhook LED cover [B]
4. Unscrew screw and nuts [C]
5. Disconnect connector

Replacement
Reverse removal procedure

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 14.22 Routing Timing Belts REP 14.23 Gear Shaft Timing Wheel
(AF602 Spare Parts Manual, PL4.0 Item 5) (AF602 Spare Parts Manual, PL4.0 item 15)
This image shows how the timing belt should be routed 1. Remove Cover, Rear (3.3.1)
2. Loosen tension on both timing belts by loosening screws [A, B]
Screw [B] is from the inside, possible to reach through opening [C]
or by removing Cover, Top (14.5)
3. Loosen set screw and remove timing wheel [D]
4. Remove screw [E]
C B A
5. Remove gear shaft

Replacement
D 1. Reverse removal procedure
2. Make sure that belt tension is as
before and fasten screws [A, B]

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 14.24 Chain 5. Remove screws and nuts [C] and slide out this end of the chain
(AF602 Spare Parts Manual, PL4.1 Item 7) 6. Move out the lower bin and repeat removal procedure
7. Disconnect chain brackets from chain by opening the chain master link
CAUTION [D]
There is a risk of tilting the machine with the back cover off and paper in the bins.
Make sure that there is no paper in the bins before fully sliding them out.

1. Ensure that both tray tables are below chain fastening level
2. This job is easiest to perform with all covers off (REP 14.0 - REP
14.6). At a minimum, remove Cover, Rear (REP 14.0)
3. Remove screws and washers [A]; remove chain frame [B]
4. Move out the upper bin

Replacement
Reverse removal procedure

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 14.25 Structural Shaft/Associated Parts (AF602 V2)
(AF602 Spare Parts Manual, PL2.3b Items 2,9,22,23,24)
A
CAUTION D
There is a risk of tilting the machine with the back cover off and paper in the bins.
Make sure that there is no paper in the bins before fully sliding them out. C
B
1. Remove Feed Roller Assy [A]
2. Remove R-Clip [B] and slide off clutch [C]
3. Unhook timing belt [D]
4. Remove retaining ring and bearing [E]
5. Unhook Springs [F] (x2)
6. Push Structural Shaft [G] in direction shown to loosen bearing [H]
from bracket.
7. The structural shaft and associated brackets/parts may now be
lifted out of the tray
F H
G

Replacement
Replace parts as necessary on structural shaft. Reverse removal
procedure to re-mount.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 14.26 Feeder Shaft Assembly / Separator Arm Assembly

CAUTION
There is a risk of tilting the machine with the back cover off and paper in the bins. A
Make sure that there is no paper in the bins before fully sliding them out.

The Feeder Shaft Assembly may jam / get stuck out of its proper posi- B
tion, which results in machine fault codes. The feed rollers need to
fall down into default position when the tray is lowered in order for the
bracket (highlighted by yellow arrows) to trigger sensors Q104/Q204.

The most common root cause is that the separator arm holding the sepa-
rator pad is not moving freely. The separator arm is mounted with the
screw (highlighted by red arrow). The play is adjusted with shim rings.

Procedure
1. Remove the separator arm assembly [A] and, if needed, remove
shim(s) [B] to obtain a play of 0.2-0.7mm (using a hammer to knock
out the pin as shown)
2. Reinstall separator arm assembly
3. Verify that the feed roller shaft falls down easily

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 14.27 Exit Sensor REP 14.28 Exit Feed Stepper Motor (M301)
(AF602 Spare Parts Manual, PL3.1 Item 3) (AF602 Spare Parts Manual, PL3.1 Item 6)

Check
1. Enter service mode and run motor
2. Check that set screw is firmly torqued in sprocket and against the D-
surface of the shaft
Replace
1. Remove Cover, Top (REP 14.5) 1. Remove Cover, Rear (REP 14.0)
2. Disconnect connector [A] 2. Remove Cover, Top (REP 14.5)
3. Remove screw [B] and remove sensor [C] 3. Disconnect connector [A]
4. Remove screws [B] and remove cover frame [C] to gain access to
motor
5. Loosen screw [D] on belt tensioner
6. Loosen tension on belt and unhook belt from motor

A
B

Replacement
Reverse removal procedure
Continued on next page....
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 14.28 Continued REP 14.29 Drive Shaft, Paper Path
(AF602 Spare Parts Manual, PL3.0 Item 3)
7. Remove screws [E] and remove motor
8. Measure placement of timing pulley [F] (for later replacement)
9. Remove timing pulley by loosening set screw [G] B

A
G

1. Drive shafts [A] (5x)

2. Remove Cover, Rear (REP 14.0)
3. Remove Cover, Front (REP 14.1)
4. Remove Cover, Top (REP 14.5)
5. Loosen screw [B] on belt tensioner
6. Loosen tension on belt and unhook belt from shaft
7. Remove screw, axial lock [C]
8. Open upper bin and remove drive shaft. For the bottom shaft you need
to move away two beams on front and back [D] loosen screw [E] and
gently push down the beam (same on back side)
F
D
Measure
C

Replacement Replacement
Reverse removal procedure Reverse removal procedure

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-228
REP 14.30 Drive Shaft, Exit Feed REP 14.31 Idler Shaft Exit
(AF602 Spare Parts Manual, PL3.1A Item B) (AF602 Spare Parts Manual, PL3.1A Item A)

1. Remove Cover, Rear (REP 14.0) A

2. Remove Cover, Front (REP 14.1)
3. Remove Cover, Top (REP 14.5)
4. Remove screw [B] and loosen screw [C]
5. Fold down the guide pulley bracket
6. Remove screw, axial lock [D]
7. Remove drive shaft [A]

1. Idler shafts [A] (dotted line = not visible)

2. Remove Cover, Front (REP 14.1)
3. Remove spring [B]
4. Remove retaining rings [C]
5. Remove bearing blocks [D] and idler shaft

D
C B
C

D
B

Replacement
Replacement
Reverse removal procedure
Reverse removal procedure
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 14.32 Coupling Shaft REP 14.33 Power Supply RS-75-12 (PSU1) 12 Vdc
(AF602 Spare Parts Manual, PL4.0 Item 10) (AF602 Spare Parts Manual, PL5.0 Item 4)

WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

1. Remove Cover, Rear (REP 14.0)

A 2. Disconnect wires
3. Loosen screws (x2) on backside of PSU and remove PSU

1. Coupling shafts [A]

2. Remove Cover, Rear (REP 14.0)
3. Push up the bin lock [B] and push
the bin in slightly
4. Loosen screw [C] on belt tensioner B
and unhook belt from timing wheels
5. Loosen set screw [D] and remove
timing wheel
6. Remove screws [E] and remove the C
coupling shaft

Replacement
Reverse removal procedure.
D
Check voltage levels by performing applicable part of RAP018 12/24/48V
Low or High (section 4)

Replacement E
Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-230
REP 14.34 Power Supply SP-240-24 (PSU2) 24 Vdc REP 14.35 Power Supply SP-750-27 (PSU3) 24Vdc (48V)
(AF602 Spare Parts Manual, PL5.0 Item 10) (AF602 Spare Parts Manual, PL5.0 Item 16)
WARNING! WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine. resistance inside the machine.

1. Remove Cover, Rear (REP 14.0) 1. Remove Cover, Rear (REP 14.0)
2. Disconnect wires 2. Disconnect wires
3. Remove diodes 3. Loosen screws (x2) on backside of PSU and remove PSU
4. Loosen screws (x2) on backside of PSU and remove PSU
Top

Bottom

Replacement
Reverse removal procedure.
Check voltage levels by performing applicable part of RAP018 12/24/48V
Low or High (section 4)

Replacement
Reverse removal procedure.
Check voltage levels by performing applicable part of RAP018 12/24/48V
Low or High (section 4)
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 14.36 Relay DPNO 16A/250V REP 14.37 Main PCBs
(AF602 Spare Parts Manual, PL5.0 Items 20,21,23,32) (AF602 Spare Parts Manual, PL5.0)

WARNING! CAUTION
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or
disconnecting, removing or replacing any electrical components or measuring communications problems. Failure to use proper ESD procedures will cause dam-
resistance inside the machine. age to electronic components (example: PCBs). ESD problems can be minimized by
maintaining all machine ground connections, ensuring the proper handling of circuit
boards/ sensors, refer to the general caution description at the beginning of section 3.
- Use ESD protection when working near PCBs. Failure to use ESD protection is likely
1. Remove Cover, Rear (REP 14.0) to result in a PCB failure.
2. Disconnect connectors
General:
3. Remove screws (x2) and nuts (x2) and remove relay
1. Remove connectors
2. Remove PCB
3. Mount new PCB
A1 11 14 4. Replace connectors, see figure on next page
5. Make sure the DIP switches are in the correct position (see either sec-
tion 4 or section 8 of the Service Manual)
6. Load software according to Service Manual System BM500 Section 5

PCB CPU APP 32 (PCB “A”) Main Board

Perform NVM reset according to Service manual System BM500 section 5
1. Calibrate USDS sensor (Q301/Q302) according to BM500 Operators
Manual, AF602 Sensor Calibration Section

PCB CPU APP 32 (PCB “H”) Upper bin

1. Perform NVM reset according to Service Manual System BM500 sec-
tion 5
2. Calibrate US DSD sensor (Q102) according to BM500 Operators
Manual, AF602 Sensor Calibration Section
3. Calibrate Optical DSD sensor (Q101) according to BM500 Operators
Manual, AF602 Sensor Calibration Section
A2 31 34 PCB CPU APP 32 (PCB “L”) Lower bin
1. Perform NVM reset according to Service Manual System 500 section 5
2. Calibrate US DSD sensor (Q202) according to BM500 Operators
Replacement Manual, AF602 Sensor Calibration Section
Reverse removal procedure.
3. Calibrate Optical DSD sensor (Q201) according to BM500 Operators
Connect according to marking on connectors and relay
Manual, AF602 Sensor Calibration Section
Continued on next page....
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-232
REP 14.37 Continued REP 14.38 Support PCBS
PCB M21H (PCB “G”) M301 Feed motor
1. Perform NVM reset according to Service Manual System BM500 sec- CAUTION
tion 5
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or
PCB M21H (PCB “K”) M101 Lift motor Upper bin communications problems. Failure to use proper ESD procedures will cause dam-
1. Perform NVM reset according to Service Manual System BM500 sec- age to electronic components (example: PCBs). ESD problems can be minimized by
maintaining all machine ground connections, ensuring the proper handling of circuit
tion 5 boards/ sensors, refer to the general caution description at the beginning of section 3.
PCB M21H (PCB “O”) M201 Lift motor Upper bin - Use ESD protection when working near PCBs. Failure to use ESD protection is likely
to result in a PCB failure.
1. Perform NVM reset according to Service Manual System BM500 sec-
tion 5
J2 J1 General:
1. Remove connectors
2. Remove PCB
J3 3. Mount new PCB
4. Replace connectors
fig. 5. Make sure the DIP switches are in the correct position (see either sec-
PCB CPU APP 32 tion 4 or section 8 of the Service Manual)
J5
J4
J6

J7 J8 J9 J10

J3 J2
J1

J6 J5
J4

fig.
PCB M21H
J7

J8 J9 J10 J11

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-233
REP 14.39 Bin Interlock Switch REP 14.40 Door Interlock Switch
(AF602 Spare Parts Manual, PL2.0 Item 5) (AF602 Spare Parts Manual, PL3.0 Item 2)

WARNING! WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine. resistance inside the machine.

CAUTION 1. Remove Cover, Top (REP 14.5)

There is a risk of tilting the machine with the back cover off and paper in the bins. 2. Remove Cover, Front (REP 14.1)
Make sure that there is no paper in the bins before fully sliding them out.
3. The electrical box containing the door interlock switch must be re-
1. Remove Cover, Rear (14.0) moved. Reach in from the top of the machine and loosen two screws
2. Lift bin locking latch and fully push out bin (after removing paper) [A] in order to slide out the electrical box
3. The interlock switch is located in the bottom left, aft corner of the bin.
Access the switch from area [A] and disconnect the connectors
4. Pinch locking tabs on switch and remove the interlock switch
A

A B

4. Disconnect connectors from interlock switch

5. Pinch locking tabs on switch and remove the interlock switch [B]

Replacement
Reverse removal procedure

Replacement
Reverse removal procedure

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-234
REP 15.0 Cover, Rear REP 15.1 Cover, Front
(VF602 Spare Parts Manual, Section 1.0 Item 13) (VF602 Spare Parts Manual, Section 1.0 Item 1)

CAUTION CAUTION
There is a risk of tilting the machine with the back cover off and paper in the bins. There is a risk of tilting the machine with the back cover off and paper in the bins.
Make sure that there is no paper in the bins before fully sliding them out. Make sure that there is no paper in the bins before fully sliding them out.

Front Cover
Rear Cover

[C]

[B]
[D]

[E]

[A]

Rear Cover
Front Cover
1. Loosen screw [A]
1. Lift the latch [D] (x2) and push in the bins
2. Lift up cover [B]
2. Open the front door [E]
3. Tilt out top [C]
3. Lift and remove front cover
4. Remove cover
Replacement Replacement
Reverse removal procedure Reverse removal procedure
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-235
REP 15.2 Cover, Bin REP 15.3 Door
(VF602 Spare Parts Manual, PL1.0 Item 3) (VF602 Spare Parts Manual, PL1.0 Item 5)

1. Remove screws, [A] (x6 total, x3 on either side) 1. Lift off Front Cover (REP 15.1) and place it on a flat surface
2. Remove cover 2. Remove nuts [A] (x2) and remove door
3. Remove the remaining parts [B] from the door

A A

B
Replacement
Reverse removal procedure:
1. Mount cover but do not tighten screws
2. Close bin
3. Adjust position of cover to flush with front cover
4. Open bin and tighten screws Replacement
Reverse removal procedure.
When tightening nuts for door, push door in the direction shown.
Ensure that the door closes properly and has even gaps around the edges.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-236
REP 15.4 Cover, Upper Exit REP 15.5 Cover, Top
(VF602 Spare Parts Manual, PL1.0 Item 9) (VF602 Spare Parts Manual, PL1.0 Item 11)

1. Loosen screw [A] (x2) 1. Remove Cover, Upper Exit (REP 15.4)
2. Slide cover [B] upwards 2. Press Cover, Top in arrow direction and remove

Replacement Replacement
Reverse removal procedure Reverse removal procedure

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-237
REP 15.6 Cover, Side REP 15.7 Cover, Lower Exit
(VF602 Spare Parts Manual, PL1.0 Item 12)

1. Loosen screws [A] (x2) 1. Remove screws [A] (x4)

2. Lift cover up and out 2. Remove cover

Replacement Replacement
Reverse removal procedure Reverse removal procedure

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-238
REP 15.8 Timing Belt

(VF602 Spare Parts Manual, PL2.0 Item 4)

CAUTION
There is a risk of tilting the machine with the back cover off and paper in the bins. Make
sure that there is no paper in the bins before fully sliding them out.

1. Turn off system and disconnect power

2. Remove Cover, Rear (REP 15.0) B A
3. Lift the locking latch and push out bin
4. Remove Cover, Bin (REP 15.2)
5. Loosen screw [B] to release belt tension
6. Remove the belt [A]

Replacement
Reverse removal procedure. After replacing the belt, ensure that the tray table
is level (REP 15.9 Replacement Section). Make sure that the belt tensioner is
tensioning the belt correctly and then torque the screw [B].

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-239
REP 15.9 Tray Table
1. Turn off the main power and disconnect the power cord Replacement
2. Remove Vacuum Chamber (See REP 15.27 Vacuum Belt) Reverse removal procedure. Ensure that the tray table is level (with respect to
3. Move the paper guides [A] inwards and position them around 1 cm away the tray). Put a ruler between the sides of the tray (in locations marked [D]). Re-
from the middle of the tray lease timing belt tension (REP 15.8). Finely adjust the tray table until it is level
4. Remove the countersunk screws [B] (4x) by manually rotating the lead screw assemblies [E] until the tray table is flush
against the rulers. When the tray table is level, tension the timing belt.
5. Put a piece of duct tape on the paper stop of each fan to keep it down
when lifting tray table up, see picture [C]
6. Lift out the tray table

A E

D
E

B B

*Feeder Assembly hidden for clarity

C
*Feeder Assembly hidden for clarity
E E

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-240
REP 15.10 Solenoid SOL 102/202 (Bin Lock Solenoid) REP 15.11 Solenoid SOL 103/203 (Vacuum Feed Solenoid)
(VF602 Spare Parts Manual, PL2.0 Item 10) (VF602 Spare Parts Manual, PL2.3 Item 15)
1. Remove Cover, Rear (REP 15.0) 1. Turn off the main power and disconnect the power cord
2. Lift the locking latch and push out bin half way to gain access to solenoid 2. Remove Vacuum fan assembly (REP 15.36)
from the back. 3. Remove screws [A] (3x) and nut [B]
3. Disconnect connectors from solenoid 4. Remove solenoid assembly [C]
4. Remove screw [A]
5. Remove screw [B] (x3) and remove solenoid assembly
B
B

C
1-2mm

Replacement
1. Replace solenoid in reverse order
2. The screws [A] mate to slotted holes. These screws must be tightened with
Replacement
the solenoid in proper position:
Replace solenoid in reverse order. Adjust position of solenoid so that the tray
• Loosely attach the vacuum fan assembly in place
locking latch engagement distance is 1-2mm when the solenoid is activated.
• Hold the solenoid in place and push down the link arm [D]
orange connector

Ensure the orange connector is

mounted on the indicated side.
Same side as line on the Diode.

Indicated side Line on Diode

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-241
 CAUTION:

Ensure that Orange lead is connected to terminal marked with orange dot.

orange connector

• Make sure the vacuum plate (plate with gasket) fully closes when pushed
down [E], otherwise move the solenoid up or down

Ensure the orange connector is

mounted on the indicated side.
Same side as line on the Diode.

Indicated side Line on Diode

1 mm

• After having adjusted the solenoid position, move the solenoid 1 mm down
• Note location of solenoid with respect to slotted holes
• Remove vacuum fan assembly to access screws [A], torque screws [A] to
secure the solenoid in noted location
3. Re-attach vacuum fan assembly to tray

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-242
REP 15.12 Blower Fans and Fan Exhaust Plastic Inserts
(VF602 Spare Parts Manual, PL2.1 Item 1) - FAN101-FAN104, FAN201-
(Spare PL2.2 Item 12)
FAN204
Fan Replacement Fan Exhaust Insert Replacement

1. Turn off the main power and disconnect the power cord 1. With the fan removed, take off fan bracket by removing nuts [D] (3x)
2. Open relevant tray 2. Remove bracket
3. Disconnect connector [A] 3. Remove nut [E] (if applicable)
4. Unhook harness from cable holders [B] 4. Remove Insert
5. Loosen nuts [C] (2x)
6. Slide fan out C
D E

B
Replacement Replacement
Reverse removal procedure Reverse removal procedure

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-243
REP 15.13 Separation Fan Replacement (FAN105, FAN 205) REP 15.14 Vacuum Fan Replacement (FAN106, FAN206)
(VF602 Spare Parts Manual, PL2.1 Item 1) (VF602 Spare Parts Manual, PL2.3 Item 19)

1. Disconnect connector 1. Disconnect connector

2. Remove screws/washers [A] (x2) 2. Unhook harness from cable holders
3. Remove fan 3. Remove screws/nuts [A] (x2)
4. Remove fan

B D A C D B

Replacement Replacement
Reverse removal procedure. Reverse removal procedure
If Air Knife Fan Bracket [C] requires adjustment, loosen [B] (x4) screws and
align the bracket in position. The nominal position of the bracket (and hence
separation fan) is when holes [D] are perfectly aligned with the holes in the
separation frame.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-244
REP 15.15 Torsion Spring, Paper Stop Upper (Side Guides) REP 15.16 Lead Screw Assembly
(VF602 Spare Parts Manual, PL2.1 Items 2-4) (VF602 Spare Parts Manual, PL2.2 Items 15)

1. Remove nuts [A] (x3) Before starting, find something to keep Elevator Yoke [red] in place after
2. Fold out the fan assy disassembly (ex. a piece of string or some tape)
3. Move the pin half way out [B]
4. Remove the spring [C]

B
1. Move tray table to its lower position, either in service menu or by hand
2. Remove Tray Table (REP 15.9)
3. If lead screw is on front side, remove Cover, Bin (REP 15.2)
C 4. Remove Timing Belt (REP 15.8)
5. Loosen set screw [A] and remove timing wheel and spacer
6. Remove screws [B]

Replacement
Reverse removal procedure
Apply pre-tension of 70° - 120° to spring before mounting

Continued on next page....

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-245
REP 15.16 Continued
7. Remove screws [C] and screw cover [D] (on relevant screw assy)
8. Remove Lead Screw Assembly [E]

Replacement
C
Reverse removal procedure. Adjust/reinstall timing belt using REP 15.8. Level
Tray Table using REP 15.9 (Replacement Section).

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-246
REP 15.17 Stepper Motor M101 / M201
(VF602 Spare Parts Manual, PL2.2 Item 3)

Check Motor
1. Enter service mode and run motor between end positions.
2. Check that set screw is firmly torqued in sprocket and against the D-
surface of the shaft.
Replace motor
1. Remove Tray Table (REP 15.9)
2. Remove Timing Belt (REP 15.8)
3. Disconnect connector M101/M201 [B]
4. Unhook harness from cable holders [C]
D
5. Remove nuts [D] (x4) and remove motor
6. Measure position of pulley for later replacement [E] F
7. Move screws [F], spacers [G] and timing pulley (H) over to new motor.

E
G
H

Replacement
Reverse removal procedure
Make sure to mount timing pulley using measured position [E]
Note!
Torque the set screw against flat surface [I] on motor shaft.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-247
REP 15.18 Side Guide Adjustment Cable REP 15.19 PCB LED (Q101LED, Q201LED) (Optical DSD)
(VF602 Spare Parts Manual, PL2.2 Item 8) (VF602 Spare Parts Manual, PL2.3 Item 2)

1. Remove Tray Table (REP 15.9) 1. Open tray

2. Remove screws [A] 2. Disconnect connector [A]
3. Loosen screws [B] 3. Remove screws [B]
4. Remove cable [C] 4. Remove PCB LED

A
D

B
B

Relevant parts are painted red.

Replacement Replacement
Reverse removal procedure 1. Reverse removal procedure
Note! 2. Perform Calibration Optical DSD according to BM500 Operator
Before torquing screws [B], move the sleds [D] as far in as possible Manual, VF602 Sensor Calibration Section

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-248
REP 15.20 PCB Sensor (Q101PHT, Q201PHT) (Optical DSD) REP 15.21 Ultrasound DSD Sensor (Matched Pair)
(VF602 Spare Parts Manual, PL2.3 Item 3) (VF602 Spare Parts Manual, PL2.3 Item 4)
1. Open tray 1. Open tray
2. Disconnect connector [A] 2. Disconnect connector [A]
3. Remove nuts [B] and hook off the grounding cable [C] 3. Remove nuts and washers [B]
4. Remove PCB photo transistor 4. Remove the US DSD receiver box [C]
5. Disconnect connector [D]
6. Remove nuts and washers [E]
7. Remove the US DSD transmitter box [F]
C A B C

Replacement F
1. Reverse removal procedure
2. Perform Calibration Optical DSD according to BM500 Operator
Manual, VF602 Sensor Calibration Settings D
Replacement
1. Reverse removal procedure
2. Perform Calibration US DSD BM500 Operator Manual, VF602 Sensor
Calibration Settings

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-249
REP 15.22 PCB White LED Lamp (LAMP101, LAMP201) REP 15.23 Timing Belts, Routing
(VF602 Spare Parts Manual, PL2.3 Item 1) (VF602 Spare Parts Manual, PL4.0 Item 5)

1. Remove Cover Bin (REP 15.2) This image shows how the timing belt should be routed
2. Remove screw [A] and make sure to hold spacer [B] not to drop it into
the machine.
3. Unhook LED cover [C]
4. Unscrew screws and nuts [D] (2x)
5. Disconnect connector and remove PCB

A B

Replacement
Reverse removal procedure

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 15.24 Gear Shaft Timing Wheel REP 15.25 Separation Pads
(VF602 Spare Parts Manual, PL4.0 Item 15) (VF602 Spare Parts Manual, PL2.4 Item 2)
1. Remove Cover, Rear (REP 15.0) 1. Open the bin
2. Loosen tension on both timing belts by loosening screws [A, B]. 2. Peel off existing separation pads
Screw [B] is from the inside and is possible to access through the
3. Clean mounting surface
opening labeled [C], or by removing Cover, Top (REP 15.5)
4. Mount new separation pads (self-adhering)
3. Loosen set screw and remove the timing wheel [D]
5. Adjust position of each separator pad such that the top of each pad is
4. Remove screw [E]
1 mm from the bottom of the vacuum belt. Position may be adjusted
5. Remove gear shaft C B by loosening screws [A] and sliding the separator pad [B] up/down
(from outside the tray)

A
A
B

Replacement
1. Reverse removal procedure
D 2. Make sure that belt tension is as
before and fasten screws [A, B]
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 15.26 Chain 5. Remove screws and nuts [C] and slide out this end of the chain
(VF602 Spare Parts Manual, PL4.1 Item 7) 6. Move out the lower bin and repeat removal procedure
7. Disconnect chain brackets from chain by opening the chain master link
CAUTION [D]
There is a risk of tilting the machine with the back cover off and paper in the bins.
Make sure that there is no paper in the bins before fully sliding them out.

1. Ensure that both tray tables are below chain fastening level
2. This job is easiest to perform with all covers off (REP 15.0 - REP
15.6). At a minimum, remove Cover, Rear (REP 15.0)
C
3. Remove screws and washers [A]; remove chain frame [B]
4. Move out the upper bin

Replacement
Reverse removal procedure

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 15.27 Vacuum Belt
(VF602 Spare Parts Manual, PL2.3 Item 14) 6. Bearing [D] needs to be pushed out of its mating bracket. Push the entire
vacuum assembly in the direction shown [E]. The entire vacuum chamber
1. Disconnect connectors from vacuum solenoid and vacuum fan assembly is now loose
2. Remove screws [A] (x2) to loosen vacuum chamber 7. Unhook the timing belt [F] and pull the vacuum chamber assembly towards
3. Remove screws [B] (x2) and remove entire vacuum fan assembly the inside of the tray and upwards.
4. Remove screw [C] to loosen the vacuum brake bracket 8. Shafts [G] are held in by the tension of the vacuum belts. Pull them in the
5. Remove clutch/stop clutch connectors direction shown in order to remove them.
9. With the [G] shafts loose, remove/replace vacuum belts by pulling them
over the support bracket in the direction shown. After belts are in place,
A re-mount [G] shafts.

E D

B Replacement
Reverse removal procedure
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 15.28 Upper Support Assy
(VF602 Spare Parts Manual, PL5.0 Item 1)
A
Plockmatic recommends replacing the entire upper support assembly
when any of the components in the assembly malfunctions. For advanced
technicians, Individual Paper Stops (Spare PL5.0 Item 2) are available.

1. Remove Cover, Rear (REP 15.0) and Cover, Front (REP 15.1)
2. Remove nuts and screws [A] from electrical box and rotate electrical
box out 45 degrees (to access upper support assy mounting screws)
3. Remove [B] screws/spacer/nuts (x2)
4. Continued on next page... A

Top Upper Support Assy

Aft View
Bottom Upper Support Assy

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 15.28 Continued
5. Remove [D] screws/nuts (x2)
6. Disconnect the US Distance Sensor connector [E] and loosen the har-
ness from cable ties.
- For the top upper support assy: remove Cover, Top (REP
15.5) for access.
- For the bottom upper support assy: open up the top bin and
access the connectors from the back of the machine.
7. Pull out upper support assembly

Replacement
Reverse removal procedure. Shift lever [F] back and forth in direction
shown and make sure that asssembly moves freely.

US Distance Sensor E

Top Upper Support Assy

D
Front View
(bin covers hidden for clarity) Bottom Upper Support Assy

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 15.29 Exit Sensor (Q303) REP 15.30 Exit Feed Stepper Motor (M301)
(VF602 Spare Parts Manual, PL3.1 Item 3) (VF602 Spare Parts Manual, PL3.1 Item 6)
Check
1. Enter service mode and run motor
2. Check that set screw is firmly torqued in sprocket and against the D-
surface of the shaft
Replace
1. Remove Cover, Rear (REP 15.0)
2. Remove Cover, Top (REP 15.5)
1. Remove Cover, Top (REP 15.5) 3. Disconnect connector [A]
2. Disconnect connector [A] 4. Remove screws [B] and remove cover frame [C] to gain access to
3. Remove screw [B] and remove sensor [C] motor
5. Loosen screw [D] on belt tensioner
6. Loosen tension on belt and unhook belt from motor

C A

A B

Replacement
Reverse removal procedure
Continued on next page....
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 15.30 Continued REP 15.31 Drive Shaft, Paper Path
(VF602 Spare Parts Manual, PL3.0 Item 3)
7. Remove screws [E] and remove motor
8. Measure placement of timing pulley [F] (for later replacement)
9. Remove timing pulley by loosening set screw [G] B

G A

1. Drive shafts [A] (5x)

2. Remove Cover, Rear (REP 15.0)
3. Remove Cover, Front (REP 15.1)
4. Remove Cover, Top (REP 15.5)
5. Loosen screw [B] on belt tensioner
6. Loosen tension on belt and unhook belt from shaft
7. Remove screw, axial lock [C]
8. Open upper bin and remove drive shaft.
For the bottom shaft you need to move away two beams on front and
F back [D] loosen screw [E] and gently push down the beam (same on
back side)
Measure
D

Replacement
Replacement
Reverse removal procedure
Reverse removal procedure

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 15.32 Drive Shaft, Exit Feed REP 15.33 Idler Shaft, Exit
(VF602 Spare Parts Manual, PL3.1A Item B) (VF602 Spare Parts Manual, PL3.1A Item A)

A
1. Remove Cover, Rear (REP 15.0)
2. Remove Cover, Front (REP 15.1)
3. Remove Cover, Top (REP 15.5)
4. Remove screw [B] and loosen screw [C]
5. Fold down the guide pulley bracket
6. Remove screw, axial lock [D]
7. Remove drive shaft [A]

1. Idler shafts [A] (dotted line = not visible)

2. Remove Cover, Front (REP 15.1)
3. Remove spring [B]
4. Remove retaining rings [C]
5. Remove bearing blocks [D] and idler shaft.

C B
C

D B

Replacement Replacement
Reverse removal procedure Reverse removal procedure
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 15.34 Baffle Hardware

If baffles require adjustment, refer to this section for critical hardware

details.

-Lower Baffle Tension Spring [A] requires 180-270 degrees pre-tension

-Other Baffle Tension Springs [B] require 70-120 degrees pre-tension
-Leave a 1-2mm gap between locking nut [C] and standoff [D] to allow
for middle baffle to rotate freely

B
D
C

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 15.35 SP Sensor
(VF602 Spare Parts Manual PL 2.1)
1. Turn off the main power and disconnect the power cord
2. Remove relevant bin’s Cover (REP 15.2)
3. Remove Fan and Fan Bracket (REP 15.12)
4. Disconnect SP sensor connector
5. Remove screws [A] (2x)
6. Remove the SP sensor

Replacement
Reverse removal procedure

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 15.36 Vacuum fan assembly

(VF602 Spare Parts Manual PL 2.3)

1. Turn off the main power and disconnect the power cord
2. Open relevant tray B
3. Remove Rear Cover (REP 15.0)
4. Disconnect connectors from vacuum solenoid and vacuum fan
5. Note position of screws [A] (2x) in slotted holes and remove them
6. Remove entire vacuum fan assembly

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 15.37 Coupling Shaft REP 15.38 Power Supply RS-75-12 (PSU1) 12Vdc

(VF602 Spare Parts Manual, PL4.0 Item 10) (VF602 Spare Parts Manual, PL6.0 Item 4)
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

A 1. Remove Cover, Rear (REP 15.0)

2. Disconnect wires
3. Loosen screws (x2) on backside of PSU and remove PSU

1. Coupling shafts [A]

2. Remove Cover, Rear (REP 15.0)
3. Push up the bin lock [B] and push
the bin in slightly
4. Loosen screw [C] on belt tensioner B
and unhook belt from timing wheels
5. Loosen set screw [D] and remove
timing wheel
6. Remove screws [E] and remove the C
coupling shaft

Replacement
D Reverse removal procedure.
Check voltage levels by performing applicable part of RAP018 12/24/48V
Low or High (section 4)

E
Replacement
Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-262
REP 15.39 Power Supply SP-240-24 (PSU2) 24Vdc REP 15.40 Power Supply SP-750-27 (PSU3) 24Vdc (48V)
(VF602 Spare Parts Manual, PL6.0 Item 9) (VF602 Spare Parts Manual, PL6.0 Item 14)

WARNING! WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring resistance disconnecting, removing or replacing any electrical components or measuring resistance
inside the machine. inside the machine.

1. Remove Cover, Rear (REP 15.0) 1. Remove Cover, Rear (REP 15.0)
2. Disconnect wires 2. Disconnect wires
3. Remove diodes 3. Loosen screws (x2) on backside of PSU and remove PSU
4. Loosen screws (x2) on backside of PSU and remove PSU
Top

Bottom

Replacement
Reverse removal procedure.
Check voltage levels by performing applicable part of RAP018 12/24/48V Low
or High (section 4)

Replacement
Reverse removal procedure.
Check voltage levels by performing applicable part of RAP018 12/24/48V Low
or High (section 4)
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 15.41 Relay DPNO 16A/250V REP 15.42 Main PCBs
(VF602 Spare Parts Manual, PL6.0 Items 18,19,21,30) (VF602 Spare Parts Manual, PL6.0)
CAUTION
WARNING! ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before communications problems. Failure to use proper ESD procedures will cause dam-
disconnecting, removing or replacing any electrical components or measuring age to electronic components (example: PCBs). ESD problems can be minimized by
resistance inside the machine. maintaining all machine ground connections, ensuring the proper handling of circuit
boards/ sensors, refer to the general caution description at the beginning of section 3.
- Use ESD protection when working near PCBs. Failure to use ESD protection is likely
to result in a PCB failure.
1. Remove Cover, Rear (REP 15.0)
2. Disconnect connectors
General:
3. Remove screws (x2) and nuts (x2) and remove relay 1. Remove connectors
2. Remove PCB
3. Mount new PCB
A1 11 14 4. Replace connectors, see figure on next page
5. Make sure the DIP switches are in the correct position (see either sec-
tion 4 or section 8 of the Service Manual)
6. Load software according to Service Manual System BM500 Section 5
PCB CPU APP 32 (PCB “A”) Main Board
Perform NVM reset according to Service manual System BM500 section 5
NOTE: USDS sensors (Q301/Q302) do not need to be calibrated.
PCB CPU APP 32 (PCB “H”) Upper bin
1. Perform NVM reset according to Service Manual System BM500 sec-
tion 5
2. Calibrate US DSD sensor (Q102) according to BM500 Operators
Manual, VF602 Sensor Calibration Section
3. Calibrate Optical DSD sensor (Q101) according to BM500 Operators
Manual, VF602 Sensor Calibration Section

PCB CPU APP 32 (PCB “L”) Lower bin

A2 31 34 1. Perform NVM reset according to Service Manual System BM500 sec-
tion 5
2. Calibrate US DSD sensor (Q202) according to BM500 Operators
Replacement Manual, VF602 Sensor Calibration Section
Reverse removal procedure. 3. Calibrate Optical DSD sensor (Q201) according to BM500 Operators
Connect according to marking on connectors and relay Manual, VF602 Sensor Calibration Section

Continued on next page....

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-264
REP15.40 Continued REP 15.43 Support PCBs
PCB M21H (PCB “G”) M301 Feed Motor
1. Perform NVM reset according to Service Manual System BM500 sec- CAUTION
tion 5
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or
PCB M21H (PCB “K”) M101 Lift Motor Upper Bin communications problems. Failure to use proper ESD procedures will cause dam-
1. Perform NVM reset according to Service Manual System BM500 sec- age to electronic components (example: PCBs). ESD problems can be minimized by
tion 5 maintaining all machine ground connections, ensuring the proper handling of circuit
boards/ sensors, refer to the general caution description at the beginning of section 3.
PCB M21H (PCB “O”) M201 Lift Motor Upper Bin - Use ESD protection when working near PCBs. Failure to use ESD protection is likely
1. Perform NVM reset according to Service Manual System BM500 sec- to result in a PCB failure.
tion 5
J2 J1 General:
1. Remove connectors
2. Remove PCB
3. Mount new PCB
J3
4. Replace connectors
5. Make sure the DIP switches are in the correct position (see either sec-
fig.
tion 4 or section 8 of the Service Manual)
PCB CPU APP 32
J5
J4
J6

J7 J8 J9 J10

J3 J2
J1

J6 J5
J4

fig.
PCB M21H
J7

J8 J9 J10 J11

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-265
REP 15.44 Bin Interlock Switch REP 15.45 Door Interlock Switch
(VF602 Spare Parts Manual, PL2.0 Item 5) (VF602 Spare Parts Manual, PL3.0 Item 2)
WARNING! WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring disconnecting, removing or replacing any electrical components or measuring resistance
resistance inside the machine. inside the machine.

CAUTION 1. Remove Cover, Top (REP 15.5)

There is a risk of tilting the machine with the back cover off and paper in the bins. 2. Remove Cover, Front (REP 15.1)
Make sure that there is no paper in the bins before fully sliding them out.
3. The electrical box containing the door interlock switch must be re-
1. Remove Cover, Rear (15.0) moved. Reach in from the top of the machine and loosen two screws
2. Lift bin locking latch and fully push out bin (after removing paper) [A] in order to slide out the electrical box
3. The interlock switch is located in the bottom left, aft corner of the bin.
Access the switch from area [A] and disconnect the connectors
4. Pinch locking tabs on switch and remove the interlock switch
A

A B

4. Disconnect connectors from interlock switch

5. Pinch locking tabs on switch and remove the interlock switch [B]

Replacement
Reverse removal procedure

Replacement
Reverse removal procedure

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-266
REP 15.46 Transformer (TR1)
(VF602 Spare Parts Manual, PL3.1A Item 5)

WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

1. Remove Cover, Lower Exit (REP 15.7)

2. Disconnect antistatic bars [A]
3. Disconnect harness [B], remove screws [C] (x2) and slide out the high
voltage PSU
4. Disconnect connector between TR1 and REL303
5. Remove screws/nuts [D] (x4) and remove TR1

Replacement
Reverse removal procedure

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-267
REP 16.1 Front Cover REP 16.2 Rear Cover
Parts List on PL 1.0 Parts List on PL 1.1
1. Turn off the main power switch and disconnect the power cord. 1. Turn off the main power switch and disconnect the power cord.
2. Open Top cover and loosen screws [A] (x2). 2. Open Top Cover and remove screws [A] (x2).
3. Lift off Front Cover [B]. 3. Lift off Rear Cover [B].
CAUTION:
Be careful not to damage the Interlock switch [C] when lifting off the Front Cover.

Replacement
Replacement Reverse removal procedure.
Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-268
REP 16.3 Top Cover 8. Remove Top Cover.
Parts List on PL 1.0
WARNING
Keep supporting Top Cover during removal to avoid personal injury
and damages of machine.
When any of the Gas Spring end sockets are pryed off of their brack-
ets, the Top Cover can fall down causing personal injury and/or dam-
ages to the machine.
1. Open Top cover.
2. Turn off the main power switch and disconnect the power cord.
3. Remove Rear Cover (REP 16.2).
4. Pry the Gas Spring end socket off of the lower bracket [A].
C
5. Pry the Gas Spring end socket off of the upper bracket [B].
6. Close the Top Cover.
7. Remove screws and nuts [C] (x4).
Replacement
Reverse removal procedure.

Make sure that gaps are even all around and rubber bumpers touches
evenly. Make sure Top Cover Interlock switch is properly activated [D]
when Top Cover closes.
If not, adjust as follows.

B D

Continued on next page....

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-269
Top cover, continued
Interlock actuator:
Adjustment 6. Open Top Cover.
7. Loosen screws [G] (x2) to adjust position of Interlock actuator [H].
Minor rear height and scew adjustment:
1. Loosen screws [C] slightly to adjust height.

H
Rear height, scew and front to back adjustment:
2. Turn off the main power switch and disconnect the power cord.
3. Remove Rear Cover (REP 16.2).
4. Loosen nuts [E] (x4) slightly.
5. Move hinge bracket [F] to adjust scew.

E
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-270
REP 16.4 Frame cover plates REP 16.5 Electronics cover
Parts List on PL 1.0, 1.1 1. Turn off the main power switch and disconnect the power cord.
1. Turn off the main power switch and disconnect the power cord. 2. Remove Front Cover (REP 16.1).
2. Remove screws [A] (x4). 3. Remove Rear Cover (REP 16.2).
3. Remove Cover [B]. 4. Remove either of the two Frame cover plates (REP 16.4).
5. Remove screws [A] (x4).

Replacement
Reverse removal procedure.

Continued on next page....

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-271
Electronics cover, continued

1. Lower electronics cover [B] at the operator side.

2. Lift out and remove.

Replacement
Reverse removal procedure.
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-272
REP 16.6 Front side, Interlock switch CR-SW2, CR-SW3 REP 16.7 Front side, Main power Switch CR-SW1

Parts List on PL 1.4 Parts List on PL 1.4

1. Turn off the main power switch and disconnect the power cord. 1. Turn off the main power switch and disconnect the power cord.
2. Remove Front Cover (REP 16.1). 2. Remove Front Cover (REP 16.1).
3. Note position or wires [A]. 3. Note position or wires [A].
4. Press at [B]. 4. Press at [B].
5. Remove Interlock switch [C]. 5. Remove Main Power switch [C].

B C B B C B

A A

Replacement Replacement
Reverse removal procedure. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-273
REP 16.8 Front side, Lead screw motor CR-M2 Replacement
Reverse removal procedure.
Parts List on PL 1.5
Adjustment
1. Turn off the main power switch and disconnect the power cord.
Check that the drive pin has 0,5-3mm (1/64”-7/64”) clearance from the bot-
2. Remove Front Cover (REP 16.1). tom of the drive dog slot.
3. Disconnect connector [A]. Loosen screw [D] and make sure the clutch adaptor [E] is correctly in-
4. Remove screws and nuts [B] (x4). stalled.
5. Remove Lead screw motor CR-M2 [C]. If clearance still cannot be achieved, loosen screws [F] and move Lead
screw motor bracket [G].

D E
G

0,5-3mm
1/64”-7/64”

A C B

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-274
REP 16.9 Front side, Lead screw bearing assembly REP 16.10 Front side, Lead screw assembly
Parts List on PL 1.5 Parts List on PL 1.5
1. Turn off the main power switch and disconnect the power cord. 1. Turn off the main power switch and disconnect the power cord.
2. Remove Front Cover (REP 16.1). 2. Remove Lead screw bearing assembly (REP 16.10).
3. Insert an allen wrench at [A] and hold to stop lead screw from turning. 3. Loosen screws [A] (x2).
4. Remove screw [B]. 4. On the back side of the Lead screw bracket [B] there are washers
5. Remove screws [C] and remove bearing assembly [D]. (x3) and a spacer (x1) [C] on each screw. In order not to loose these,
unscrew screws [A] and hold them in place while turning lead screw
A bracket around the lead screw.

B
A
D

Replacement Replacement
Reverse removal procedure. Reverse removal procedure.

Adjustment Adjustment
See (REP 16.9). See (REP 16.9).
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-275
REP 16.11 Rear side, Transport timing belt
Parts List on PL 1.2 Replacement
1. Turn off the main power switch and disconnect the power cord. Reverse removal procedure.
2. Remove Rear Cover (REP 16.2).
Adjustment
3. Remove either of the two Frame cover plates (REP 16.4). 1. Push the tensioner [B] in the direction of the spring [C]. Let relax and
4. From inside the module, loosen screw [A] to relieve Timing belt ten- re-tighten screw [A].
sion. 2. Turn the Paper transport motor CR-M1 pulley [D] two revolutions
5. Remove Timing belt. clockwise.
3. From inside the module, repeat loosening screw [A] to relieve Timing
belt tension.
4. Push the tensioner [B] in the direction of the spring [C]. Let relax and
re-tighten screw [A].

B C A
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-276
REP 16.12 Rear side, Paper transport motor CR-M1
Parts List on PL 1.2 CAUTION:
CAUTION: Support the motor while removing the last screw and nut.
ESD Hazard! Use ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure, see (REP 3.1).
1. Turn off the main power switch and disconnect the power cord.
2. Remove the Frame cover plate on the exit side (REP 16.4).
3. Remove Transport timing belt (REP 16.12).
4. Disconnect Paper transport motor CR-M1 [A].
5. Remove screws and nuts [B] (x4)

Replacement
Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-277
REP 16.13 Creaser

Parts List on PL 1.3 5. Remove screw [C], bearing [D], washers (x3) and spacer (x1) [E]
1. Turn off the main power switch and disconnect the power cord. behind bearing.
2. Remove Front Cover (REP 16.1). 6. Remove bearing bracket [F] by removing screws [G] (x2).
NOTE
3. Support Creaser assembly at operator side using a wire or similar [A]. It is not necessary to remove bracket in order to remove the bearing.
4. Support spacer [B]

F B E D

Replacement
Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-278
REP 16.14 Creaser Timing belt

Parts List on PL 1.7

1. Turn off the main power switch and disconnect the power cord. E
2. Remove Rear Cover (REP 16.2).
3. Remove the Frame cover plate on the exit side (REP 16.4). C
4. Remove Electronics cover (REP 16.6).
5. Loosen screw [A] to relieve Timing belt tension.
6. Remove Timing belt [B].

B
F

A
Replacement

1. Reverse removal procedure.

NOTE
While installing the Timing belt, position pulleys [C] and [D] so that the screws [E] and [F]
securing them are pointing to the right to obtain good access when adjusting later on.
2. Perform adjustment described on next page.

Continued on next page....

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-279
Creaser timing belt, continued 5. Keep pulleys [C] and [D] in position and align the creaser tools so that
one of the lower creaser tool rulers mates with the fine tool groove
Adjustment (the narrower one) of the upper creaser tool. This can be observed as
1. Turn the eccentric [G] counter clockwise to tension the Timing belt [B] illustrated [H].
firmly so that there is no slack. Hold eccentric [G]. 6. Tighten screw [E].
2. Check position of pulleys [C] and [D] so that the screws [E] and [F] 7. Hold the lower creaser tool steady and turn pulley [C] to position the
are pointing to the right for good access. If not, relax belt tension and side of the fine tool groove towards the ruler of the lower creaser tool
repositon pulleys [C] and [D]. as illustrated [I].
3. Tighten screw [A].
4. Loosen the screws [E] and [F].

D H

B I

Process Groove is
direction leading

Continued on next page....

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-280
Creaser timing belt, continued

1. Select the fine crease tool. 10. Run a SRA3 (12x18”) Colotech 120gsm (32lb Bond) or similar.
2. Run a SRA3 (12x18”) Colotech 120gsm (32lb Bond) or similar. 11. Check that the crease is within the nominal length / 2 ±0,5mm (±1/64”)
3. Check that the crease is within the nominal length / 2 ±0,5mm (±1/64”) from lead edge. If not, enter Service mode (Section 5 GP1).
from lead edge. If not, enter Service mode (Section 5 GP1). 12. Select target CR500.
4. Select target CR500. 13. Select NVM
5. Select NVM 14. Change Index value 2 Coarse offset.
6. Change Index value 1 Fine offset. 15. Exit Service mode.
7. Exit Service mode. 16. Repeat procedure until within tolerances.

if the fine crease is if the coarse crease is

lead edge

lead edge
positioned like the red line positioned like the red line
- -
increase Index #1 value increase Index #2 value

if the fine crease is if the coarse crease is

lead edge

lead edge
positioned like the red line positioned like the red line
- -
decrease Index #1 value decrease Index #2 value

8. Repeat procedure until within tolerances.

9. Select the coarse crease tool.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 16.15 Creaser motor CR-M3
Parts List on PL 1.7
NOTE
Creaser motor CR-M3 can be removed without removing the Creaser assembly. However,
removing Creaser assembly (REP 16.14) facilitates removal of Creaser motor.
CAUTION:
ESD Hazard! Use ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure, see (REP General Cautions)
1. Turn off the main power switch and disconnect the power cord. B
2. Remove Creaser timing belt (REP 16.15).
3. Disconnect Creaser motor CR-M3 [A].
4. Position timing belt tensioner [B] as far up as possible. E
5. Remove nut, screw and washers (x4) at lower rod end [C] and move
the lower end of the creaser assembly to the right in order to get better
access to the leftmost screw fastening the motor. C

CAUTION:
Support the motor while removing the last screw and nut.

Replacement
1. Reverse removal procedure.
6. Remove screws, nuts (x4) [D] and the Creaser motor CR-M3 [E]. Adjustment
NOTE
The leftmost screw and nut is the most diffucult one. Start with that one when removing mo-
1. Perform adjustment in (REP 16.14).
tor.
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-282
REP 16.16 Creaser baffle
7. Lift off springs to Creaser baffle at both sides [C].

Parts List on PL 1.6

1. Turn off the main power switch and disconnect the power cord.
2. Open the Top cover.
3. Remove Front Cover (REP 16.1).
4. Remove Rear Cover (REP 16.2).
5. Undo cable ties [A].
6. Disconnect connectors [B].

Continued on next page....

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-283
Creaser baffle, continued

1. Loosen the allen screw [D] and the stud [E].

NOTE
Be careful not to loose the washer [F] between the Creaser baffle and the Creaser frame.
2. Remove Creaser baffle as illustrated.
D E
1
2

Replacement
Reverse removal procedure.

Hint when installing:

1. Using an allen wrench, hold allen screw and washer in position.
2. Move the Creaser baffle almost in position.
3. Carefully back the allen screw off so that the Creaser baffle can be put
in position without loosing the washer.

Adjusment
F 1. Loosen nut [G] and adjust screw [H] so that the distance between the
upper and lower Creaser baffles is 4±0,5mm (5/32”±1/64”).

D
H
4±0,5mm
E 5/32”-1/64”
G

lead screw assembly not shown for clarity

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 16.17 Creaser assembly 9. Disconnect creaser motor CR-M3 [D] at [E].
Parts List on PL 1.6, 1.7
CAUTION:
ESD Hazard! Use ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure, see (REP General Cautions).
1. Turn off the main power switch and disconnect the power cord.
2. Remove Front Cover (REP 16.1). D
3. Remove Rear Cover (REP 16.2).
4. Remove Frame cover plates (REP 16.4).
5. Remove Electronics cover (REP 16.5).
6. Undo cable ties and disconnect sensor CR-Q1 to CR-Q4 phototransis-
tors [A] (x4).
7. Disconnect creaser home position sensor CR-Q6 [B]. E

10. Remove screws [F] (x8).

A B
F
8. Inside module, undo cable ties and disconnect sensor CR-Q1 to CR-
Q4 LED’s [C] (x4).

C Continued on next page....

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-285
Creaser assembly, continued 4. On the back side of the Lead screw bracket [J] there are washers
(x3) and a spacer (x1) [K] on each screw. In order not to loose these,
1. Remove baffles [G]. unscrew screws [I] and hold them in place while turning lead screw
bracket around the lead screw.
G

2. Support Creaser assembly at operator side using a wire or similar [H].

H
5. Remove upper nut, screw and washers (x4) [L].

3. Loosen screws [I] (x2).

Continued on next page....

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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Creaser assembly, continued CAUTION:
Creaser assembly is very heavy.
3. Hold Creaser assembly [O] at operator side and remove supporting
1. Support Creaser assembly at non operator side to avoid it from falling
wire.
down and remove lower nut, screw and washers (x4) [M].
4. Move Creaser assembly slightly towards non operator side, lift at op-
erator side and lift out Creaser assembly.

2. Lower Creaser assembly at the non operator side to resting position at

the bottom of the hole in the frame [N].

Replacement
1. Reverse removal procedure.
2. Perform adjustment described as follows.

Continued on next page....

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-287
Creaser assembly, continued Adjustment

M N When the Creaser assembly moves to compensate for the skew in which
the sheets are fed, it describes a pendulum motion. This is obtained by
letting the operator side of the creaser assembly [O] travel along a lead
screw while the other end turns around two rod end bearings [M] and [N].
The position of the lead screw and the lead screw nut is fixed. The dis-
tance from the pivot point to the lead screw is shortest when the creaser
tools [P] are parallell to the fixing rollers [Q] and increases in any of the
end positions. To be able to compensate for this difference in distance, the
hole in the lead screw bracket [J] where the lead screw nut goes, is slot-
ted.

1. Turn the lead screw so that the creaser tools are parallell to the fixing
rollers.

Continued on next page....

O
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-288
Creaser assembly, continued 3. Check that there is min. 0,5mm / 1/64” clearance between the cut-out
in the main frame [S] and the creaser sub frame [T] as illustrated.
1. Loosen both screws and nuts [R] (x2) securing the rod ends. The
holes in the bracket are slotted and allows for adjusting the creaser
assembly.

min 0,5mm
min 1/64”

4. Turn the lead screw so that the creaser assembly moves towards the
exit side.
5. Check that the screw [U] clears the bearing bracket [J]. If necessary,
2. Move the creaser assembly towards the operator side untill the inside of loosen nut [X], tighten screw [U] and re-tighten nut [X].
the slotted hole in the lead screw bracket just touches the lead screw nut.
V U X

6. Check/adjust of Angle offset NVM Index value 3 (REP 16.10).

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 16.18 Creaser tools 7. Remove screws [E] (x2) and remove eccentrics [F] (x2).
Parts List on PL 1.6, 1.7
1. Turn off the main power switch and disconnect the power cord. non operator side
2. Remove Creaser assembly (REP 16.4).
3. Remove Creaser timing belt (REP 16.15).
4. Remove screws (x2) and remove Creaser tools home positions sensor
CR-Q6 [A].
5. Loosen screws [B] (x2) and remove pulleys.
6. Remove screw [C] and Timing belt tensioner [D].

F E
operator side

Continued on next page....

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-290
Creaser tools, continued 2. Loosen nuts and set screws [I] (x2) to retract plungers [J] (x2).
1. Remove screws [G] (x4) and remove brackets [H] (x2). 3. Remove plunger mechanism.
non operator side non operator side

H G J I
operator side
operator side

G I J
H Continued on next page....

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-291
Creaser tools, continued Replacement
Reverse removal procedure.
1. Remove screws [K] (x6) and remove guide brackets [L] (x2).
2. Remove Creaser Tools [M].

Adjustment
1. Relieve Timing Belt Tension.
2. Align the tool ruler into the fine tool groove as illustrated.

non operator side

K M

operator side

K L Continued on next page....

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-292
Creaser tools, continued 4. Loosen the locknuts [N] and turn the set screw [I] (x2) so that the limit-
ing plunger [J] gets in contact with the ball bearing and back out 1/8
1. Loosen screws [E] (x2) and [G] (x4). turn.
2. Position the Creaser Tools Anvils with the eccentrics [F] (x2) so that 5. Tighten the locknuts [N] (x2).
the tools barely touch each another. 6. Adjust Creaser timing belt (REP 16.15).
3. Tighten screws [E] and [G]. 7. Check that tools not interfere on any side by turning them in process
direction with M6 pulley.
F
non operator side
non operator side

I N

E G F operator side

operator side

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-293
REP 16.19 Rollers, Idler and Fixing rollers
D
Parts List on PL 1.2, 1.3
NOTE
Only the infeed rollers are described here. Principle is the same for the exit rollers. E
CAUTION:
Rollers are heavy. Especially the fixing rollers. Support them for example with a piece of wire
or similar to help prevent them from falling down. Wires also makes removal and replacement
easier.
B

9. Disconnect connector [F] to Lead screw motor CR-M2 [G].

10. From inside the creaser module, remove screws securing Lead screw
motor bracket [H]. Remove motor and bracket.

1. Turn off the main power switch and disconnect the power cord.
2. Remove Front Cover (REP 16.1).
3. Remove Rear Cover (REP 16.2).
4. Remove Transport timing belt (REP 16.12). G
5. Remove pulley [A].
6. Remove roller holders [B] (x2).
7. Remove screw [C] securing roller frame [D]. F
8. Remove roller frame [D] and spring [E].
CAUTION:
Remove roller frame and spring with care. Rollers are now loose and can possibly fall down.
Continued on next page....

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-294
Idler and fixing rollers, continued 5. Remove Fixing roller as illustrated.

1. Remove roller holders [I] (x2).

2. Remove screw [J] securing roller frame [K].
3. Remove roller frame [K] and spring [L].
CAUTION: 4
Remove roller frame and spring with care. Rollers are loose and can possibly fall down.

K 2

L 1

4. Remove Idler roller [M] as illustrated.

Replacement
Reverse removal procedure.
4

3 2

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-295
REP 16.20 Sensors, Creaser trigger sensors CR-Q1 to Q4, REP 16.21 Creaser trigger sensors CR-Q1 to Q4, LED’s
phototransistors Parts List on PL 1.6
Parts List on PL 1.6 1. Turn off the main power switch and disconnect the power cord.
1. Turn off the main power switch and disconnect the power cord. 2. Remove Electronics cover (REP 16.5)
2. Open the Top cover. 3. Undo cable tie(s) [A].
3. Undo cable tie(s) [A]. 4. Disconnect connector(s) and remove screw(s).
4. Disconnect connector(s) and remove screw(s). 5. Remove sensor(s) [B].
5. Remove sensor(s) [B].

B
B

1
2
Replacement A
Reverse removal procedure.
Adjustment
If replacing sensor(s) 2 and/or 3:
1. Check/adjust Fine and Coarse tool offset NVM Index value 1 and 2
(REP 16.14).
2. Check/adjust of Angle offset NVM Index value 3 (REP 16.10).
Replacement
If replacing sensor(s) 1 and/or 4: Reverse removal procedure.
3. Check/adjust Fine and Coarse tool offset NVM Index value 1 and 2
(REP 16.14).
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-296
REP 16.22 Sensors, Exit sensor CR-Q5 REP 16.23 Sensors Creaser tools home position sensor
Parts List on PL 1.4 CR-Q6
NOTE Parts List on PL 1.6
Removing sensor can be made easier by removing the lower screws x2 fastening the exit
cover [A] and rotating the lower side out from the module. Skip step 2, 3 and 4 if you decide 1. Turn off the main power switch and disconnect the power cord.
not to do this. 2. Open the Top cover.
1. Turn off the main power switch and disconnect the power cord. 3. Undo cable tie [A].
2. Remove Front Cover (REP 16.1). 4. Disconnect connector [B], remove screws [C] (x2) and washers behind
3. Remove Rear Cover (REP 16.2). sensor (x4).
4. Remove screws [B] (x2) and rotate the lower end of the exit cover out 5. Remove sensor [D].
from the module.
5. Open the Top cover.
6. Remove screw [C], disconnect and remove sensor [D].

B A

A
Replacement
Reverse removal procedure.
Make sure the actuator on the creaser tool hits the center of the sensor
C D slot.
Adjustment
Replacement
Check/adjust Fine and Coarse tool offset NVM Index value 1 and 2 (REP
Reverse removal procedure.
16.14).
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-297
REP 16.24 Sensors, Lead screw home position sensor CR-
Q7
Parts List on PL 1.5 Adjustment
1. Select the fine crease tool.
1. Turn off the main power switch and disconnect the power cord.
2. Run a SRA3 (12x18”) Colotech 120gsm (32lb Bond) or similar.
2. Remove Front Cover (REP 16.1).
3. Check that the crease is parallell to the lead edge of the sheet within
3. Note position or wires [A]. ±0,5mm (±1/64”). If not, enter Service mode (Section 5, GP1).
4. Press at [B]. 4. Select target CR500.
C B
5. Remove Interlock switch [C]. 5. Select NVM
6. Change Index value 3 Angle offset.
7. Exit Service mode.

if crease is angled like

lead edge
the red line
-
increase Index #3 value

if crease is angled like

lead edge
the red line
-
decrease Index #3 value

8. Repeat procedure until within tolerances.

Replacement
Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-298
REP 16.25 Electronics, PCB CPU APP 32, PCB “A” REP 16.26 Electronics, PCB M21H, PCB “E” (CR-M1)
Parts List on PL 1.8 Parts List on PL 1.8
CAUTION: CAUTION:
ESD Hazard! Use ESD protection when working near PCBs. Failure to use ESD protection is ESD Hazard! Use ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure, see (REP General Cautions). likely to result in a PCB failure, see (REP General Cautions).
1. Turn off the main power switch and disconnect the power cord. 1. Turn off the main power switch and disconnect the power cord.
2. Remove Front Cover (REP 16.1). 2. Remove Rear Cover (REP 16.2).
3. Disconnect connectors (x9). 3. Disconnect connectors (x4). The connector Paper transport motor CR-
4. Squeeze barbs [A] on stand-offs and remove PCB “A”. M1 is unmarked.
4. Squeeze barbs [A] on stand-offs and remove PCB “E”.
Replacement
1. Check DIP switch positions. Replacement
2. Reverse removal procedure. 1. Check DIP switch positions.
NOTE 2. Reverse removal procedure.
If PCB is renewed, load software according to GP 19. NOTE
If PCB is renewed, load software according to GP 19.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 16.27 Electronics, PCB M21H, PCB “G” REP 16.28 Electronics, PCB M21H, PCB “H” (CR-M3)
Parts List on PL 1.8 Parts List on PL 1.8
CAUTION: CAUTION:
ESD Hazard! Use ESD protection when working near PCBs. Failure to use ESD protection is ESD Hazard! Use ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure, see (REP General Cautions). likely to result in a PCB failure, see (REP General Cautions).
1. Turn off the main power switch and disconnect the power cord. 1. Turn off the main power switch and disconnect the power cord.
2. Remove Front Cover (REP 16.1). 2. Remove Rear Cover (REP 16.2
3. Disconnect connectors (x5). The connector to the Lead screw motor 3. Disconnect connectors (x6). The connector to the Creaser motor CR-
CR-M2 is unmarked. M3 is unmarked.
4. Squeeze barbs [A] on stand-offs and remove PCB “G”. 4. Squeeze barbs [A] on stand-offs and remove PCB “H”.
Replacement Replacement
1. Check DIP switch positions. 1. Check DIP switch positions.
2. Reverse removal procedure. 2. Reverse removal procedure.
NOTE NOTE
f PCB is renewed, load software according to GP 19. If PCB is renewed, load software according to GP 19.

A A

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 16.29 Electronics, PCB “K” PTC110, short circuit REP 16.30 Electronics, PCB “L” PTC110, short circuit
protection protection
Parts List on PL 1.8 Parts List on PL 1.8
1. Turn off the main power switch and disconnect the power cord. 1. Turn off the main power switch and disconnect the power cord.
2. Remove the Frame cover plate on the infeed side (REP 16.4). 2. Remove the Frame cover plate on the infeed side (REP 16.4).
3. Disconnect connectors [A] (x2). 3. Disconnect connectors [A] (x2).
4. Squeeze barbs on stand-offs [B] (x2) and remove PCB “K” [C]. 4. Squeeze barbs on stand-offs [B] (x2) and remove PCB “L” [C].

B B

A A

Replacement Replacement
Reverse removal procedure. Reverse removal procedure.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-301
REP 16.31 Electronics, PCB “M” SCP Universal, short 5. Lift off PSU assembly [B] to access PCB “M”.
circuit protection
Parts List on PL 1.8
CAUTION:
ESD Hazard! Use ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure, see (REP General Cautions).
1. Turn off the main power switch and disconnect the power cord.
2. Remove Rear Cover (REP 16.2).
3. Remove the Frame cover plate on the infeed side (REP 16.4).
4. Loosen screws [A] (x2). B

6. Disconnect connectors [C] (x2).

7. Squeeze barbs on stand-offs [D] (x4) and remove PCB “M” [E].

B
A

Replacement
Reverse removal procedure.
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 16.32 Electronics, PCB “N” SCP Universal, short REP 16.33 Electronics, PSU1 Power supply, RS-35-12
circuit protection Meanwell
Parts List on PL 1.8 Parts List on PL 1.8
CAUTION: CAUTION:
ESD Hazard! Use ESD protection when working near PCBs. Failure to use ESD protection is ESD Hazard! Use ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure, see (REP General Cautions). likely to result in a PCB failure, see (REP Genral Cautions).
1. Turn off the main power switch and disconnect the power cord. 1. Turn off the main power switch and disconnect the power cord.
2. Remove the Frame cover plate on the infeed side (REP 16.4). 2. Remove Rear Cover (REP 16.2).
3. Disconnect connectors [A] (x2). 3. Remove the Frame cover plate on the infeed side (REP 16.4).
4. Squeeze barbs on stand-offs [B] (x4) and remove PCB “N” [C]. 4. Loosen screws [A].

Replacement
Continued on next page....
Reverse removal procedure.
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-303
Electronics, PSU1 Power supply, RS-35-12 Meanw., continued

3. Note position of wiring [D] and disconnect.

4. Remove PSU1.
1. Lift off PSU assembly [B] to access PSU1.

2. Remove screws [C] (x2).

Replacement
Reverse removal procedure.

Adjustment
1. Measure voltage between -V (ground) and +V (12VDC).
2. Set voltage to 12±0.1 VDC by adjusting the potentiometer at +V ADJ.
NOTE
This in only one turn trimmer. A 1/4 turn is about 3VDC. Turn clockwise to increase and counter
clockwise to decrease the output voltage.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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REP 16.34 Electronics, PSU2 Power supply, SP-240-24 Meanw. 7. Note position of wiring [D] and disconnect.
Parts List on PL 1.8
CAUTION:
ESD Hazard! Use ESD protection when working near PCBs. Failure to use ESD protection is likely to
result in a PCB failure, see (REP General Cautions).
1. Turn off the main power switch and disconnect the power cord.
2. Remove Rear Cover (REP 16.2).
3. Remove the Frame cover plate on the infeed side (REP 16.4).
4. Loosen screws [A].
5. Lift off PSU assembly [B] to access PSU2.

8. Remove PSU2.

A
6. Remove screws [C] (x3).
D
Replacement
Reverse removal procedure.

Adjustment
1. Measure voltage between -V (ground) and +V (12VDC).
2. Set voltage to 24±0.1 VDC by adjusting the potentiometer at +V ADJ.
NOTE
B
This in only one turn trimmer. A 1/4 turn is about 3VDC. Turn clockwise to increase and coun-
ter clockwise to decrease the output voltage.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-305
Electronics, PSU3 Power supply, SP-240-24 Meanw. 7. Note position of wiring [D] and disconnect.
Parts List on PL 1.8
CAUTION:
ESD Hazard! Use ESD protection when working near PCBs. Failure to use ESD protection is likely
to result in a PCB failure, see (REP 3.1).
1. Turn off the main power switch and disconnect the power cord.
2. Remove Front Cover (REP 16.1).
3. Remove the Frame cover plate on the infeed side (REP 16.4).
4. Loosen screws [A].
5. Lift off PSU assembly [B] to access PSU3. C

8. Note position/polarity of diodes [E] and disconnect.

9. Remove PSU3.

A
6. Remove screws [C] (x3).
Replacement
D
Reverse removal procedure.
Adjustment
1. Measure voltage between -V (ground) and +V (12VDC).
2. Set voltage to 24±0.1 VDC by adjusting the potentiometer at +V ADJ.
NOTE
This in only one turn trimmer. A 1/4 turn is about 3VDC. Turn clockwise to increase and counter
B clockwise to decrease the output voltage.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-306
REP 16.35 Electronics, Relay, interlock CR-REL1 6. Remove screws [C] (x2)
Parts List on PL 1.8
CAUTION:
ESD Hazard! Use ESD protection when working near PCBs. Failure to use ESD protection is likely
to result in a PCB failure, see (REP 3.1).
1. Turn off the main power switch and disconnect the power cord.
2. Remove Rear Cover (REP 16.2).
3. Remove the Frame cover plate on the infeed side (REP 16.4).
4. Loosen screws [A]. C

7. Note position of wiring [D] and disconnect.

8. Remove Relay.

A
5. Lift off PSU assembly [B] to access PSU2.

B Replacement
Reverse removal procedure.
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-307
REP 16.36 Electronics, Counter
Parts List on PL 1.0
1. Turn off the main power switch and disconnect the power cord.
2. Remove Rear Cover (REP 16.2).
3. Disconnect connector [A].
4. Squeeze barbs and remove counter [B].

Replacement
Reverse removal procedure.

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 REP 17.0 Docking/Undocking TWC

Parts List on PL 15.0, 15.1

Removal (TWC from RCT)

1. Turn off the main power and disconnect the Power Cord.
2. Behind the RCT, loosen the knobs [A] and remove Cable Protection Extension [B].
3. Unhook the O-ring [C].
4. Loosen knob [D] to be able to undock the TWC from the RCT.
5. Open the Schackle [E] to remove the Safety Wire [F] from the Conveyor support [G] and
move the TWC away from the RCT.

[B]

[A]

[G] [E] [F]

[C]

[D]

continued on next page

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
3-309
 REP 17.0 Docking/Undocking TWC, continues
[F]
Replacement
1 Reverse the removal procedure.
2. Ensure that the Trim Waste Conveyor is parallel to the Booklet Maker and lock the cast-
ers.
3. Hook up the O-ring [C] on the pulleys and ensure it is twisted the right way to make the
Belt go in the desired transport direction.

WARNING:
To prevent the Waste Conveyor from falling over, a safety wire [F] must be installed
between the Conveyor support and the Booklet Maker. Use the height adjustment
between the Booklet Maker on the exit side and the base as an anchor point.
4. Make a noose [H] around the height adjustment spindle [I].
5. Attach the other end of the Safety Wire around the Conveyour Support with a shackle
[E] Tighten the schackle firmly with a pair of pliers or an adjustable spanner.

[I]
[C] [H]

[E]

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 REP 17.1 Cable Protection REP 17.2 Belt Protection

Parts List on PL 15.1 Parts List on PL 15.1

Removal Removal
1. Undock the TWC from the RCT (REP 15.0). 1. Turn off the main power and disconnect the Power Cord.
2. Remove screw [A]. 2. Loosen nuts (x3) [A].
3. Remove the Cable Protection [B]. 3. Remove the Belt Protection [B].

Replacement Replacement
1 Reverse the removal procedure. 1 Reverse the removal procedure.

[B]
[A]

[A] [B]

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 REP 17.4 Antistatic Brush REP 17.3 Tray assembly

Parts List on PL 15.2 Parts List on PL 15.0

Removal (TWC from RCT) Removal

1. Remove the Belt Protection (REP 15.2). 1. Undock the TWC from the RCT (REP 15.0).
2. Remove nuts (x3) fastening the Belt Protection and Antistatic Brush. 2. Remove the Belt Protection (REP 15.2).
3. Remove the Antistatic Brush [A]. 3. Remove screws (x4) [A].
4. Remove the Tray assembly [B].
Replacement
1 Reverse the removal procedure. Replacement
1 Reverse the removal procedure.

[B]

[A]
[A]
[A]

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 REP 17.5 Support Rollers REP 17.6 Corrugator Roller

Parts List on PL 15.2 Parts List on PL 15.2

Removal Removal
1. Turn off the main power and disconnect the Power Cord. 1. Turn off the main power and disconnect the Power Cord.
2. Lift the Belt. 2. Loosen the screws (x2) [A]
3. Lift the Rollers [A] at the side with the groove [B]. 3. Lift the Belt and hold the Corrugator Roller [B].
4. Remove the Rollers (x6). 4. Remove the screws (x2) [A] and remove the Corrugator Roller [B].

Replacement Replacement
1 Reverse the removal procedure. Start from the Idler Roller end (upper end). 1 Reverse the removal procedure.
2 Orientation of the rollers is not critical as long as they are properly seated in the grooves
[B]. Adjustment
1 With the Idler Roller, Drive Shaft and Conveyor Belt in place, adjust the Corrugator
Roller so that the Belt is as close to the Plastic Waste Guides (see REP 15.7) as
possible without touching them.

[A]

[B]
[A]
[B]

[A]

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 REP 17.7 Plastic Waste Guides REP 17.8 Caster Bracket

Parts List on PL 15.2 Removal

1. Undock the TWC from the RCT (REP 15.0).
Removal 2. Remove the Cable Protection (REP 15.1).
1. Pull out the Waste Guides (x12) [A] 3. Remove the Belt Protection (REP 15.2).
4. Support the Conveyor and remove screws (x4) [A].
Replacement 5. Remove the Caster Bracket [B].
1 Reverse the removal procedure.
The Waste Guides should snap into position.
Replacement
1 Reverse the removal procedure.
Adjustment
1 Check adjustment of the Corrugator Roller (REP 15.6).

[A]
[A]

[B]

[A]

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 REP 17.9 Idler Roller REP 17.10 Drive Shaft

Parts List on PL 15.2 Parts List on PL 15.2

Removal Removal
1. Turn off the main power and disconnect the Power Cord. 1. Undock the TWC from the RCT (REP 15.0).
2. Pull the Idler Roller [A] out of the upper frame by tensioning the Conveyor Belt [B]. 2. Remove the Cable Protection (REP 15.1).

WARNING: 3. Remove the Idler Roller (REP 15.9).

Belt tension is strong. Beware not to pinch fingers or hands between the Idler roller 4. To facilitate removal of the Drive Shaft, remove the Belt Protection (REP 15.2).
and the Upper Frame while removing/installing the Idler Roller. 5. Remove the Drive Shaft [A].
3. Remove the Idler Roller.
Replacement
Replacement 1 Reverse the removal procedure.
1 Reverse the removal procedure. NOTE
NOTE Ensure that the clips [B] on the bearings are on the outside of the Lower Frame.
Ensure that the clips [C] on the bearings are on the outside of the Upper Frame.
[A]

[A] [B]

[C]
[C] [B] [B]

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 REP 17.11 Conveyor Belt REP 17.12 O-ring

Parts List on PL 15.0 Parts List on PL 15.1

Removal Removal
1. Remove the Drive Shaft (REP 15.10). 1. Undock the TWC from the RCT (REP 15.0).
2. Remove the Support Rollers (REP 15.5). 2. To facilitate replacing the O-ring, remove the Cable Protection (REP 15.1).
3. Remove the Corrugator Roller (REP 15.6). 3. Remove the O-ring [A].
4. Remove the Conveyor Belt [A].
Replacement
Replacement 1 Reverse the removal procedure.
1 Reverse the removal procedure. NOTE
NOTE Hook up the O-ring [A] on the Pulleys [B] and [C] as shown in order to to make the Conveyor
Install all parts before attempting to adjust the Corrugator Roller. Belt go in the desired transport direction.

[A]

[B]

[A]

[C]

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ADJ 1.4 Top Cover Height Rear Height Adjustment
Pupose
The purpose is to check that the magnet on the Top Cover Assembly is properly adjusted. 1. Check that the Top Cover rests against the rubber dampers when Top Cover is closed [A].
If not, proceed to step 2.
Check 2. Loosen screws (x2) [B].
1. Remove Front and Rear Cover (REP 1.1 Front and Rear Cover). When Top Cover rests against rubber dampers, tighten screws .

2. Close the Top Cover. 3. Check ADJ 1.6 Interlock Switch Assembly

3. Check front height adjustment and rear height adjustment. 4. Adjust the spring tension by turning the adjustment screws (x2) [C].

Turn screws (x2) [C] clockwise to increase tension (Top Cover will close slower)
Front Height Adjustment
1. Check that the Top Cover rests against the rubber dampers when Top Cover is closed [A]. Turn screws (x2) [C] counterclockwise to increase tension (Top Cover will close faster)
If not, proceed to step 2.
2. Loosen screws (x2) [B]. 5. Fasten the screws (x2) [B].
When Top Cover rests against rubber dampers, tighten screws.

[B]
[A]

[B] [A]
Continued on next page.
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 ADJ 1.4 Top Cover Height continued

[C]

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ADJ 1.6 Interlock Switch Assembly
[E]
Purpose
To check that the Interlock Switch Assembly is properly adjusted. [C]

WARNING: [A]
Overriding or cheating the interlock allows the BM500 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 overriding the
[D]
interlock system is carried out.

Adjustment [B]
1. Correctly adjusted (figure 1), the hooks [A] should stay locked under the rollers [B], [F]
so that the Top cover stays locked without play after the Top cover is closed.

The metal switch actuator [C] on the Top cover should not touch the Interlock switch [D]. [G]
The handle [E] should be flush with the Top cover surface.

2. Check visually that the metal switch actuator [C] clears from the Interlock switch [D].

figure 1
3. Close the Top cover and grab the Top cover by its sides and try to move it upwards and downwards.
Check for play or if the Top cover opens.

Incorrect position of handle [E] indicates either that the Interlock box is positioned to low (figure 2)
and/or that the rollers [B] are positioned to far towards the rear of the machine (figure 3).

If necessary, adjust as follows:

1. Check that the Top cover is correctly adjusted (ADJ 1.4 Top Cover Height)
2. Adjust the metal switch actuator by bending gently using a pair of pliers
3. Loosen screws [F] (two on each side) to Interlock box to adjust Interlock box up/down (x4).
Tighten screws after adjustment
4. Loosen screws [G] (two on each side) to to move the rollers [B] in/out ( x4 )
Tighten screws after adjustment.

figure 2 figure 3

Continued on next page.

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 ADJ 1.6 Interlock Switch Assembly continued
Pupose
The purpose is to adjust the Interlock Box Height.

Adjustment
1. Enter service mode (GP1).
2. Select BM.
3. Select Sensors.
4. Select BM-SW17 (soft).
5. Check that they change state when top cover is closed/opened (GP4).
6. To check BM-SW16 (hard), select Voltmeter.
Open top cover and check that voltage drops to 0V.
7. The vertical position of the interlock mechanism [A] should be parallel to the Top cover.
If not parallel, adjust by turning the screws (x4) [B].
[A]

[BM-SW1]

NOTE:
In wiring diagram, the switch as a unit is named BM-SW1. It actually consists of two switches.
One software (BM-SW17) and one hardware safety interlock switch BM-SW16.

[B]

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ADJ 4.1 Staple Quality [C]

Purpose
To ensure correct position of the staples on the booklet, proper staple forming.
Adjustment staple stop gate
1. Remove screws (x4) [A] for the stapler bracket.
2. Disconnect connector P49 (x1) [B].
3. Disconnect connectors P43, P44 and P47(x3) [C] for the stapler.
4. Remove stapler bracket assembly.
5. Remove nuts (x4) [D] and bracket [E].
6. Enter service mode, select [Motors].
[D]
7. Select [M22 Stop gate stapler].
8. Press [Cycle 1] until the stop gate is at its uppermost position. [D]

9. Insert a A4 or 8.5 x 11 “ paper.

10. Trail edge of the sheet should be touching each finger on the stop gate assembly [F] [E]
if not reform the stop gate fingers.
11. Select [M9 Staple fold position].
12. Press [Out] until the edge of the paper is just beneath the clinchers [G].
13. Press [Up] until the paper aligns with the clinchers [G].
[F]

14. The difference between distance X and distance Y should be less 0.2 mm.

X= The distance between the paper and the left clincher

Y= The distance between the paper and the right clincher

If difference not within range proceed to next step, otherwise proceed to step 19.

[A]
[A]

X Y

[B] [G] Continued on next page.

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 ADJ 4.1 Staple Quality, continued

15. Remove the inserted paper.

16. Loosen screws (x3) [H] until the stop gate can rotate around the middle screw.
17. Adjust position of stop gate to achieve specification in step 13.
18. Tighten screws (x3) [H].
19. Check staple position along the traveling position, see next two sections :

“Adjustment staple position cross process direction”

“Adjustment staple position in process direction”.

[H].

Continued on next page.

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ADJ 4.1 Staple Quality, continued

Adjustment staple position cross process direction

1. Enter Service mode.
2. Select [Motors] and then motor M20 (Left stapler).
3. Press [Cycle 2] few times until the staple head is reaching the clincher.
4. If needed press [Exit], select the other motor M21 (Right stapler) and
repeat step 1-3 for the second stapler motor.
5. Exit by selecting [Cycle both staplers].
Remove any staples that has dropped down in the clinchers.
6. If the stapler head(s) is not centered over the clincher, according to figure 1, x y x y
loosen screws [A] (x4). Fig. 1: Fig. 2:
7. Position stapler bracket [B] so the stapler head(s) are centered over the clincher, Staple head not centered. Staple head centered.
according to figure 2, and tighten the screws [A] (x4). Distance x and y are not equal. Distance x and y are equal.
8. Insert three sheets of paper and press [Cycle both staplers] to complete
the stapling cycle and return the stapler head(s] to home position.
9. Move sheets a couple of cm’s (an inch) up towards the infeed and press
[Cycle both staplers].
Verify function by repeating a couple of times. [B]

[A]

[A]

Continued on next page.

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 ADJ 4.1 Staple Quality, continued
Adjustment staple position/forming in process direction
1. Insert three sheets of paper and press [Cycle both stapler] to
complete the stapling cycle and return the stapler head(s) to home position.
2. Check the staple quality.
If staples looks like figure 3, no adjustment is needed and you can exit service mode.
If not, proceed with adjustment described below.
If staples looks like figure 4, adjustment is necessary. figure 3 figure 4
The legs of the the staple will point in the direction in which the staple head should be moved. correctly formed not centered lengthwise
Loosen the screws [C] (x4),
adjust with the screws [D] to move the staple bracket up towards the infeed.
Re-tighten the screws [C] (x4).

3. If staples look like figure 5, the staple head is far off center.
Adjust it by moving the staple head bracket in process direction.
4. Loosen screws [C] (x4).
5. Adjust the position of the staple head bracket by turning the screws [D] (x2).
6. Tighten screws [C] (x4)
7. Repeat procedure until staples are centered according to figure 3.
8. Insert three sheets of paper and press [Cycle both stapler]
to complete a stapling cycle in order to verify the adjustment. figure 5
extremely off center lenghtwise
9. Measure the distances x and y from lead edge to staple.
Distances must not differ more than 0.2mm.
If they do, repeat step 2. A certain variation in staple forming must be accepted.
10. Exit service mode.
x
[D]
[D]

y
[C]

[C]

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ADJ 4.2 Set Transport Calibration [D]
Purpose
To get a correct transportation from stapler area to fold area.
The feed rollers are therefore important and can be adjusted in two ways:
• by pivoting (to get equal feed force between them)
• by adjusting their position up and down (to determine the magnitude of the feed force).

The pivoting is adjusted mechanically and the magnitude of the feed force is adjusted from UI (by setting a
NVM value).
[C] [C]
1. Set the machine to A4 / 8.5x11”.
2. Enter [Service mode].
3. Select [Calibrate transport pressure].
4. Insert one strip of paper (1 sheet) between transport drive rollers [E].
5. Adjust the drive force by pressing [+] or [-] until the force is just enough to move the paper inwards.
Move the strip to the other rollers, and check that the drive force is equal.
If not, proceed to next step.
[B]
6. Disconnect connectors P43, P44 and P47 (x3) [A].
7. Disconnect connector P49 (x1) [B].
8. Remove screws (x4) [C].
9. Remove staple bracket assembly [D].
10. Adjust by loosen the screws / nuts (x2) [F] and move the pivoting roller bracket,
repeat until the feed force is equal between the gray rollers.
11. Tighten screws / nuts (x2) [F] and make sure the feed force is equal.
12. As a second adjustment the feed force magnitude shall be adjusted for these rollers.
Increase the feed force step by step (starting at no feed force at all) until just having a slight drag,
then increase/ the value by adding 6 digits (steps). The adjustment is now completed.
13. Re-assemble the staple bracket assembly [D].
14. Check that staple position along paper travelling direction is proper (ADJ 4.1 Staple Quality).
[F]
[A]

[E]

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ADJ 4.3 Set Transport Drive
Purpose
The purpose is to set corret drive belt tension.

Adjustment

1. See REP 4.3 BM-M5 Set Transport Motor &BM-Q40 Set Transport Motor Sensor.
2. To adjust the tension, loosen screws (x2) [A].
Adjust the tension by moving the motor [B] and tighten the screws [A].

Too much tension will affect the speed negatively.

[B] [A]

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ADJ 6.1 BM-M8 Stop Gate Folder Motor,
BM-Q7Stop Gate Folder sensor &
BM-Q48 Clinch Trigger Sensor Right

Adjustment

1. Check that the distance between the paper guide fold stop [A] and the lower paper path [B]
is within 6.5 ± 0.5 mm ( 2.6 ± 0.02”).
Loosen screws [C] to adjust.
2. Check that the distance between the paper guide fold stop [A] and the lower paper guide of the exit cover [D]
is within 1.5 ± 1 mm ( 0.6 ± 0.04”).
If not within range, adjust the lower paper guides of the exit cover by reforming.

m
± 1 m 4”)
. 0
1.5 ± 0
6
(0.

mm
± 0.5 .02”)
6.5 .6 ± 0
(2

[B]

[D] [C] [A]

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ADJ 6.4 Fold Transmission Chain ADJ 6.6 Upper Fold Roller
Purpose Purpose
The purpose is to adjust proper chain tension. The purpose is to adjust proper distance between the upper fold rollers.

Adjustment Adjustment
1. Loosen screws (x2) [A]. 1. Insert a 0,2 mm feeler gauge between the Upper folder rollers [A],
to ensure 0,2 ± 0,05 mm gap [A] between the Upper folder rollers. If not, go to step 2.
2. Adjust shaft [B], so the tension of the chain is almost tense.
2. Loosen nuts [B] on the front and rear side of the Booklet Maker (x2).
3. Lubricate chain with oil.
3. Adjust eccenter [C] on the front and rear side of the Booklet maker, according to step 1.
4. Tighten nuts [B] (x2).

[B] 5. After tightening nuts [B], re-check the distance between the Upper folder rollers [A].
6. Lubricate with Molybdenum grease, on the upper side [D] of the Cams to the upper
[A] folder rollers and the plastic wire guides.
[A]

[D] [D]

[B]

[C]

[B]

[A]

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ADJ 6.7 Lower Fold Roller ADJ 8.0 Stacker Module
Purpose Purpose
The purpose is to adjust proper spring tension for the fold rollers. The purpose is to adjust the angle of the exit module so that booklets will not jam at the exit.

Adjustment Adjustment
1. Adjust the spring tension with the nuts [A] (x4), so that the distances [B] are 25 mm. 1. Loosen nuts [A] and turn eccenters (x2) [B].
Note: There are two nuts on each sides.
2. Adjust the distance betwwen the plastic rollers [C] and the belts [D] to approximately 2mm.
2. Run a booklet with 30 sheets of 80 gsm (20lb Bond) and
stop the booklet when it has entered the upper fold rollers, by opening the top cover. 3. Run 2 sheet jobs and 35 / 50 sheet jobs.

The fold rollers [C] should then have been moved symmetric from each other
(with a max. tolerance of 3 mm difference).
If not, adjust the nuts [A] and repeat step 2.

[A]

[A]

[B]

[C]

[D]

[B] [C]

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ADJ 10.1 Top Cover
Pupose
The purpose is to adjust proper Top Cover Height.

Adjustment
1. Loosen screws [A] (x4).
2. Adjust Top cover so frame edge [B] is aligned with top of the hinge [C].
3. Tighten screws(x4) and nuts [A] (x4).

[C]

[B]

[A]

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ADJ 10.5 TR-SW10 Interlock Switch & TR-Q1 Interlock Sensor
Pupose
The purpose is to adjust the Interlock Height.

WARNING:
Overriding or cheating the interlock allows the BM500 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 overriding the interlock system is carried out.

Adjustment

Correctly adjusted (figure 1):

The hooks [A] should stay locked under the rollers [B],
so that the Top cover stays locked without play after the Top cover is closed.
The metal switch actuator [C] on the Top cover should not touch the Interlock switch [D].
The handle [E] should be flush with the Top cover surface.

figure 2 figure 3

Check visually that the metal switch actuator [C] clears from the Interlock switch [D].

Close the Top cover and grab the Top cover by its sides and try to move it upwards and downwards.
[E]
[C] Check for play or if the Top cover opens.

Incorrect position of handle [E] indicates:

[A]
The Interlock box is positioned too low (figure 2)
[D] and/or that the rollers [B] are positioned to far towards the rear of the machine (figure 3).

If necessary, adjust as follows:

[B]
[F] 1. Check that the Top cover is correctly adjusted (ADJ 10.1).
2. Adjust the metal switch actuator by bending gently using a pair of pliers.
[G] 3. Loosen screws [F] (two on each side) to Interlock box to adjust Interlock box up/down (x4).
Tighten screws after adjustment.
4. Loosen screws [B] (two on each side) to to move the rollers [G] in/out (x4)
Tighten screws after adjustment.

figure 1

Continued on next page.

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ADJ 10.5 TR-SW10 Interlock Switch & TR-Q1 Interlock Sensor, continued
Pupose
The purpose is to adjust the Interlock Actuator Height.

Adjustment
1. Enter service mode (GP1).
2. Select TR.
3. Select Sensors.
4. Select TR-Q1 and TR-SW10 (soft).
5. Check that they change state when top cover is closed/opened (GP4).
6. To check TR-SW9 (hard), select Voltmeter.
Open top cover and check that voltage drops to 0V.
7. The vertical position of the interlock mechanism [A] should be parallel to the Top cover.
If not parallel, adjust by turning the screws (x4) [B].

NOTE:
For Trimmer there are two actuators: the safety interlock switch TR-SW10
and the interlock sensor TR-Q1. [TR-Q1]
[A]

[TR-SW1]

NOTE:
In wiring diagram, the switch as a unit is named TR-SW1. It actually consists of two switches.
One software (TR-SW10) and one hardware safety interlock switch TR-SW9.

On the Trimmer there is also an interlock sensor TR-Q1.

[B]
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ADJ 10.13 TR-Q4 Transport Belt Sensor ADJ 10.21 TR-Q11 Length Adjustment Home Position Sensor
Pupose
The purpose is to adjust speed registration.
Pupose
The purpose is to check the TR-Q11 Sensor and its home position.
Adjustment
1. Enter service mode (GP1). Adjustment
2. Select TR and then Motors. 1. Enter service mode (GP1).
3. Start the belts by running M1 (GP 4). 2. Select TR and then Sensors.
Check speed (m/s). Compare to table in GP 5.
3. Select TR-Q11 and check that it changes state when blocked / unblocked (GP 4).
4. If no, or erratic speed, loosen screw [A] .
4. Check on the LCD that sensor TR-Q11 changes state when
5. Re-position sensor to obtain the correct speed registration. blocked / unblocked.
6. Tighten screw [A].

TR-Q11

[A]

ADJ 10.19 Lower Trim Knife

Adjustment

1. See REP 10.17 Lower Trim Knife.

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ADJ 11.3 Top Cover
Pupose
The purpose is to adjust proper Top Cover Height.

Adjustment
1. Loosen screws [A] (x4).
2. Adjust Top cover so frame edge [B] is aligned with top of the hinge [C].
3. Tighten screws(x4) and nuts [A] (x4).

[C]

[B]

[A]

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ADJ 11.9 SQF-M4 Roll Motor Assembly
Pupose
The purpose is to adjust the bearing of the roller motor assembly.
[E]
1. Adjust the position of the bearing by removing the nuts (x5) [A].
2. Remove the bracket [B].
3. Remove the screws (x2) [C] and the shafts with bearings [C].
4. Loosen the nut (x1) [D].
5. Check that the clearance [E] with a feeler gauge is within 0 to 0.2 mm,
and that the assembly moves smootly.

If clearance outside range, proceed to next step.

6. Adjust the position of the bearings by moving the screw with bearing
in the slot [F].

[C]

[F]

[A]

[D] [B]

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ADJ 11.18 SQF-SW1 Interlock Switch
Purpose
To check that the Interlock Switch Assembly is properly adjusted.

WARNING:
Overriding or cheating the interlock allows the BM500 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 overriding the interlock system is carried out.

Adjustment
Correctly adjusted (figure 1), the hooks [A] should stay locked under the rollers [B],
so that the Top cover stays locked without play after the Top cover is closed.

The metal switch actuator [C] on the Top cover should not touch the Interlock switch [D].

The handle [E] should be flush with the Top cover surface.

figure 2 figure 3

Check visually that the metal switch actuator [C] clears from the Interlock switch [D].

Close the Top cover and grab the Top cover by its sides and
[E]
try to move it upwards and downwards.
[C]
Check for play or if the Top cover opens.

[A] Incorrect position of handle [E] indicates:

[D] The Interlock box is positioned too low (figure 2)

and/or that the rollers [B] are positioned to far towards the rear of the machine (figure 3).

[B] If necessary, adjust as follows:

[F]
1. Check that the Top cover is correctly adjusted (REP 11.3).
2. Adjust the metal switch actuator by bending gently using a pair of pliers.
[G]
3. Loosen screws [F] (two on each side) to Interlock box to adjust Interlock box up/down (x4).
Tighten screws after adjustment.
4. Loosen screws [B] (two on each side) to to move the rollers [G] in/out (x4)
Tighten screws after adjustment.
figure 1

Continued on next page.

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ADJ 11.18 SQF-SW1 Interlock Switch, continued
Pupose
The purpose is to adjust the Interlock Box Height.

Adjustment
1. Enter service mode (GP1).
2. Select SQF.
3. Select Sensors.
4. Select SQF-SW2 (soft).
5. Check that they change state when top cover is closed/opened (GP4).
6. To check SQF-SW3 (hard), select Voltmeter.
Open top cover and check that voltage drops to 0V.
7. The vertical position of the interlock mechanism [A] should be parallel to the Top cover.
If not parallel, adjust by turning the screws (x4) [B].

[A]

[SQF-SW1]

NOTE:
In wiring diagram, the switch as a unit is named SQF-SW1. It actually consists of two switch-
es. One software (SQF-SW2) and one hardware safety interlock switch SQF-SW3.

[B]

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 ADJ 12.6 Interlock Switch Slide Door
Purpose
To ensure that the Interlock Switch Slide Door Actuator is correctly adjusted.

Adjustment
1. Ensure that the Slide Door Retaining magnet is adjusted so that
the outer surface of the Slide Door is level with the surrounding surface of
the Front Cover (Figure 1).
2. Check / Adjust the Interlock Switch Slide Door Actuator so that
there is 1±0.5mm play in the switch,
when the Slide Door is closed (Figure 1).

Figure 1 Adjusting Slide Door and Interlock Switch Slide Door Actuator

1. Loosen counter nuts and adjust magnet.

2. Loosen screws (x2) and adjust Actuator.

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ADJ 12.10 Drive Motor (M1) Primary Timing Belt
Purpose
To tension the Drive Motor (M1) Primary Timing Belt correctly.

Adjustment
1. Loosen screw [A].
2. Push the tensioner in the direction of the spring [B],
let relax and re-tighten the screw [A].
3. Turn the Drive Motor (CT-M1) Primary Timing Belt Pulley clockwise 2 revolutions [C].
4. Repeat step 1-2.

Intentionally blank
[C] [B] ]A[

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ADJ 12.11 Drive Motor (CT-M1) Secondary Timing Belt
Purpose
To tension the Drive Motor (CT-M1) Secondary Timing Belt correctly.

Adjustment
[C]
1. Loosen screw [A].
2. Push the tensioner in the direction of the spring [B],
let relax and tighten the screw [B].
3. Turn the Drive Motor (CT-M1) Secondary Timing Belt Pulley clockwise 2 revolutions [C].
4. Repeat step 1-2.

[A]

[B]

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 ADJ 12.12 Docking Bracket, Infeed
Purpose
The purpose of this procedure is to position the Infeed Docking Bracket so that incoming 4. Adjust by loosen screws [C] and adjust Infeed Docking Bracket on the CST to achieve toler-
sheets enter the Paper Path correctly in Rear to Front position. ance.
5. Repeat until alignment is correct.
Adjustment
1. Using 80 gsm/20 lb Bond sheets, send five sets of 2 sheets of SRA3/12x18” 80 gsm/20
lb Bond (2 sheets of SRA3/12x18” equals a booklet containing 8 pages of SRA4/12x9”)
to the Booklet Maker system.
2. Check for the correct feeding of the sheets in the CST and the Booklet Maker.
3. The sheets OB (outboard) edges [A] should enter the CST at the corresponding mark
on the label [B] ± 3mm (0.12”). If not, the infeed docking bracket on the CST must be
adjusted.

[A]

[B]

[C]
[D]

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ADJ 12.13 Docking Bracket, Exit
Purpose
To ensure that incoming sheets in the Booklet Maker enter the Paper Path correctly in Rear to Front position.

Adjustment
1. Using 80 gsm/20 lb Bond sheets, send five sets of 2 sheets of SRA3/12x18” 80 gsm/20
lb Bond (2 sheets of SRA3/12x18” equals a booklet containing 8 pages of SRA4/12x9”)
to the Booklet Maker system.
2. Check for the correct feeding of the sheets in the Booklet Maker.
3. The sheets [A] should enter the Booklet Maker centered between
the side guides ±3mm (0.12”) [B].
If not, the position of the Booklet Maker must be adjusted.
4. Undock the Booklet Maker from the CST.
5. On the CST Exit docking bracket, loosen screws [C].
6. Adjust Exit Docking Bracket [D] to achieve tolerance.
7. Tighten screws and dock Booklet Maker to the CST.
8. Repeat until alignment is correct.

[D] [C]

sheet (non-operator side) edge

[A]

[B]

sheet (operator side) edge

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ADJ 12.23 Lower Drive Shaft ADJ 12.28 Upper Drive Shaft
Purpose Purpose
To position the Flex Coupling so that the Drive Dog engages the Dovel Pin without any axial play. To position the Flex Coupling axially on the Upper Drive Shaft.

Adjustment Adjustment
1. Ensure that the Slide Drawer is properly latched and 1. Ensure that the Flex Coupling is positioned 12±0.5 mm from
that all other drive dogs are engaged with their pins. the bearing housing and tighten the screw on the non-operator side.
2. Ensure that the Dovel pin is at bottom of drive dog groove. (Figure 1) 2. Lock the Nip Roller and turn the Upper Drive Shaft a couple of revolutions
to relive any axial tension.
3. Compress the Flex Coupling slightly (0.3±0.3 mm) to eliminate any play.
3. Tighten the screw on the operator side.
NOTE:
Compression beyond 0.3±0.3 mm will reduce life of the Flex Coupling. NOTE:
Exessive axial compression or tension will reduce life of the Flex Coupling.

Figure 1 : Position of Flex Coupling

Figure 1: Position of Flex Coupling

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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ADJ 12.31 Rotator Disengage Solenoid (CT-SOL1) ADJ 12.34 Rotator Disengage Solenoid (CT-SOL2)
Purpose Purpose
The purpose of this procedure is to position the Rotator Disengage Solenoid correctly. The purpose of this procedure is to position the Rotator Disengage Solenoid correctly.

Adjustment Adjustment
1. Enter the service mode GP1 1. Enter the service mode GP1

2. Activate solenoid CT-SOL1 according to GP4 2. Activate solenoid CT-SOL2 according to GP4

3. Position Rotator Disengage Solenoid (CT-SOL1) and tighten the screws to 3. Position Rotator Disengage Solenoid (CT-SOL2) and tighten the screws to
achieve the play according to Figure 1 when activated. achieve the play according to Figure 1 when activated.

Figure 1 : Rotator Disengage Solenoid (CT-SOL1) position, activated Figure 1: Rotator Disengage Solenoid (SOL2) position, activated

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ADJ 12.43 Registration M4 Home Sensor (CT-Q3)
Purpose
To position the Registration relative the Bleed Trimmer correctly,
so that ”Image Offset 0.0 mm” produces trimmer waste from the operator/register side with correct width.

Adjustment
1. Set Units to metric.
2. Set Image Offset to 0.
3. Set Creasing to Off.
4. Select SRA3T or ”12 x 18”T format.
5. Perform / check Registration Secondary Alignment Rail (ADJ 12.49).
6. Perform / check Bleed Trimmer Home Sensor (Q6) (ADJ 13.4).
7. Process one sheet of SRA3 or ”12 x 18”.

Measure Operator side waste strip and calculate the difference in 0.1 mm units.
(Difference = Operator side measured width - Operator side theoretical width).

Adjust NVM value if the difference is bigger than ± 0.5 mm.

8. Enter the service mode (GP1).
9. Enter NVM Values (GP9).
10. Add the Difference calculated in step #7 to the current value in NVM Value Index #37,
CT-M4 Offset.
11. Leave Service Mode (GP1).
12. Process one sheet of SRA3 or ”12 x 18”.

Measure Operator side waste strip and calculate the difference in 0.1 mm units.

(Difference = Operator side measured width - Operator side theoretical width).

Adjust NVM value if the difference is bigger than ± 0.5 mm.

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ADJ 12.44 Registration Cross Rollers Drive Shaft

Purpose
To tension the Registration Cross Rollers Drive Shaft Timing Belt correctly.
[C]
Adjustment
1. Loosen screw [A].
2. Pivot the Registration Cross Rollers Drive Shaft Timing Belt tensioner in the direction of
the spring [B] in order to help distribute tension evenly over the entire belt. Let relax and
tighten the screw [A].
3. Turn the CT-M1 pulley counter clockwise 2 revolutions [C].
4. Repeat step 1 and 2 once more.

[B]

[A]
[B]

rear side of slide

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ADJ 12.47 Registration Cross Rollers Idler Roller
Purpose
The purpose of this procedure is to adjust the Registration Cross Rollers Idler Rollers position
and pressure correctly. Adjustment is carried out the same way on all Idler Rollers although
the number of turns of the screws differs.

Adjustment Turn these

1. Check that the plastic Registration Cross Rollers Idler Rollers [A] are centred over the screws coun-
rubber wheel [B]. If not, loosen nuts [C] and reposition the Registration Cross Rollers terclockwise
Idler Rollers and tighten nuts [C]. 2 turns when
adjusting
2. Check/adjust height of Idler Rollers.
For adjustment, use a 0,5mm (0.020”) feeler gauge or shim stock.
3. Loosen lock nut [D].
4. Insert the 0,5mm (0.020”) feeler gauge or shim stock [E].
5. Turn screw [F] clockwise until feeler gauge moves freely.
6. Turn screw [F] counterclockwise until the two white plastic wheels move, when the feeler
gauge is moved according to the arrow in figure [E].
7. Remove shim/feeler gauge. Check illustration to the right and adjust screw [F] accor-
dingly by turning screw counterclockwise.
8. Tighten lock nut [D].

[C]

[E] [B]

[A] Turn these screws counterclock- Turn these screws counterclock-

wise 2 turns when adjusting wise 3 turns when adjusting

[D]

[F]

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ADJ 12.48 Registration Primary Alignment Rail
Purpose
The purpose of this procedure is to install and adjust the Registration Primary Alignment Rail
correctly. [C]
[D]
Adjustment
1. The Registration Primary Alignment Rail [A] is fastened with plastic washers (x2) and
lock nuts.
2. Tighten the locknuts [B] and loosen ½ turn so that the rail is pivoting freely around the
center stud with a minimum of play.
3. Insert a folded piece of paper [C] to disengage CT-SOL4 mechanism [D].
viewed from under the slide
4. Feed manually a SRA3 or ”12 x 18” 120-160 gsm (32-43 lb Bond) sheet from Primary to
Secondary Alignment Rail. [A]
5. Loosen nut [E] and turn set screw [F] to adjust the angle of Registration Primary Align-
ment Rail [A] so that the sheets operator side edge hits 5±1mm (13/64±3/64) inside of
Registration Secondary Alignment Rail [G]. Tighten nut [E].
6. Check / perform ADJ 12.47 Registration Cross Rollers Idler Roller.

[F] [E]

[A] viewed from primary alignment rail side

[G] Measure 5±1mm

(13/64±3/64)

[B]

viewed from secondary alignment rail side

5 ± 1 mm
viewed from secondary alignment rail side to be able to point at nuts [B]
Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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ADJ 12.49 Registration Secondary Alignment Rail
Purpose [E]
The purpose of this procedure is to install and adjust the Registration Secondary Alignment
Rail correctly. [C]
Adjustment
1. Using a sheet of paper (dashed line) [A], align the Support Bracket [B] to the Secondary
Alignment Rail [C] and tighten nuts [D] (x2).
2. The Registration Secondary Alignment Rail [C] is fastened with plastic washers (x2)
and lock nuts (x2) [E].
3. Tighten the locknuts [E] and loosen ½ turn so that the rail is pivoting freely
around the center stud with a minimum of play.
4. Process a SRA3 or ”12 x 18” 120-160gsm (32-43 lb Bond) sheet and measure the
Registration (operator side) waste strip width:
The Lead Edge Width and the Trail Edge Width should be equal within ±0.5 mm.
Mark operator side lead edge of the stack in the bin so that it’s easily identified.
5. Turn the knurled set screw [F], and adjust the Registration Secondary Alignment Rails
angle so that the Registration (operator side) waste strip width is within ±0.5 mm.
6. Check / perform ADJ 12.47 Registration Cross Rollers Idler Roller.
viewed from primary alignment rail side to be able to point at nuts [D]
[A]
[F]

viewed from
secondary
[B] alignment rail
side

Process direction

Turn the adjustment

screw counter clock-
wise to remedy this
misalignment.

Plockmatic BM500 system 20 May 2019 3. Repairs and adjustments (REP and ADJ)
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ADJ 12.50 Registration Disengage Solenoid (CT-SOL5)
Purpose
To install and adjust the Registration Disengage Solenoid (CT-SOL5) correctly.

Adjustment
1. Check / perform ADJ 12.47 Registration Cross Rollers Idler Roller.
2. Position a 4 mm spacer in-between the Solenoid plungers E-clip and rubber washer to
define the length of the stroke (Figure 1).
3. Loosen screws (x2) and position solenoid linkage in contact with ball bearings (Figure1).
Tighten screws.
4. Position the Home Position Bracket so that there is 1±0.5 mm play (Figure 1).

Figure 1 : Adjusting Registration Disengage Solenoid (CT-SOL5)

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 ADJ 12.52 Creaser Assembly
Purpose
To install and adjust the Creaser Assembly correctly.
Adjustment [C]
1. Align the reference marks with the eccentric [A]. Tighten the star shaped knob [B].
2. Process one sheet and SRA3 or ”12 x 18” and check that the crease is perpendicular to
the registration (non operator side) edge.
3. Hold the Creaser Space Unit [C] and loosen screws [D] (x2). Position the Creaser As-
sembly so that the Crease is perpendicular within ±0.5 mm.

[D]

[A]

[B]

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ADJ 12.54 Creaser Trigger Sensor (CT-Q4) ADJ 12.55 Creaser Tools M6 Home Sensor (CT-Q5)
Phototransistor Purpose
To position the Crease correctly in the middle of the paper,
Purpose so that the Coarse Tool with 0.0mm correction on the UI, will produce a crease in the middle of the sheet.
To position the Creaser Trigger Sensor (CT-Q4) Phototransistor correctly.

Adjustment
Adjustment
1. Set Units to metric.
1. Enter the service mode (GP1).
2. Set the Coarse Tool correction to 0 and.
2. Check creaser trigger sensor CT-Q4 phototransistor according to section 5.
3. Select Creasing Coarse.
3. Align the Creaser Trigger Sensor (CT-Q4) Phototransistor and tighten screw [A]
to achieve a reading lower than 0.5V when not activated. 4. Select SRA3T or 12”x18”T format.
5. Ensure that the Face Trimmer is set to off.
6. Perform / check Registration Secondary Alignment Rail (ADJ 12.49)
[A] 7. Process one sheet of SRA3 or 12”x18”.

Measure the distance from the Lead Edge to the center of the Crease.

Calculate the difference in 0.1mm units.

Difference = Measured distance from Lead Edge - Theoretical distance from Lead Edge.

8. Adjust NVM value if the difference is bigger than ±0.5mm.

9. Enter the service mode (section 5).
10. Select the CST.
11. Enter NVM Values.
12. Add the Difference calculated in step #7 to the current value in NVM Value Index CT Creasing Offset.
13. Leave Service Mode (section 5).
14. Process one sheet of SRA3 or 12”x18”.
15. Measure the distance from the Lead Edge to the center of the Crease.
Calculate the difference in 0.1mm units.
Difference = Measured distance from Lead Edge - Theoretical distance from Lead Edge.

Adjust NVM value if the difference is bigger than ±0.5mm.

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ADJ 12.56 Creaser Timing Belt
5. Keep pulleys [C] and [D] in position and align the creaser tools so that one of creaser
Purpose tool [H] rulers mates with the fine tool groove (the narrower one) of creaser tool [ I ].
The purpose of this procedure is to tension the Creaser Timing Belt correctly. 6. Tighten screw [E].
Adjustment 7. Hold the creaser tool [ I ] steady and turn pulley [C] to position the lower side of the fine
1. Turn the eccentric [A] counter to tension the Timing belt [B] firmly so that there is no tool groove towards the ruler of the creaser tool [ I ] as illustrated [J].
slack. Hold eccentric [A]. 8. Tighten screw [F].
2. Check position of pulleys [C] and [D] so that the screws [E] and [F] are pointing to the
right for good access. If not, relax belt tension and repositon pulleys [C] and [D]. [H] [I]
3. Tighten screw [G].
4. Loosen the screws [E] and [F].

[A]

[G]
[B]

Groove is
leading
[F]

[E]

Process
[D] [C] direction

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 ADJ 12.57 Creaser Tools [B]
Purpose
To set up the Creaser Tools correctly.

Adjustment
1. Relieve Timing Belt Tension by loosening screw [A].
2. Align the tool ruler into the fine tool groove [B].
3. On front and rear side, loosen screws [B] (x6) and position the Creaser Tools Anvils
with the eccentrics [D] (x2) so that the tools barely touch each other.
4. Tighten screws [C].
5. Loosen the locknuts [E] and turn the set screw (x2) [F] so that the Limiting plunger gets
in contact with the ball bearing and back out 1/8 turn
6. Tighten the locknuts [E] (x2)
7. Perform Creaser Timing Belt adjustment (ADJ 12.56)
8. Check that tools not interfere on any side by turning them in process direction with CT-
M6 pulley.

[A]

[D] [C]

[F]

[E]

NOTE:
Viewed from front side of module.

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 ADJ 12.59 Creaser Baffle ADJ 13.4 Bleed Trimmer Home Sensor (CT-Q6)
Purpose Purpose
To install and adjust the Creaser Baffle correctly. To ensure that the Sheet Width set on the UI corresponds to
the the actual measured Sheet Width.
Adjustment
1. Loosen nuts [A] (x2) and adjust the creaser baffle using the screws [B] (x2) so that
there is 4±0.5mm / 0.1575±0.0197” between the baffle [C] and the paper path [D]. Adjustment
1. Set Units to metric.
[B]
2. Perform /check ADJ 12.49 Registration Secondary Alignment Rail.
3. Select SRA3T or ”12 x 18”T format.
4. Process one 120 gsm sheet. Measure the width of the sheet.

Calculate the difference in 0.1 mm units.

Difference = Measured Width - Theoretical Width.

5. Adjust NVM value if the difference is bigger than ±0.5 mm.
6. Enter the service mode (section 5).
7. Select the CST.
[A] [A] 8. Enter NVM Values.
9. Add the Difference calculated in step #4 to the current value in NVM Value Index CT-M7
Offset.
10. Leave Service Mode (section 5).
11. Process one 120 gsm sheet. Measure the width of the sheet.

Calculate the difference in 0.1 mm units.

Difference = Measured Width - Theoretical Width .

Adjust NVM value if the difference is bigger than ± 0.5 mm.

[C] [D]

4±0,5mm
0.1575±0.0197”

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ADJ 13.6 Bleed Trimmer Disengage Solenoid (CT-SOL3) ADJ 13.7 Bleed Trimmer Disengage Shaft
Purpose Purpose
To install and adjust the Bleed Trimmer Disengage Solenoid (CT-SOL3) correctly. To install and adjust the Bleed Trimmer Disengage Shaft correctly.

Adjustment
1. Check / perform ADJ 13.7 Bleed Trimmer Disengage Shaft. Adjustment
2. Position a 4mm (5/32”) spacer in-between the Solenoid plungers E-clip and 1. Check / adjust the positions of the ball bearings so that the Upper Knife moves
rubber washer to define the length of the stroke [A]. 0.6±0.3mm (0.0236±0.0118”) from the Lower Knife when actuated.
Ensure that Solenoid lever is in contact with the stop when screws (x4) are tightened [A].
3. Loosen screw and position solenoid linkage to achieve 2±0.5mm (5/64±1/64”)
when solenoid is closed [B]. Tighten screw.

[A]

[B]

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 ADJ 13.12 Transportation Disengage Solenoid (SOL4)
Purpose
To position the Transportation Disengage Solenoid (SOL4) correctly.

Adjustment
1. Enter the service mode, see section 5.
2. Activate transportation disengage solenoid CT-SOL4 according to section 5
3. Loosen screws (x2).
Position solenoid CT-SOL4 and tighten the screws to achieve the play
according to below figure (when activated).

Transportation Disengage Solenoid (CT-SOL4) position, activated.

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 ADJ 13.15 Slide Latch Mechanism
Purpose
To position the Slide Latch Mechanism correctly.

Adjustment
1. Position the stop collar [A] so that the set screw is perpendicular to the recess at the [C]
shaft end.
2. Attach the handle [B] and set the anvil (Allen screw) [C] so that the handle is vertical
±0.5° in closed position.
3. Set the anvil (Allen screw) [D] so that the handle [B] is horizontal ±0.5° in open position.
[B]

[A]

[B]

[D]

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ADJ 13.21 Slide R/H Lower Baffle ADJ 13.36 12V Power Supply Unit
Purpose Purpose
The purpose of this procedure is to position the Spring Shafts of Slide R/H Lower Baffle cor- To set the output voltage of the PSU correctly.
recltly.
Adjustment
Adjustment
1. Measure Voltage between V - (Ground) and V+ (12 VDC).
1. Position the opertor side spring shaft, attach the spring [A] and tighten the screw [B].
2. Position the non operator side spring shaft, attach the spring [C] and tighten the screw 2. Set the voltage to 12±0.1 VDC by adjusting the potentiometer at +V ADJ.
[D].

ADJ 13.37 24V Power Supply Unit (1)

Purpose
To set the output voltage of the PSU correctly.
Adjustment
1. Measure Voltage between V - (Ground) and V+ (24 VDC).
2. Set the voltage to 24±0.1 VDC by adjusting the potentiometer at +V ADJ.

[B] [A]

ADJ 13.38 24V (48V) Power Supply Unit (2)

Purpose
To set the output voltage of the PSU correctly.
Adjustment
1. Measure Voltage between V - (Ground) and V+ (24 VDC).
2. Set the voltage to 24±0.1 VDC by adjusting the potentiometer at +V ADJ.

[C] [D]

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4 TROUBLESHOOTING (RAP) CT-121 Stepper Motor Driver PCB “E” Voltage too low................................................ 4-26
CT-123 Stepper Motor Driver PCB “J” Voltage too low................................................ 4-26
Contents
CT-124 Stepper Motor Driver PCB “D” Voltage too low................................................ 4-27
Common Procedures
CT-126 Stepper Motor Driver (M6) PCB “H” Voltage too low....................................... 4-27
Entry RAP............................................................................................................................ 4-9
CT-127 Stepper Motor Driver (M7) PCB “C” Voltage too low....................................... 4-28
Blown Fuse Conditions.................................................................................................... 4-11
CT-130 Solenoid Driver PCB “B” Voltage too low......................................................... 4-28

CST CT-140 Interlock circuit Mismatch CT-Q8, CT-Q9 state with voltage........................... 4-29

CST Entry RAP.................................................................................................................. 4-12 CT-141 Bad EEPROM....................................................................................................... 4-31

CT-001 Registration M4 Home Sensor CT-Q3 CT-150 CAN communication with Booklet Maker interrupted...................................... 4-32
Not activated in time after start of M4................................................................ 4-13 CT-170 Temp Sensor CT-Q13 Failed RAP....................................................................... 4-33
CT-002 Registration M4 Home Sensor CT-Q3 CT-171 Temp Sensor CT-Q13 overheated RAP.............................................................. 4-34
Not deactivated in time after start of M4........................................................... 4-13
CT-201 Entrance Sensor CT-Q1 Not activated in time.................................................. 4-35
CT-003 Bleed Trimmer M7 Home Sensor CT-Q6
Not activated in time after start of M7................................................................ 4-14 CT-202 Entrance Sensor CT-Q1 Activated too long...................................................... 4-35

CT-004 Bleed Trimmer M7 Home Sensor CT-Q6 CT-203 Rotator Sensor CT-Q2 not activated in time..................................................... 4-36
Not deactivated in time after start of M7........................................................... 4-14
CT-204 Rotator Sensor CT-Q2 activated too long......................................................... 4-37
CT-005 Creaser Tools M6 Home Sensor CT-Q5
CT-205 Registration Solenoid SOL5 Trigger Sensor
Not activated in time after start of M6................................................................ 4-15
CT-Q10 not activated in time.............................................................................. 4-38
CT-101 Registration M4 Home Sensor (Q3)
CT-206 Registration Solenoid SOL5 Trigger Sensor
Not activated in time after start of M4................................................................ 4-15
CT-Q10 activated too long.................................................................................. 4-39
CT-102 Registration M4 Home Sensor (Q3)
CT-207 Creaser Trigger Sensor CT-Q4 not activated in time....................................... 4-40
Not deactivated in time after start of M4........................................................... 4-16
CT-208 Creaser Trigger Sensor Q4 Activated too long................................................. 4-41
CT-103 Bleed Trimmer M7 Home Sensor (Q6)
Not activated in time after start of M7................................................................ 4-16 CT-209 Exit Sensor CT-Q7 Not activated in time........................................................... 4-42
CT-104 Bleed Trimmer M7 Home Sensor (Q6) CT-210 Exit Sensor CT-Q7 Activated too long............................................................... 4-42
Not deactivated in time after start of M7........................................................... 4-17
CT-211 Creaser Tools M6 Home Sensor CT-Q5 Not activated in time......................... 4-43
CT-105 Creaser Tools M6 Home Sensor (Q5)
Not activated in time after start of M6................................................................ 4-17 CT-212 Waste Transport Sensor CT-Q14 Activated too long........................................ 4-43

CT-109 Entrance Sensor CT-Q1 blocked without a preceding Sheet Exit Signal....... 4-18 CT-503 Waste Bin Full Sensor CT-Q11 activated........................................................... 4-44

CT-111 Stepper Motor Driver CT-M1 PCB “E” No CAN communication...................... 4-19 Drive Motor CT-M1 RAP................................................................................................... 4-45

CT-113 Stepper Motor Driver CT-M3 PCB “J” No CAN communication...................... 4-20 Rotator Motor CT-M3 RAP............................................................................................... 4-46

CT-114 Stepper Motor Driver CT-M4 PCB “D” no CAN communication...................... 4-21 Registration Width Adjustment Motor CT-M4 RAP........................................................ 4-47

CT-116 Stepper Motor Driver CT-M6 PCB “H” No CAN communication..................... 4-22 Creaser Motor CT-M6 RAP............................................................................................... 4-48

CT-117 Stepper Motor Driver CT-M7 PCB “C” No CAN communication..................... 4-23 Bleed Trimmer Width Adjustment Motor CT-M7 RAP.................................................... 4-49

CT-119 PCB Printer Interface PCB “F” No Internal communication............................ 4-24 Rotator Disengage Solenoid CT-SOL1 RAP................................................................... 4-50

CT-120 Solenoid Driver PCB “B” No CAN communication.......................................... 4-25 Rotator Disengage Solenoid CT-SOL2 RAP................................................................... 4-51
Bleed Trimmer Disengage Solenoid CT-SOL3 RAP...................................................... 4-52

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-1
Transportation Disengage Solenoid CT-SOL4 RAP...................................................... 4-53 Counter RAP, CT............................................................................................................... 4-89
Registration Disengage Solenoid CT-SOL5 RAP.......................................................... 4-54 Bleed Trimmer Knives noisy RAP................................................................................... 4-90
Entrance Sensor CT-Q1 RAP........................................................................................... 4-55 Drive Motor (M1) Transmission RAP.............................................................................. 4-91
Rotator Sensor CT-Q2 RAP............................................................................................. 4-56 Rotator Motor (M3) Transmission RAP........................................................................... 4-93
Registration M4 Home Sensor CT-Q3 RAP.................................................................... 4-57 Registration Width Adjustment Motor (M4) Transmission RAP................................... 4-94
Creaser M6 Trigger Sensor CT-Q4 RAP.......................................................................... 4-58 Creaser Motor (M6) Transmission RAP.......................................................................... 4-95
Creaser Tools M6 Home Sensor CT-Q5 RAP................................................................. 4-59 Bleed Trimmer Width Adjustment Motor (M7) Transmission RAP............................... 4-96
Bleed Trimmer M7 Home Sensor CT-Q6 RAP................................................................ 4-60
Booklet Maker (BM)
Exit Sensor CT-Q7 RAP.................................................................................................... 4-61
BM-001 Infeed Motor BM-M1 No Displacement Pulses................................................. 4-97
“Close Cover(s)”. Slide Door Interlock Switch CT-Q8/SW2 and/or Top Cover
Interlock Switch CT-Q9/SW3 Not activated....................................................... 4-62 BM-002 Infeed Motor M1 Short Circuit........................................................................... 4-98

Slide Door Interlock Switch CT-Q8 RAP......................................................................... 4-63 BM-003 Infeed Motor BM-M1 Open Circuit..................................................................... 4-98

Top Cover Interlock Switch (Q9/SW3) RAP.................................................................... 4-64 BM-004 Back Jogger Motor sensor BM-Q45 No displacement pulses ...................... 4-99

Registration Solenoid SOL5 Trigger Sensor CT-Q10 RAP........................................... 4-65 BM-005 Back Jogger Motor (M2) Cycle Timeout......................................................... 4-100

Waste Transport Sensor CT-Q14 RAP............................................................................ 4-66 BM-006 Back Jogger Motor BM-M2 Short circuit........................................................ 4-101

CPU / Controller PCB “A” RAP....................................................................................... 4-67 BM-007 Back Jogger Motor BM-M2 Open Circuit........................................................ 4-101

Solenoid Driver PCB “B” RAP......................................................................................... 4-68 BM-008 Side Jogger Motor BM-M3 no displacement pulses...................................... 4-102

Stepper Motor (M7) Driver PCB “C” RAP....................................................................... 4-69 BM-009 Side Jogger Motor BM-M3 cycle timeout....................................................... 4-103

Stepper Motor Driver (M4) PCB “D” RAP....................................................................... 4-70 BM-010 Side Jogger Motor BM-M3 Short Circuit......................................................... 4-104

Stepper Motor Driver (M1) PCB “E” RAP....................................................................... 4-71 BM-011 Side Jogger Motor BM-M3 Open Circuit......................................................... 4-105

I/O Extension PCB “G” RAP............................................................................................ 4-72 BM-012 Set Transport Motor BM-M5 Motor Sensor BM-Q40 No displacement
pulses................................................................................................................. 4-106
Stepper Motor Driver (M6) PCB “H” RAP....................................................................... 4-73
BM-013 Set Transport Motor BM-M5 Short Circuit...................................................... 4-107
Stepper Motor Driver (M3) PCB “J” RAP........................................................................ 4-74
BM-014 Set Transport Motor M5 Open Circuit............................................................. 4-108
SCP (Short Circuit Protection) PCB “K” RAP................................................................ 4-75
BM-015 Fold Roller Motor BM-M6 No Displacement Pulses...................................... 4-109
SCP (Short Circuit Protection) PCB “L” RAP................................................................ 4-76
BM-016 Fold Roller Motor BM-M6 Short Circuit.......................................................... 4-110
12V Power Supply Unit RAP............................................................................................ 4-77
BM-017 Fold Roller Motor BM-M6 Open Circuit........................................................... 4-110
24V Power Supply Unit (1) RAP...................................................................................... 4-78
BM-018 Fold Knife Motor BM-M7 Cycle Timeout......................................................... 4-111
24V (48V) Power Supply Unit (2) RAP............................................................................. 4-80
BM-019 Fold Knife Motor BM-M7 Short Circuit............................................................ 4-112
Interlock Relay Circuit (REL1) RAP................................................................................ 4-81
BM-020 Fold Knife Motor BM-M7 Open Circuit............................................................ 4-113
F1 Blown Fuse RAP.......................................................................................................... 4-83
BM-021 Stop Gate Folder Motor BM-M8 Sensor BM-Q43 No displacement pulses.4-114
Antistatic Bars Waste Transport (optional) RAP........................................................... 4-85
BM-022 Stop Gate Folder Motor BM-M8 Sensor BM-Q44 Cycle Timeout.................. 4-115
Antistatic Bars Exit (optional) RAP................................................................................. 4-87
BM-023 Stop Gate Folder Motor BM-M8 Short Circuit................................................ 4-116
Cooling Fan (FAN1) RAP.................................................................................................. 4-88
BM-024 Stop Gate Folder Motor BM-M8 Open Circuit................................................ 4-116

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-2
BM-025 Stop Gate Folder Motor BM-M8 Max voltage exceeded................................ 4-117 BM-152 30VDC High at Lower MD6DC PCB “C” ......................................................... 4-149
BM-026 Staple/Fold Positioning Motor(M9) Sensor BM-Q10 No displacement BM-153 30VDC low at Middle MD6DC PCB “B”........................................................... 4-150
pulses................................................................................................................. 4-118
BM-154 30VDC low at Upper MD6DC PCB “H” ........................................................... 4-152
BM-027 Staple/Fold Pos. Motor (M9) Sensor BM-Q11 Cycle Timeout....................... 4-119
BM-156 Relay off Timeout RAP (BM) ........................................................................... 4-154
BM-028 Staple/Fold Positioning Motor BM-M9 Short Circuit..................................... 4-120
BM-157 Trimmer Communication Lost......................................................................... 4-155
BM-029 Staple/Fold Positioning Motor BM-M9 Open Circuit..................................... 4-120
BM-158 Square Folder Communication Lost............................................................... 4-157
BM-042 Primary Infeed Motor (M19) Sensor (Q43) No displacement pulses............ 4-121
BM-159 PCB MD6DC “B” Not Connected..................................................................... 4-158
BM-044 Primary Infeed Motor (M19) Open Circuit....................................................... 4-122
BM-160 PCB MD6DC “C” Not Connected .................................................................... 4-159
BM-045 Stapler Home Position Left Sensor BM-Q50 Cycle Timeout........................ 4-123
BM-161 PCB MD6DC “H” Not Connected..................................................................... 4-160
BM-046 Clinch Trig Sensor Left, BM-Q51, Cycle timeout........................................... 4-124
PCB MD3DC “O” Not Connected (Option)................................................................... 4-161
BM-047 Stapler Left Motor BM-M20 Short Circuit....................................................... 4-125
BM-164 Addon PCB “F”Not connected........................................................................ 4-162
BM-048 Stapler Left Motor BM-M20 Open Circuit........................................................ 4-126
BM-165 Cover sensor SW1 (Interlock) faulty............................................................... 4-162
BM-049 Stapler Home Pos Right Sensor BM-Q47 Cycle Timeout............................. 4-127
BM-168 Stacker Motor ST-M1 Short Circuit................................................................. 4-163
BM-050 Clinch Trig Sensor Right BM-Q48 Cycle timeout........................................... 4-128
BM-169 Stacker Motor ST-M1 Open Circuit................................................................. 4-163
BM-051 Stapler Right Motor BM-M21 Short Circuit..................................................... 4-129
BM-170 Incompatible CST Software............................................................................. 4-164
BM-052 Stapler Right Motor BM-M21 Open Circuit..................................................... 4-130
BM-201 Sensor BM-Q1 Not activated in time............................................................... 4-165
BM-053 Stop Gate BM-M22 Motor Sensor BM-Q41
no displacement pulses.................................................................................... 4-131 BM-202 Sensor BM-Q1 Activated too long................................................................... 4-165

BM-054 Home Pos. Stop Gate Stapler BM-M22 Sensor Timeout............................... 4-132 BM-203 Sensor BM-Q4 Not activated in time............................................................... 4-166

BM-055 Stop Gate Stapler Motor BM-M22 Short Circuit............................................. 4-133 BM-204 Sensor BM-Q4 Activated too long................................................................... 4-166

BM-056 Stop Gate Stapler Motor BM-M22 Open Circuit............................................. 4-133 BM-205 Sensor BM-Q7 Not activated in time............................................................... 4-167

BM-057 Thick Set Motor BM-M23 Sensor BM-Q37 no displacement pulses............ 4-134 BM-206 Sensor BM-Q7 Activated too long................................................................... 4-167

BM-058 Thick Set Motor BM-M23 home sensor BM-Q36 Cycle Timeout.................. 4-135 BM-207 Sensor BM-Q8 not activated in time............................................................... 4-168

BM-059 Thick Set Motor BM-M23 Short Circuit........................................................... 4-136 BM-208 Sensor BM-Q8 Activated too long................................................................... 4-168

BM-060 Thick Set Motor BM-M23 Open Circuit........................................................... 4-136 BM-211 Infeed unit sensor BM-Q53 Not activated in time.......................................... 4-169

BM-062 Paper infeed sensor BM-Q1 Faulty................................................................. 4-137 BM-212 Infeed unit sensor BM-Q53 Activated too long.............................................. 4-169

BM-063 Start sensor Saddle stapling BM-Q4 Faulty................................................... 4-138 BM-401 Staple Miss Right Stapler (BM-Q20) ............................................................... 4-170

BM-064 Stop Gate Folder sensor BM-Q7 Faulty.......................................................... 4-139 BM-402 Staple Miss Left Stapler (BM-Q19) ................................................................. 4-172

BM-065 Exit Sensor BM-Q8 Faulty................................................................................ 4-140 BM-403 Staple Miss Both Staplers (BM-Q19, BM-Q20) .............................................. 4-173

BM-069 Staple Detection Clinch Left Sensor BM-Q19 Short Circuit......................... 4-141 BM-404 Set too thick...................................................................................................... 4-173

BM-070 Staple Detection Clinch Right Sensor BM-Q20 Short Circuit....................... 4-142 BM-405 Remove Purged Set ......................................................................................... 4-173

BM-071 Docking Sensor BM-Q35 faulty....................................................................... 4-143 BM-407 Too many sheets............................................................................................... 4-173

BM-150 30VDC low at Lower MD6DC PCB “C” ........................................................... 4-144 BM-409 Unfinished set in compiler .............................................................................. 4-173

BM-151 30VDC very low at Lower MD6DC PCB “C” .................................................. 4-145 BM-501 Staples, Low Stapler Right BM-Q46................................................................ 4-174

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-3
BM-502 Staples, Low Stapler Left, BM-Q49................................................................. 4-175 SQF-002 Transport Belt Motor SQF-M1 Open circuit.................................................. 4-209
BM-503 Staples, Low both stapler (BM-Q46, BM-Q49)................................................ 4-176 SQF-003 Stop Gate Motor SQF-M2 Pulse timeout....................................................... 4-210
BM-504 Stacker Full/Empty Stacker............................................................................. 4-176 SQF-004 Stop Gate Motor SQF-M2 Cycle timeout....................................................... 4-211
Booklet Maker Communication Lost (UI: “No Com”).................................................. 4-177 SQF-005 Stop Gate Motor SQF-M2 Short Circuit......................................................... 4-212
Blank UI (no backlight)................................................................................................... 4-179 SQF-006 Stop Gate Motor SQF-M2 Open Circuit......................................................... 4-212
Compiler RAP................................................................................................................. 4-182 SQF-007 Clamp Motor SQF-M3 Short circuit............................................................... 4-213
Stapler RAP..................................................................................................................... 4-182 SQF-008 Clamp Motor SQF-M3 Open circuit............................................................... 4-213
Pre Fold Transport RAP................................................................................................. 4-183 SQF-009 Clamp Motor SQF-M3 Pulse Timeout............................................................ 4-214
Length adjustment Unit RAP......................................................................................... 4-183 SQF-010 Roll Motor SQF-M4 Short circuit................................................................... 4-215
Folding Unit RAP............................................................................................................ 4-184 SQF-011 Roll Motor SQF-M4 Open circuit.................................................................... 4-215
MD6DC PCB RAP............................................................................................................ 4-185 SQF-012 Roll Motor SQF-M4 cycle timeout.................................................................. 4-216
Counter RAP, Booklet Maker......................................................................................... 4-186 SQF-013 Roll Motor SQF-M4 Pulse timeout................................................................. 4-218
RS232 Program Loading Chassis 9-P, D-sub RAP...................................................... 4-186 SQF-014 Infeed Sensor SQF-Q5 Faulty........................................................................ 4-219
F1 Blown Up RAP........................................................................................................... 4-187 SQF-015 Clamp Sensor SQF-Q6 Faulty........................................................................ 4-220
No 30VDC from SCP PCB “D” RAP.............................................................................. 4-189 SQF-016 Exit Sensor SQF-Q7 Faulty............................................................................ 4-221
Mains Voltage connectivity check RAP........................................................................ 4-191 SQF-017 SOL1 / 3 Open circuit..................................................................................... 4-222
BM-SW1 Interlock circuit (SW16) RAP......................................................................... 4-193 SQF-018 SOL2 / 4 Open circuit..................................................................................... 4-222
SW1 Software signal SW17 RAP................................................................................... 4-195 SQF-150 30V Input low................................................................................................... 4-223
Interlock Relay REL-1 RAP............................................................................................ 4-197 SQF-151 30V Input high................................................................................................. 4-225
No 12VDC, machine not starting RAP.......................................................................... 4-198 SQF-201 Infeed Sensor SQF-Q5 Not activated in time............................................... 4-226
User Interface (Display) not working RAP................................................................... 4-202 SQF-202 Infeed Sensor SQF-Q5 Activated to long...................................................... 4-226
Booklet Maker, Top Cover LED Lamp Faulty............................................................... 4-203 SQF-203 Clamp Sensor SQF-Q6 Not activated in time............................................... 4-227
Power Save Mode RAP ................................................................................................. 4-205 SQF-204 Clamp Sensor (SQF-Q6) Activated too long................................................. 4-227
Close Cover/s RAP......................................................................................................... 4-205 SQF-205 Exit Sensor SQF-Q7 not activated in time.................................................... 4-228
SQF-206 Exit Sensor SQF-Q7 activated too long........................................................ 4-228
Stacker (ST)
SQF-501 Stacker Full..................................................................................................... 4-229
Belt Stacker RAP............................................................................................................ 4-206
Clamp RAP...................................................................................................................... 4-229
ST-001 Stacker Motor ST-M1 Short circuit................................................................... 4-206
Square Folder Stop Gate RAP....................................................................................... 4-229
ST-001 Stacker Motor ST-M1 Short circuit................................................................... 4-207
Square Folder Transport RAP....................................................................................... 4-229
ST-002 Stacker Motor ST-M1 Open Circuit................................................................... 4-207
SQF-SW1 Interlock circuit SQF-SW3 RAP .................................................................. 4-230
ST-002 Stacker Motor ST-M1 Open Circuit................................................................... 4-208
SQF-SW1 Software signal SQF-SW2 RAP.................................................................... 4-232

Square Folder (SQF) RS232 Program Loading Chassis 9-P D-sub RAP....................................................... 4-235

SQF-001 Transport Belt Motor SQF-M1 Short circuit.................................................. 4-209 Square Folder does not square form a 4 sheet booklet RAP..................................... 4-235

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-4
Square Folder, LED Lamp PCB “L”Faulty.................................................................... 4-236 TR-201 Infeed Sensor TR-Q13 not activated in time................................................... 4-267
No 12VDC RAP................................................................................................................ 4-237 TR-202 Infeed Sensor TR-Q13 activated too long....................................................... 4-267
Counter RAP, SQF.......................................................................................................... 4-239 TR-203 Paper Path Sensor TR-Q14 not activated in time........................................... 4-268
TR-204 Paper Path Sensor TR-Q14 activated too long............................................... 4-268
Trimmer (TR)
TR-205 Exit Sensor TR-Q6 not activated in time......................................................... 4-269
TR-001 Transport knife Motor TR-M1 pulse timeout TR-Q4....................................... 4-240
TR-206 Exit Sensor TR-Q6 activated too long............................................................. 4-269
TR-002 Transport Knife Motor TR-M1 timeout TR-Q5................................................. 4-241
TR-501 Waste Bin Full.................................................................................................... 4-270
TR-003 Transport Knife Motor TR-M1 short circuit..................................................... 4-243
TR-502 Stacker Full........................................................................................................ 4-270
TR-004 Transport Knife Motor TR-M1 open circuit...................................................... 4-243
TR-503 Close Trimmer Infeed Belts.............................................................................. 4-270
TR-005 Trim Knife Motor TR-M2 short circuit.............................................................. 4-244
TR-504 Close Trimmer Exit Belts.................................................................................. 4-270
TR-006 Trim Knife Motor TR-M2 open circuit............................................................... 4-244
TR-505 Close Trimmer Infeed and Exit Belts............................................................... 4-270
TR-007 Trim Knife Motor TR-M2 Cycle timeout Q5...................................................... 4-245
Trim Knife RAP............................................................................................................... 4-271
TR-008 Stop Gate Motor TR-M3 cycle timeout TR-Q7................................................. 4-247
Trimmer Blower RAP...................................................................................................... 4-271
TR-009 Stop Gate Motor TR-M3 short circuit............................................................... 4-248
Trimmer Transport RAP................................................................................................. 4-271
TR-010 Stop Gate Motor TR-M3 open circuit............................................................... 4-248
No 12VDC RAP................................................................................................................ 4-272
TR-011 Length Adjustment Motor TR-M4 pulse timeout ............................................ 4-249
TR-SW1 Interlock circuit (TR-SW9,TR-SW10) RAP .................................................... 4-275
TR-012 Length Adjustment Motor TR-M4 cycle timeout ............................................ 4-250
Trimmer, LED Lamp Faulty RAP.................................................................................... 4-276
TR-013 Length Adjustment Motor TR-M4 short circuit .............................................. 4-251
TR-014 Length Adjustment Motor TR-M4 open circuit............................................... 4-251 AF602 FAULT CODE DESCRIPTIONS
TR-015 Blower Motors Motor TR-M5/TR-M6 open circuit........................................... 4-252 Entry RAP........................................................................................................................ 4-277
TR-016 Lift Motor TR-M8 cycle timeout ....................................................................... 4-253 Fault Codes..................................................................................................................... 4-277
TR-017 Lift Motor TR-M8 short circuit.......................................................................... 4-254 Fault Codes Only Presented at Performed Diagnostics
............................................................................................................................. 4-278
TR-018 Lift Motor TR-M8 open circuit........................................................................... 4-254
TR-019 Infeed Sensor TR-Q13 faulty............................................................................ 4-255 AF602 RAPs
TR-020 Control Sensor Infeed TR-Q2 faulty ................................................................ 4-256 RAP 100/200 Misfeed Bin A/B........................................................................................ 4-280
TR-021 Control Sensor Exit TR-Q3 faulty..................................................................... 4-257 RAP 101/201 Jam, Too Long, Bin A/B.......................................................................... 4-281
TR-022 Exit Sensor TR-Q6 faulty.................................................................................. 4-258 RAP 102/202 Too Long, Bin A/B.................................................................................... 4-281
TR-023 Trim Bin Full Sensor TR-Q8 faulty................................................................... 4-258 RAP 103/203 Too Short, Bin A/B................................................................................... 4-281
TR-024 Paper Path Sensor TR-Q14 Faulty................................................................... 4-259 RAP 104/204 Too Thick, Bin A/B................................................................................... 4-281
TR-025 Lift Motor Sensor TR-Q15 Faulty..................................................................... 4-259 RAP 105/205 DSD Functionality Uncertain, Bin A/B................................................... 4-281
TR-150 30V Input low..................................................................................................... 4-260 RAP 106/206 Too Thick US DSD, Bin A/B..................................................................... 4-281
TR-151 30V Input high.................................................................................................... 4-263 Perform RAP 002 Ultrasonic DSD (Double Sheet Detection)..................................... 4-281
TR-152 TR-SW1 Software signal TR-SW10 RAP.......................................................... 4-264 RAP 107/207 Bin Empty, Bin A/B................................................................................... 4-283
TR-153 Interlock Sensor Faulty TR-Q1......................................................................... 4-266

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-5
RAP 108/208 Too Thin, Bin A/B..................................................................................... 4-284 RAP 028 CPU PCB ”L”................................................................................................... 4-319
RAP 300 Exit Miss.......................................................................................................... 4-285 RAP 029 Door Switch Interlock Circuit......................................................................... 4-321
RAP 301 Exit Error.......................................................................................................... 4-286 RAP 030 Door Switch Software Signal......................................................................... 4-322
RAP 302 No Feed Sequence.......................................................................................... 4-286 RAP 031 F1 Blown Fuse................................................................................................. 4-323
RAP 401 No Answer on PAC (Propose, Accept, Confirm).......................................... 4-287 RAP 032 Interlock Mismatch......................................................................................... 4-325
RAP 001 Optical DSD Sensor........................................................................................ 4-288 RAP 033 Motor Relay..................................................................................................... 4-327
RAP 002 Ultrasonic DSD (Double Sheet Detection).................................................... 4-289 RAP 034 PSU (12V)......................................................................................................... 4-329
RAP 003 Ultrasonic DS (Distance Sensor) Q301 / Q302............................................. 4-290 Go to RAP 031 F1 Blown Fuse...................................................................................... 4-329
RAP 004 No ICAN Communication Entry..................................................................... 4-291 RAP 035 REL301............................................................................................................. 4-331
RAP 005 No XCAN Communication.............................................................................. 4-293 RAP 036 REL302............................................................................................................. 4-332
RAP 006 ICAN Circuit..................................................................................................... 4-295 RAP 037 Stepper Motor Driver M101 PCB ”K”............................................................ 4-333
RAP 007 EEPROM.......................................................................................................... 4-296 RAP 038 Stepper Motor Driver M201 PCB ”O”............................................................ 4-335
RAP 008 M101/M201 Lower Home Position Sensor Not Activated In Time/ RAP 039 Stepper Motor Driver M301 PCB ”G”............................................................ 4-336
Activated Too Long........................................................................................... 4-296
RAP 040 Stepper Motor M101 PCB 48V Very Low....................................................... 4-337
RAP 009 M101/M201 Bin Elevator Upper Home Position Sensor Not Activated in
Time/Activated Too Long.................................................................................. 4-296 RAP 041 Stepper Motor M201 PCB 48V Very Low....................................................... 4-337

RAP 010 Bin Elevator Upper and Lower Home Position Sensor............................... 4-297 RAP 042 Stepper Motor M301 PCB 48V Very Low....................................................... 4-339

RAP 011 Fan X Pulse Time Out..................................................................................... 4-298

VF602 FAULT CODE DESCRIPTIONS
RAP 012 Drive Clutch and Roller.................................................................................. 4-299
Entry RAP........................................................................................................................ 4-341
RAP 013 M301 Drive Motor............................................................................................ 4-300
Fault Codes..................................................................................................................... 4-341
RAP 014 M101/M201 Elevator Motor............................................................................. 4-300
Fault Codes Only Presented at Performed Diagnostics............................................. 4-342
RAP 015 Bin A/B Opening.............................................................................................. 4-302
RAP 016 Lamp RAP........................................................................................................ 4-303 VF602 RAPs
RAP 017 Counter............................................................................................................ 4-304 RAP 100/200 Misfeed Bin A/B........................................................................................ 4-344

RAP 018 12/24/48V Low or High.................................................................................... 4-305 RAP 101/201 Jam, Too Long, Bin A/B.......................................................................... 4-345

RAP 019 24/48V Secondary Circuit............................................................................... 4-306 RAP 102/202 Too Long, Bin A/B.................................................................................... 4-345

RAP 020 24V/48V Very Low Entry RAP......................................................................... 4-308 RAP 103/203 Too Short, Bin A/B................................................................................... 4-345

RAP 021 24V/48V Very Low........................................................................................... 4-308 RAP 104/204 Too Thick, Bin A/B................................................................................... 4-345

RAP 022 BIN A 24V Very Low........................................................................................ 4-309 RAP 105/205 DSD Functionality Uncertain, Bin A/B................................................... 4-345

RAP 023 BIN B 24V Very Low........................................................................................ 4-311 RAP 106/206 Too Thick US DSD, Bin A/B..................................................................... 4-345

RAP 024 Antistatic Bars................................................................................................. 4-312 Perform RAP 002 Ultrasonic DSD (Double Sheet Detection)..................................... 4-345

RAP 025 BIN Switch Software Signal........................................................................... 4-314 RAP 107/207 Bin Empty, Bin A/B................................................................................... 4-347

RAP 026 CPU PCB ”A” .................................................................................................. 4-315 RAP 108/208 Too Thin, Bin A/B..................................................................................... 4-348

RAP 027 CPU PCB ”H”................................................................................................... 4-317

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-6
RAP 300 Exit Miss.......................................................................................................... 4-349 RAP 030 Door Switch Software Signal......................................................................... 4-386
RAP 301 Exit Error.......................................................................................................... 4-350 RAP 031 F1 Blown Fuse................................................................................................. 4-387
RAP 302 No Feed Sequence.......................................................................................... 4-350 RAP 032 Interlock Mismatch......................................................................................... 4-389
RAP 401 No Answer on PAC (Propose, Accept, Confirm).......................................... 4-351 RAP 033 Motor Relay..................................................................................................... 4-391
RAP 001 Optical DSD Sensor........................................................................................ 4-352 RAP 034 PSU (12V)......................................................................................................... 4-393
RAP 002 Ultrasonic DSD (Double Sheet Detection).................................................... 4-353 Go to RAP 031 F1 Blown Fuse...................................................................................... 4-393
RAP 003 Ultrasonic DS (Distance Sensor) Q301 / Q302............................................. 4-354 RAP 035 REL301............................................................................................................. 4-395
RAP 004 No ICAN Communication Entry..................................................................... 4-355 RAP 036 REL302............................................................................................................. 4-396
RAP 005 No XCAN (External) Communication............................................................ 4-357 RAP 037 Stepper Motor Driver M101 PCB ”K”............................................................ 4-397
RAP 006 ICAN Circuit..................................................................................................... 4-359 RAP 038 Stepper Motor Driver M201 PCB ”O”............................................................ 4-399
RAP 007 EEPROM.......................................................................................................... 4-360 RAP 039 Stepper Motor Driver M301 PCB ”G”............................................................ 4-400
RAP 008 M101/M201 Lower Home Position Sensor Not Activated In Time/ RAP 040 Stepper Motor M101 PCB 48V Very Low....................................................... 4-401
Activated Too Long........................................................................................... 4-360
RAP 041 Stepper Motor M201 PCB 48V Very Low....................................................... 4-401
RAP 010 Bin Elevator Lower Home Position Sensor.................................................. 4-361
RAP 042 Stepper Motor M301 PCB 48V Very Low....................................................... 4-403
RAP 011 Fan X Pulse Time Out..................................................................................... 4-362
RAP 043 SP Sensor........................................................................................................ 4-405
RAP 012 Drive Clutch and Roller.................................................................................. 4-363
RAP 044 Vacuum Solenoid and Brake Clutch ............................................................ 4-406
RAP 013 M301 Drive Motor............................................................................................ 4-364
DIP Switch Settings........................................................................................................ 4-407
RAP 014 M101/M201 Elevator Motor............................................................................. 4-364
RAP 015 Bin A/B Opening.............................................................................................. 4-366 CR500 Fault Code Descriptions
RAP 016 Lamp RAP........................................................................................................ 4-367 CR-001 Entrance sensor CR-Q2 Blocked without a preceding Sheet exit signal.... 4-408

RAP 017 Counter............................................................................................................ 4-368 CR-002 Entrance sensor CR-Q2 Not activated in time............................................... 4-408

RAP 018 12/24/48V Low or High.................................................................................... 4-369 CR-003 Sensor CR-Q1, CR-Q2, CR-Q3 or CR-Q4 Activated too long........................ 4-408

RAP 019 24/48V Secondary Circuit............................................................................... 4-370 CR-005 Exit sensor CR-Q5 Activated too long............................................................ 4-408

RAP 020 24V/48V Very Low Entry RAP......................................................................... 4-372 CR-101 Creaser tools home position sensor CR-Q5 Not activated intime after
start of CR-M3.................................................................................................... 4-408
RAP 021 24V/48V Very Low........................................................................................... 4-372
CR-102 Lead screw motor CR-M2 home position sensor CR-Q7 Not activated in
RAP 022 BIN A 24V Very Low........................................................................................ 4-373 time after start of CR-M2................................................................................... 4-408
RAP 023 BIN B 24V Very Low........................................................................................ 4-375 CR-103 Lead screw motor CR-M2 home position sensor CR-Q7 Activated too
RAP 024 Antistatic Bars................................................................................................. 4-376 long after start of CR-M2................................................................................... 4-408

RAP 025 BIN Switch Software Signal........................................................................... 4-378 CR-111 Stepper motor driver CR-M1 PCB “E” No CAN communication................... 4-408

RAP 026 CPU PCB ”A” .................................................................................................. 4-379 CR-112 Stepper motor driver CR-M1 PCB “G” No CAN communication.................. 4-408

RAP 027 CPU PCB ”H”................................................................................................... 4-381 CR-113 Stepper motor driver CR-M1 PCB “H” No CAN communication.................. 4-408

RAP 028 CPU PCB ”L”................................................................................................... 4-383 CR-114 Stepper motor driver CR-M1 PCB “E” too high / too low.............................. 4-408

RAP 029 Door Switch Interlock Circuit......................................................................... 4-385 CR-115 Stepper motor driver CR-M1 PCB “G” too high / too low.............................. 4-408

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-7
CR-116 Stepper motor driver CR-M1 PCB “H” too high / too low.............................. 4-408 RAP 024 48V to high/low entry RAP............................................................................. 4-436
CR-117 Stepper motor CR-M1 Short / Open circuit..................................................... 4-408 RAP 025 12/24/48V low or high..................................................................................... 4-436
CR-118 Stepper motor CR-M2 Short / Open circuit..................................................... 4-408 RAP 026 Stepper Motor M1 PCB 48V to low................................................................ 4-437
CR-119 Stepper motor CR-M3 Short / Open circuit..................................................... 4-408 RAP 027 Stepper Motor M2 PCB 48V to low................................................................ 4-437
CR-120 Sensor CR-Q1 Activated too long................................................................... 4-408 RAP 028 Stepper Motor M3 PCB 48V to low................................................................ 4-439
CR-121 Sensor CR-Q3 Activated too long................................................................... 4-408 RAP 029 48V to low........................................................................................................ 4-441
CR-122 Sensor CR-Q4 Activated too long................................................................... 4-408 RAP 030 48V secondary circuit..................................................................................... 4-442
CR-140 Interlock circuit Mismatch CR-SW2, CRSW3 state with voltage.................. 4-408 RAP 031 REL1................................................................................................................. 4-444
CR-141 Bad EEPROM..................................................................................................... 4-408 RAP 032 EEPROM.......................................................................................................... 4-445
CR-150 CAN communication with Booklet Maker Interrupted................................... 4-408

CR500 RAPs
RAP 001 Edge detetection sensor RAP........................................................................ 4-409
RAP 002 Q5 Exit sensor RAP........................................................................................ 4-410
RAP 003 Q7 Home position M2 sensor RAP................................................................ 4-411
RAP 004 Q6 Home position M3 sensor RAP................................................................ 4-412
Common Procedures
RAP 005 Counter............................................................................................................ 4-413
RAP 006 M1 motor RAP................................................................................................. 4-414 CAUTION!
RAP 007 M2 motor RAP................................................................................................. 4-415
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, data and/or
RAP 008 M3 motor RAP................................................................................................. 4-416 communications problems.

RAP 010 No ICAN Communication entry RAP............................................................. 4-417 Failure to use proper ESD procedures will cause damage to electronic components
RAP 011 ICAN Circuit..................................................................................................... 4-418 (example: PCBs).

RAP 012 CPU PCB ”A” .................................................................................................. 4-419 ESD problems can be minimized by maintaining all machine ground connections, en-
suring the proper handling of circuit boards/ sensors.
RAP 013 No XCAN Communication.............................................................................. 4-421
RAP 014 Stepper Motor Driver M1 PCB ”E”................................................................. 4-422 Use ESD protection when working near PCBs.
Failure to use ESD protection is likely to result in a PCB failure (3.1).
RAP 015 Stepper Motor Driver M1 PCB ”G”................................................................ 4-424
RAP 016 Stepper Motor Driver M3 PCB ”H”................................................................ 4-425
RAP 017 Interlock mismatch......................................................................................... 4-426
RAP 018 Top Cover Switch Interlock circuit................................................................ 4-428
RAP 019 Top Cover Switch software signal................................................................. 4-429
RAP 020 SCP PCB ”K”................................................................................................... 4-430
RAP 021 SCP PCB ”L”................................................................................................... 4-431
RAP 022 PSU (12V)......................................................................................................... 4-432
RAP 023 F1 Blown Fuse................................................................................................. 4-433

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-8
Entry RAP The UI Screen is blank (no backlight).

This RAP determines the correct starting point to analyse all issues within the system. Y N
Always start with this RAP before you procede to an actual fault code RAP. • Power off the booklet maker system.
Initial actions • Manually clear the entire system of any sheets of paper / trim strips and
empty Waste Bins.
• Verify that the main power cord (PL 1.1) is properly connected to a functional wall outlet.
• Power on the system and Enter Service (GP 1).
• Check fuse F1 (PL 4.0 & CST T07090 PL 12.11).
• Perform a Diagnostics Test (GP 3).
• If a Square Folder and / or Trimmer Module is installed.
Ensure that the Communication and Power Cables (PL 1.1) are properly installed. A fault code is displayed on the UI.

• Ensure that the Interlock Jumper (PL 1.1) are properly installed. Y N

• Ensure that the Termination Plugs (PL 1.1) are properly installed in the first and last modeule • Run one set of the job that caused the problem.
of the system A fault code is displayed on the UI.

• Ensure that all dip switches are set correctly (Figure 1). Y N

• Ensure that all modules installed (CST or CR, BM, SQF and TR) are loaded with the same • Restart the job that caused the problem.
version S/W and are compatible with the software in the selected feeder (refer to Software
• Go to the Booklet Quality (section 9)
Release document).
for any output qualityissues.

System Check
Procedure • Set booklet maker to 11x17” / A3.
Open the Infeed Top Cover (PL 1.0).
Manually feed one set (11x17” / A3, 6 sheets) into the machine.
The booklet Maker starts up and produces a booklet.
Y N
Go to Hand Feed RAP

• Verify that paper delivery from the upstream device

is delivered to the booklet maker per that device specification.
Go to the RAP for the fault code displayed.
• Go to the Blank UI (no backlight) RAP.

Continued on next page.

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-9
 Continued on next page.

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-10
Blown Fuse Conditions
This procedure explains what symptoms the system will have if a fuse is blown.

Booklet Maker

Fuse Parts List Rating Symptom at Power On

F1 PL 3.0 5A No response.
(Trimmer and Square Folder no response.)

(Trimmer and Square Folder have no fuses.

Supplied with 12Vdc and 30 Vdc from Booklet Maker.)

Note: Always use original fuses.

CST
Fuse Parts List Rating Symptom at Power On
F1 5A CST Option not available on Booklet Maker UI,
if Booklet Maker is powered on with broken F1 fuse.

Or

If F1 fuse blows while Booklet maker is powered on

CT-150 will be indicated (Communication lost).

Note: Always use original fuses.

CR
Fuse Parts List Rating Symptom at Power On
F1 5A CR Option not available on Booklet Maker UI,
if Booklet Maker is powered on with broken F1 fuse.

Or

If F1 fuse blows while Booklet maker is powered on

CR-150 will be indicated (Communication lost).

Note: Always use original fuses.

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-11
CST
CST Entry RAP
This procedure determines the correct starting point to analyse the fault.

Initial actions
Ensure that all dip switches are set correctly (Refer to Figure below).

System Check
Procedure
The UI Screen is blank (no backlight).
Y N
• Turn off power.
• Manually clear all sheets from system.
• Turn on power.
• Enter Service (GP 1).
• Go to GP 3 and run Diagnostics.
A fault code is displayed on the UI.
Y N
• Run one set of the job that caused the problem.
• A fault code is displayed on the UI.
Y N
• Restart the job that caused the problem.
• Go to the Booklet Quality (section 9)
for any output quality issues.
• Check communication cable.
• Go to the RAP for the fault code displayed.

Go to the RAP for the fault code displayed.

Go to the UI Blank (no backlight) RAP.

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-12
CT-001 Registration M4 Home Sensor CT-Q3 CT-002 Registration M4 Home Sensor CT-Q3
Not activated in time after start of M4 Not deactivated in time after start of M4
At “initialization” the Registration M4 Home Sensor CT-Q3, was not blocked within timeout. At “initialization”, the Registration M4 Home Sensor CT-Q3 was blocked exceeding timeout.
Initial Actions Initial Actions
• Ensure that all connectors are properly connected. • Ensure that all connectors are properly connected.
• Ensure that the Registration M4 Home Sensor CT-Q3 (PL 12.21) is clean. • Ensure that the Registration M4 Home Sensor CT-Q3 (PL 12.21) is clean.
• Check that there are no obstructions in the paper path • Check that there are no obstructions in the paper path.

Procedure
• Enter Service (GP 1).
Procedure
• Enter Service (GP 1).
• Check registration M4 home sensor Q3 according to GP 4.
• Check registration M4 home sensor Q3 according to GP 4.
Registration M4 Home Sensor (Q3) works OK.
Registration M4 Home Sensor (Q3) works OK.
Y N
Y N
Go to Registration M4 Home Sensor (Q3) RAP.
Go to Registration M4 Home Sensor (Q3) RAP.
Check drive motor M1 according to GP4.
Check drive motor M1 according to GP4.
Drive Motor (M1) works OK.
Drive Motor (M1) works OK.
Y N
Y N
Go to Drive Motor (M1) RAP.
Go to Drive Motor (M1) RAP.
Go to Registration Width Adjustment Motor (M4) RAP and
check that the linear guides and the lead screw mechanism are in good working order. Go to Registration Width Adjustment Motor (M4) RAP and
check that the linear guides and the lead screw mechanism are in good working order.
Linear Guides and Screw Mechanism are working OK.
Linear Guides and Screw Mechanism are working OK.
Y N
Y N
Fix problem.
Fix problem.
Check registration width adjustment motor M4 according to GP4.
Check registration width adjustment motor M4 according to GP4.
Registration Width Adjustment Motor (M4) works OK.
Registration Width Adjustment Motor (M4) works OK.
N
N
Go to Registration Width Adjustment Motor (M4) RAP.
Go to Registration Width Adjustment Motor (M4) RAP.

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-13
CT-003 Bleed Trimmer M7 Home Sensor CT-Q6 CT-004 Bleed Trimmer M7 Home Sensor CT-Q6
Not activated in time after start of M7 Not deactivated in time after start of M7
The Bleed Trimmer M7 Home Sensor CT-Q6 was not blocked within timeout. The Bleed Trimmer M7 Home Sensor CT-Q6 was blocked exceeding timeout.

Initial Actions Initial Actions

• Ensure that all connectors are properly connected. • Ensure that all connectors are properly connected.
• Ensure that the Bleed Trimmer M7 Home Sensor CT-Q6 (PL 12.39) is clean. • Ensure that the Bleed Trimmer M7 Home Sensor CT-Q6 (PL 12.39) is clean.
• Check that there are no obstructions in the paper path. • Check that there are no obstructions in the paper path.

Procedure Procedure
• Enter Service (GP 1). • Enter Service (GP 1).
• Check Bleed Trimmer M7 home sensor Q6 according to GP4. • Check Bleed Trimmer home sensor Q6 according to GP4.
Bleed Trimmer M7 Home Sensor (Q6) works OK. Bleed Trimmer M7 Home Sensor (Q6) works OK.
Y N Y N
Go to Bleed Trimmer M7 Home Sensor (Q6) RAP. Go to Bleed Trimmer M7 Home Sensor (Q6) RAP.
Check Drive Motor (M1) according to GP4. Check Drive Motor (M1) according to GP4.
Drive Motor (M1) works OK. Drive Motor (M1) works OK.
Y N Y N
Go to Drive Motor (M1) RAP. Go to Drive Motor (M1) RAP.
Go to Bleed Trimmer Width Adjustment Motor (M7) RAP and check that the linear guides Go to Bleed Trimmer Width Adjustment Motor (M7) RAP and check that the linear guides
and the lead screw mechanism are in good working order. and the lead screw mechanism are in good working order.
Linear Guides and Lead Screw Mechanism are working OK. Linear Guides and Lead Screw Mechanism are working OK.
Y N Y N
Fix problem. Fix problem.
Check Bleed Trimmer width adjustment motor M7 according to GP4. Check Bleed Trimmer width adjustment motor M7 according to GP4.
Bleed Trimmer Width Adjustment Motor (M7) works OK. Bleed Trimmer Width Adjustment Motor (M7) works OK.
N N
Go to Bleed Trimmer Width Adjustment Motor (M7) RAP. Go to Bleed Trimmer Width Adjustment Motor (M7) RAP.

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-14
CT-005 Creaser Tools M6 Home Sensor CT-Q5 CT-101 Registration M4 Home Sensor (Q3)
Not activated in time after start of M6 Not activated in time after start of M4
The Creaser Tools M6 Home Sensor CT-Q5 was not blocked within timeout. Fault code indicates that at “initialization”, the Registration M4 Home Sensor (Q3), was not
blocked within timeout.
Initial Actions
Initial Actions
• Ensure that all connectors are properly connected.
- Ensure that all connectors are properly connected.
• Ensure that the Creaser Tools M6 Home Sensor CT-Q5 (PL 12.33) is clean. - Ensure that the Registration M4 Home Sensor (Q3) (PL 12.21) is clean.
- Check that there are no obstructions in the paper path
• Check that there are no obstructions in the paper path.
Procedure
WARNING!
Procedure
Turn off the RCT Main Power Switch and disconnect the Main Power Cord before discon-
• Enter Service (GP 1). necting, removing or replacing any electrical components.

• Check creaser tools M6 home sensor Q5 according to GP4. - Enter the Service Mode GP1.
Creaser Tools M6 Home Sensor (Q5) works OK. - Check registration M4 home sensor Q3 according to GP4.
Registration M4 Home Sensor (Q3) works OK.
Y N
Y N
Go to Creaser Tools M6 Home Sensor (Q5) RAP.
Go to Registration M4 Home Sensor (Q3) RAP.
Check Drive Motor (M1) according to GP4. Check drive motor M1 according to GP4.
Drive Motor (M1) works OK. Drive Motor (M1) works OK.
Y N
Y N
Go to Drive Motor (M1) RAP.
Go to Drive Motor (M1) RAP.
Go to Registration Width Adjustment Motor (M4) RAP and check that the linear guides and
Go to Drive Motor (M1) RAP and check that transportation drive and idler rollers are in good the lead screw mechanism are in good working order.
working order. Linear Guides and Screw Mechanism are working OK.
Drive and Idler Rollers are OK. Y N
Y N Fix problem.
Check registration width adjustment motor M4 according to GP4.
Fix problem
Registration Width Adjustment Motor (M4) works OK.
Check creaser motor M6 according to GP4. N
Creaser Motor (M6) works OK. Go to Registration Width Adjustment Motor (M4) RAP.
Y N
Go to Creaser Motor (M6) RAP.
Ensure that the creaser tool critical parameters are correctly adjusted (ADJ 12.57 Creaser Tools).
Parameters are correctly adjusted.
N
Go to (REP 12.54 Creaser Tools ) and (ADJ 12.57 Creaser Tools).

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-15
CT-102 Registration M4 Home Sensor (Q3) CT-103 Bleed Trimmer M7 Home Sensor (Q6)
Not deactivated in time after start of M4 Not activated in time after start of M7
Fault code indicates that at “initialization”, the Registration M4 Home Sensor (Q3), was Fault code indicates that at “initialization” , the Bleed Trimmer M7 Home Sensor (Q6), was
blocked exceeding timeout not blocked within timeout.

Initial Actions Initial Actions

- Ensure that all connectors are properly connected. - Ensure that all connectors are properly connected.
- Ensure that the Registration M4 Home Sensor (Q3) (PL 12.21) is clean. - Ensure that the Bleed Trimmer M7 Home Sensor (Q6) (PL 12.39) is clean.
- Check that there are no obstructions in the paper path - Check that there are no obstructions in the paper path.

Procedure WARNING!
Procedure WARNING!
Turn off the RCT Main Power Switch and disconnect the Main Power Cord before discon- Turn off the RCT Main Power Switch and disconnect the Main Power Cord before discon-
necting, removing or replacing any electrical components. necting, removing or replacing any electrical components.
- Enter the Service Mode GP1. - Enter the Service Mode GP1.
- Check registration M4 home sensor Q3 according to GP4. - Check bleed trimmer M7 home sensor Q6 according to GP4.
Registration M4 Home Sensor (Q3) works OK. Bleed Trimmer M7 Home Sensor (Q6) works OK.
Y N Y N
Go to Registration M4 Home Sensor (Q3) RAP. Go to Bleed Trimmer M7 Home Sensor (Q6) RAP.
Check drive motor M1 according to GP4. Check Drive Motor (M1) according to GP4.
Drive Motor (M1) works OK. Drive Motor (M1) works OK.
Y N Y N
Go to Drive Motor (M1) RAP. Go to Drive Motor (M1) RAP.
Go to Registration Width Adjustment Motor (M4) RAP and check that the linear guides and Go to Bleed Trimmer Width Adjustment Motor (M7) RAP and check that the linear guides
the lead screw mechanism are in good working order. and the lead screw mechanism are in good working order.
Linear Guides and Screw Mechanism are working OK. Linear Guides and Lead Screw Mechanism are working OK.
Y N Y N
Fix problem. Fix problem.
Check registration width adjustment motor M4 according to GP4. Check bleed trimmer width adjustment motor M7 according to GP4.
Registration Width Adjustment Motor (M4) works OK. Bleed Trimmer Width Adjustment Motor (M7) works OK.
N N
Go to Registration Width Adjustment Motor (M4) RAP. Go to Bleed Trimmer Width Adjustment Motor (M7) RAP.

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-16
CT-104 Bleed Trimmer M7 Home Sensor (Q6) CT-105 Creaser Tools M6 Home Sensor (Q5)
Not deactivated in time after start of M7 Not activated in time after start of M6
Fault code indicates that at “initialization”, the Bleed Trimmer M7 Home Sensor (Q6), was Fault code indicates that at “initialization”, the Creaser Tools M6 Home Sensor (Q5), was not
blocked exceeding timeout. blocked within timeout.

Initial Actions Initial Actions

- Ensure that all connectors are properly connected. - Ensure that all connectors are properly connected.
- Ensure that the Bleed Trimmer M7 Home Sensor (Q6) (PL 12.39) is clean. - Ensure that the Creaser Tools M6 Home Sensor (Q5) (PL 12.33) is clean.
- Check that there are no obstructions in the paper path - Check that there are no obstructions in the paper path.

Procedure WARNING! Procedure WARNING!

Turn off the RCT Main Power Switch and disconnect the Main Power Cord before discon- Turn off the RCT Main Power Switch and disconnect the Main Power Cord before discon-
necting, removing or replacing any electrical components. necting, removing or replacing any electrical components.
- Enter the Service Mode GP1. - Enter the Service Mode GP1.
- Check bleed trimmer home sensor Q6 according to GP4. - Check creaser tools M6 home sensor Q5 according to GP4.
Bleed Trimmer M7 Home Sensor (Q6) works OK. Creaser Tools M6 Home Sensor (Q5) works OK.
Y N Y N
Go to Bleed Trimmer M7 Home Sensor (Q6) RAP. Go to Creaser Tools M6 Home Sensor (Q5) RAP.
Check Drive Motor (M1) according to GP4. Check Drive Motor (M1) according to GP4.
Drive Motor (M1) works OK. Drive Motor (M1) works OK.
Y N Y N
Go to Drive Motor (M1) RAP. Go to Drive Motor (M1) RAP.
Go to Bleed Trimmer Width Adjustment Motor (M7) RAP and check that the linear guides Go to Drive Motor (M1) RAP and check that transportation drive and idler rollers are in good
and the lead screw mechanism are in good working order. working order.
Linear Guides and Lead Screw Mechanism are working OK. Drive and Idler Rollers are OK.
Y N Y N
Fix problem. Fix problem
Check bleed trimmer width adjustment motor M7 according to GP4. Check creaser motor M6 according to GP4.
Bleed Trimmer Width Adjustment Motor (M7) works OK. Creaser Motor (M6) works OK.
N Y N
Go to Bleed Trimmer Width Adjustment Motor (M7) RAP. Go to Creaser Motor (M6) RAP.
Ensure that the creaser tool critical parameters are correctly adjusted (ADJ 12.56 & 12.57).
Parameters are correctly adjusted.
N
Go to (REP 12.55) and (ADJ 12.57).

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-17
CT-109 Entrance Sensor CT-Q1 blocked without a
preceding Sheet Exit Signal
The Entrance Sensor CT-Q1 was blocked without a preceding Sheet Exit Signal.

Initial Actions
• Ensure that the communication cord is properly connected (PL 12.18).
• Ensure that the Entrance Sensor CT-Q1 (PL 12.19) is clean.
• Check that there are no obstructions in the paper path.

Procedure
• If fault persists after the initial actions.
Go to the Communication RAP.

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-18
CT-111 Stepper Motor Driver CT-M1 PCB “E” No CAN
communication
The Stepper Motor Driver (M1) PCB “E” had no CAN communication.

Initial Actions
• Ensure that all connectors to Stepper Motor Driver (M1) PCB “E” (PL 12.16) are
properly connected (REP 13.27 Stepper Motor Driver (M1) PCB “E”).
• Ensure that the dipswitches on the Stepper Motor Driver (M1) PCB “E” are
set according to (REP 13.27 Stepper Motor Driver (M1) PCB “E”).
• Ensure that the End Termination Plug J.P6 is connected to J.J6.
• Ensure that the End Termination Plug E.P6 is connected to E.J6.

Procedure
• Power off the machine.
• Disconnect the End Termination Plugs at PCB J.P6 and PCB E.P6.
• Measure the End Termination Plug resistance from J.P6-1 to J.P6-2 and
from E.P6-1 to E.P6-2.
Resistance is 120±20% ohm in each Plug.
Y N
Repair or replace End Termination Plug (PL 12.6).

Power off the machine.

Disconnect the End Termination Plugs at PCB J.P6 and PCB E.P6.
Measure continuity from J.J6-1 to E.J6-1 and continuity from J.J6-2 to E.J6-2.
Measure also that there is no short circuit between E.J6-1 to E.J6-2.
There is continuity and no short circuit.
Y N
Repair or replace harness (PL 12.6).

Go to Stepper Motor Driver (M1) PCB “E” RAP.

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-19
CT-113 Stepper Motor Driver CT-M3 PCB “J” No CAN
communication
The Stepper Motor Driver (M3) PCB “J” had no CAN communication.

Initial Actions
• Ensure that all connectors to Stepper Motor Driver (M3) PCB “J” (PL 12.29) are
properly connected (REP 13.31 Stepper Motor Driver (M3) PCB “J”).
• Ensure that the dipswitches on the Stepper Motor Driver (M3) PCB “J” are
set according to (REP 13.31 Stepper Motor Driver (M3) PCB “J”).
• Ensure that the End Termination Plug J.P6 is connected to J.J6.
• Ensure that the End Termination Plug E.P6 is connected to E.J6.

Procedure
• Power off the machine.
• Disconnect the End Termination Plugs at PCB J.P6 and PCB E.P6.
• Measure the End Termination Plug resistance from J.P6-1 to J.P6-2 and
from E.P6-1 to E.P6-2.
Resistance is 120±20% ohm in each Plug.
Y N
Repair or replace End Termination Plug (PL 12.6).

• Power off the machine.

• Disconnect the End Termination Plugs at PCB J.P6 and PCB E.P6.
• Measure continuity from J.J6-1 to E.J6-1 and continuity from J.J6-2 to E.J6-2.
• Measure also that there is no short circuit between E.J6-1 to E.J6-2.
There is continuity and no short circuit.
Y N
Repair or replace harness (PL 12.6).

Go to Stepper Motor Driver (M3) PCB “J” RAP.

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-20
CT-114 Stepper Motor Driver CT-M4 PCB “D” no CAN
communication
The Stepper Motor Driver (M4) PCB “D”, had no CAN communication.

Initial Actions
• Ensure that all connectors to Stepper Motor Driver (M4) PCB “D” (PL 12.13) are
properly connected (REP 13.26 Stepper Motor Driver (M4) PCB “D”).
• Ensure that the dipswitches on the Stepper Motor Driver (M4) PCB “D” are
set according to (REP 13.26 Stepper Motor Driver (M4) PCB “D”).
• Ensure that the End Termination Plug J.P6 is connected to J.J6.
• Ensure that the End Termination Plug E.P6 is connected to E.J6.

Procedure
• Power off the machine.
• Disconnect the End Termination Plugs at PCB J.P6 and PCB E.P6.
• Measure the End Termination Plug resistance from J.P6-1 to J.P6-2
and from E.P6-1 to E.P6-2.

Resistance is 120±20% ohm in each Plug.

Y N
Repair or replace End Termination Plug (PL 12.6).

• Power off the machine.

• Disconnect the End Termination Plugs at PCB J.P6 and PCB E.P6.
• Measure continuity from J.J6-1 to E.J6-1 and continuity from J.J6-2 to E.J6-2.
• Measure also that there is no short circuit between E.J6-1 to E.J6-2.

There is continuity and no short circuit.

Y N
Repair or replace harness (PL 12.6).

Go to Stepper Motor Driver (M4) PCB “D” RAP

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-21
CT-116 Stepper Motor Driver CT-M6 PCB “H” No CAN
communication
The Stepper Motor Driver (M6) PCB “H”, had no CAN communication.

Initial Actions
• Ensure that all connectors to Stepper Motor Driver (M6) PCB “H” (PL 12.21) are
properly connected (REP 13.30 Stepper Motor Driver (M6) PCB “H”).
• Ensure that the dipswitches on the Stepper Motor Driver PCB “H” are
set according to (REP 13.30 Stepper Motor Driver (M6) PCB “H”).
• Ensure that the End Termination Plug J.P6 is connected to J.J6.
• Ensure that the End Termination Plug E.P6 is connected to E.J6.
Procedure
• Power off the machine.
• Disconnect the End Termination Plugs at PCB J.P6 and PCB E.P6.
• Measure the End Termination Plug resistance from J.P6-1 to J.P6-2 and
from E.P6-1 to E.P6-2.

Resistance is 120±20% ohm in each Plug.

Y N
Repair or replace End Termination Plug (PL 12.6).

• Power off the machine.

• Disconnect the End Termination Plugs at PCB J.P6 and PCB E.P6.
• Measure continuity from J.J6-1 to E.J6-1 and continuity from J.J6-2 to E.J6-2.
• Measure also that there is no short circuit between E.J6-1 to E.J6-2.

There is continuity and no short circuit.

Y N
Repair or replace harness (PL 12.6).

Go to Stepper Motor Driver (M6) PCB “H” RAP

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

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CT-117 Stepper Motor Driver CT-M7 PCB “C” No CAN
communication
The Stepper Motor Driver (M7) PCB “C” had no CAN communication.
Initial Actions
• Ensure that all connectors to Stepper Motor Driver (M7) PCB “C” (PL 12.12) are properly
connected (REP 13.25 Stepper Motor Driver (M7) PCB “C”).
• Ensure that the dipswitches on the Stepper Motor Driver (M7) PCB “C” are set according
to (REP 13.25 Stepper Motor Driver (M7) PCB “C”).
• Ensure that the End Termination Plug J.P6 is connected to J.J6.
• Ensure that the End Termination Plug E.P6 is connected to E.J6.

Procedure
• Power off the machine.
• Disconnect the End Termination Plugs at PCB J.P6 and PCB E.P6.
• Measure the End Termination Plug resistance from J.P6-1 to J.P6-2 and
from E.P6-1 to E.P6-2.

Resistance is 120±20% ohm in each Plug.

Y N
Repair or replace End Termination Plug.

• Power off the machine.

• Disconnect the End Termination Plugs at PCB J.P6 and PCB E.P6.
• Measure continuity from J.J6-1 to E.J6-1 and continuity from J.J6-2 to E.J6-2.
• Measure also that there is no short circuit between E.J6-1 to E.J6-2.

There is continuity and no short circuit.

Y N
Repair or replace harness.

Go to Stepper Motor Driver (M7) PCB “C” RAP

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-23
CT-119 PCB Printer Interface PCB “F” No Internal
communication

Note! Printer Interface PCB is in use although not connected to a Printer.

The PCB Printer Interface PCB ”F” had no communication with PCB Controller PCB ”A”.

Initial Actions
Check that Ribbon Cable from A.P8 on PCB Controller PCB “A” (PL 12.12) to F, P2
on the PCB Printer Interface PCB “F” (PL 12.11) is connected.

Procedure
Replace the PCB Printer Interface PCB “F” (REP 13.29 PCB Printer Interface PCB “F).
The communication fault remains.
Y N
Exit.
Replace Ribbon Cable between A.P8 and F.P2.
The communication fault remains.
Y N
Exit.
Replace CPU/ Controller, PCB “A” (REP 13.24 CPU / Controller PCB “A”).

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

4-24
CT-120 Solenoid Driver PCB “B” No CAN communication

At “initialization”, the Solenoid Driver PCB “B”, had no CAN communication.

Initial Actions
• Ensure that all connectors to Solenoid Driver PCB “B” (PL 12.13) are
properly connected (REP 13.24 Solenoid Driver PCB “B”).
• Ensure that the dipswitches on the Solenoid Driver PCB “B” are
set according to (REP 13.24 Solenoid Driver PCB “B”).
• Ensure that the End Termination Plug J.P6 is connected to J.J6
• Ensure that the End Termination Plug E.P6 is connected to E.J6

Procedure
• Power off the machine.
• Disconnect the End Termination Plugs at PCB J.P6 and PCB E.P6.
• Measure the End Termination Plug resistance from J.P6-1 to J.P6-2 and
from E.P6-1 to E.P6-2

Resistance is 120±20% ohm in each Plug.

Y N
Repair or replace End Termination Plug (PL 12.6).

• Power off the machine.

• Disconnect the End Termination Plugs at PCB J.P6 and PCB E.P6.
• Measure continuity from J.J6-1 to E.J6-1 and continuity from J.J6-2 to E.J6-2.
• Measure also that there is no short circuit between E.J6-1 to E.J6-2.

There is continuity and no short circuit.

Y N
Repair or replace harness (PL 12.6).

Go to Solenoid Driver PCB “B” RAP

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CT-121 Stepper Motor Driver PCB “E” Voltage too low CT-123 Stepper Motor Driver PCB “J” Voltage too low

At “initialization”, the Stepper Motor Driver (M3) PCB “J”, had too low voltage.
At “initialization”, the Stepper Motor Driver (M1) PCB “E” , had too low voltage.

Initial Actions Initial Actions

• Ensure that all connectors to Stepper Motor Driver (M3) PCB “J” (PL 12.29) are
• Ensure that all connectors to Stepper Motor Driver (M1) PCB “E” (PL 12.13) are
properly connected (REP 13.31 Stepper Motor Driver (M3) PCB “J”).
properly connected (REP 13.27 Stepper Motor Driver (M1) PCB “E”).
• Ensure that connector A.P15 is properly connected. (REP 13.23 CPU / Controller PCB “A”).
• Ensure that connector A.P15 (REP 13.23 CPU / Controller PCB “A”) is
properly connected. • Ensure that connectors G.P1, G.P2 and G.P3 are properly connected.
• Ensure that connectors G.P1, G.P2 and G.P3 are properly connected. (REP 13.29 I/O Extension PCB “G”).
(REP 13.29 I/O Extension PCB “G”). Procedure
Procedure Go to Stepper Motor Driver (M3) PCB “J” RAP
Go to Stepper Motor Driver (M1) PCB “E” RAP

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CT-124 Stepper Motor Driver PCB “D” Voltage too low CT-126 Stepper Motor Driver (M6) PCB “H” Voltage too
low
At “initialization”, the Stepper Motor Driver (M6) PCB “H”, had too low voltage.
At “initialization”, the Stepper Motor Driver (M4) PCB “D” (M4), had too low voltage.
Initial Actions
Initial Actions
• Ensure that all connectors to Stepper Motor Driver (M6) PCB “H” (PL 12.21) are
• Ensure that all connectors to Stepper Motor Driver (M4) PCB “D” (PL 12.13) are
properly connected (REP 13.30 Stepper Motor Driver (M6) PCB “H”).
properly connected (REP 13.26 Stepper Motor Driver (M4) PCB “D”).
• Ensure that connector A.P15 is properly connected. (REP 13.23 CPU / Controller PCB “A”)
• Ensure that connector A.P15 is properly connected. (REP 13.23 CPU / Controller PCB “A”).
• Ensure that connectors G.P1, G.P2 and G.P3 are properly connected.
• Ensure that connectors G.P1, G.P2 and G.P3 are properly connected.
(REP 13.29 I/O Extension PCB “G”))
(REP 13.29 I/O Extension PCB “G”).
Procedure
Procedure
Go to Stepper Motor Driver (M6) PCB “H” RAP
Go to Stepper Motor Driver (M4) PCB “D” RAP

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 CT-130 Solenoid Driver PCB “B” Voltage too low
CT-127 Stepper Motor Driver (M7) PCB “C” Voltage too
low
At “initialization”, the Solenoid Driver PCB “B”, had too low voltage.
At “initialization”, the Stepper Motor Driver (M7) PCB “C”, had too low voltage.
Initial Actions
Initial Actions
• Ensure that all connectors to Solenoid Driver PCB “B” (PL 12.13) are
• Ensure that all connectors to Stepper Motor Driver (M7) PCB “C” (PL 12.6) are properly connected (REP 13.24 Solenoid Driver PCB “B”).
properly connected (REP 13.25 Stepper Motor Driver (M7) PCB “C”).
• Ensure that connector A.P15 is properly connected. (REP 13.23 CPU / Controller PCB “A”)
• Ensure that connector A.P15 is properly connected. (REP 13.23 CPU / Controller PCB “A”)
• Ensure that connectors G.P1, G.P2 and G.P3 are properly connected.
• Ensure that connectors G.P1, G.P2 and G.P3 are properly connected.
(REP 13.29 I/O Extension PCB “G”)
(REP 13.29 I/O Extension PCB “G”)
Procedure
Procedure
Go to Solenoid Driver PCB “B” RAP
Go to Stepper Motor Driver (M7) PCB “C” RAP

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CT-140 Interlock circuit Mismatch CT-Q8, CT-Q9 state The voltage is >= 1.0 VDC

with voltage Y N

Initial Actions Power off the machine, open the slide door.
Measure resistance between SW2-1 and SW2-2
• Ensure that plugs/jacks P29/J29, P30/J30, P25/J25, P26/J26, P28/J28, P31/J31 and
P32/J32 are properly connected. There is an open circuit.

• Ensure that all connectors connecting to REL1 (PL 12.8) are properly connected. Y N

• Ensure that all connectors to PCB’s “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N” Replace SW2
are properly connected (See Section 8). Power on the machine.
Measure voltage between A.P1-8 and A.P-12 (Signal and Ground).
Procedure Leave the slide door open.
The voltage is 5VDC ±10%.
Close the top cover and slide door (or use cheaters),
measure voltage between N.P2-1 and M.P2-8 (48V and Ground). Y N
Power off the machine.
Measure resistance between SW2-3 and A.P1-8.
The voltage is 48 VDC ±10%.
There is continuity.
Y N
Y N
Perform RAPs in the following order:
Repair harness
1. Interlock Relay Circuit (REL1) RAP
Measure resistance between SW2-3 and Chassis
2. I/O Extension PCB “G” RAP
Resistance >=100kohm.
3. Stepper Motor Driver (M1) PCB “E” RAP
Stepper Motor Driver (M4) PCB “D” RAP Repair harness
4. Stepper Motor Driver (M7) PCB “C” RAP Measure resistance between SW2-3 and Chassis
5. 24V(48V) Power Supply Unit (2) RAP Resistance >=100kohm.
6. 24V Power Supply Unit (1) RAP Y N
7. Stepper Motor Driver (M6) PCB “H” RAP Repair harness
8. Stepper Motor Driver (M3) PCB “J” RAP Measure resistance between SW2-4 and A.P.1-12
Disconnect P29 There is continuity.
Measure voltage between N.P2-1 and M.P2-8 (48V and Ground).
Y N
The voltage drops below 1.0 VDC within 30 seconds.
Repair harness
Y N
Replace PCB “A” Controller (REP 13.23 CPU / Controller PCB “A”)
Replace REL1
Close the slide door (or use cheater).
Open top cover and keep the slide door closed (or use cheater), wait 30 Seconds, Measure voltage between A.P1-8 and A.P-12 (Signal and Ground).
measure voltage between N.P2-1 and M.P2-8 (48V and Ground).
The voltage is below 0.5VDC
Y N

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 Power off the machine. Measure voltage between A.P.1-11 and A.P-9 (Signal and Ground).
Measure resistance between SW2-3 and A.P1-8
The voltage is below 0.5VDC
There is continuity.
Y N
Y N
Power off the machine, measure resistance between SW3-3 and A.P.1-11
Repair harness
There is continuity.
Measure resistance between SW2-4 and A.P.1-12
Y N
There is continuity.
Repair harness
Y N
Measure resistance between SW3-4 and A.P1-9
Repair harness
There is continuity.
Replace PCB “A” Controller
Y N
(REP 13.23 CPU / Controller PCB “A”)
Repair harness
Replace PCB “A” Controller (REP 13.23 CPU / Controller PCB “A”)
Replace PCB “A” Controller (REP 13.23 CPU / Controller PCB “A”)
Power off the machine.
Open the top cover, measure resistance between SW3-1 and SW3-2 Replace PCB “A” Controller (REP 13.23 CPU / Controller PCB “A”)
There is an open circuit.
Y N
Replace SW3
Power on the machine, measure voltage between A.P.1-11 and A.P-9 (Signal and Ground).
Leave the slide door open.
The voltage is 5VDC ±10%.
Y N
Power off the machine, measure resistance between SW3-3 and A.P.1-11
There is continuity.
Y N
Repair harness
Measure resistance between SW3-3 and Chassis
Resistance >=100kohm.
Y N
Repair harness
Measure resistance between SW3-4 and A.P1-9
There is continuity.
Y N
Repair harness
Replace PCB “A” Controller (REP 13.23 CPU / Controller PCB “A”)
Close the top cover (or use cheater).

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CT-141 Bad EEPROM

An NVM value is bad.

Procedure
• Perform GP 20 NVM Reset.
• Re-load S/W (GP 19).
• Replace PCB “A” Controller (REP 13.23 CPU / Controller PCB “A”).

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 There is continuity and no short circuit.
CT-150 CAN communication with Booklet Maker
Y N
interrupted
Repair harness
The Communication between the Booklet Maker and CST is interrupted.
Go to CPU / Controller PCB “A” RAP
Initial Actions
• If there is no CST connected in the system, check that is has been uninstalled.
• Ensure that the communication cables between the Booklet Maker and
the CST is properly connected.
• Ensure tha the communication cables between the Booklet Maker, Trimmer and
Square Folder are properly connected.
• Ensure the power to the CST is connected.
• Ensure that the CST main power Switch is switched ON.
• Check Fuse F1 (PL 12.11), if blown, go to F1 Blown Fuse RAP.
• Check that there is appropriate voltage in the wall outlet.

Procedure
Measure Voltage on CPU / Controller PCB “A” (PL 12.12) between A.P2-4 (12Vdc) and A.P2-5 (Ground).
(CPU / Controller PCB “A” RAP)

The voltage is 12±10%Vdc.

Y N
Go to CPU / Controller PCB “A” RAP
Power off the machine.
Uninstall the Trimmer and Square Folder Power (if installed) in the system.
There is still communication lost.
Y N
Uninstall CST and Go to Communication lost RAP.
Replace the communication cable between the Booklet Maker and the CST.
There is still communication lost.
Y N
Install Trimmer and Square Folder.
Check the harness between Controller PCB A, P4 and J23 for continuity and short circuit.
There is continuity and no short circuit.
Y N
Repair harness
Check the harness between Controller PCB A, P5 and P24 for continuity and short circuit.

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CT-170 Temp Sensor CT-Q13 Failed RAP Y N
This RAP is for troubleshooting Temp Sensor CT-Q13 when it shows too low temperature. Replace REP 13.41 Temp Sensor (CT-Q13)

Initial Actions Repair harness

• Ensure that plugs/jacks P40/J40, and CT-Q13 (PL 12.12) connector are Repair harness
properly connected. (REP 13.42 Cooling Fan (CT-FAN1))
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N” PCBs
are properly connected (See BSD section 8).

Procedure

Measure the voltage between Q13-3 (black wire) and Q13-2 (white wire) on Q13 sensor.
The voltage is <=0.56VDC
Y N
Replace PCB “D” (PL 12.13)
Power off the machine and disconnect Q13 connector and D.P7.
Measure resistance between Q13/1 and D.P7 (red wire).
There is continuity
Y N
Repair harness

Measure resistance between Q13-2 and D.P7-2 (white wire).

There is continuity.
Y N
Repair harness
Measure resistance between Q13-3 and D.P7-10 (black wire).
There is continuity.
Y N
Repair harness
Measure resistance between Q13-1 (red wire) and chassis.
There is continuity.
Y N
Measure resistance between Q13-2 (white wire) and chassis.
There is continuity.

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CT-171 Temp Sensor CT-Q13 overheated RAP
This RAP is for troubleshooting Temp Sensor (CT-Q13) Overheated.

Initial Actions
• Ensure that plugs/jacks P40/J40, Cooling Fan (PL 12.12) and CT-Q13 (PL 12.12) connec-
tor are properly connected. (REP 13.42 Cooling fan)
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N” PCBs
are properly connected (See Section 8)

Procedure
Activate CT-FAN (cooling fan) in component control.
Ensure top cover and slide door interlocks are activated.
FAN1 is blowing.
Y N
Go to Cooling Fan ( CT-FAN) RAP

Turn OFF CT-FAN (cooling fan) in component control.

Measure the voltage between Q13-3 (black wire) and Q13-2 (white wire) on Q13 sensor.
The voltage is between 0.56– 1.52 VDC.
Y N
Power off the machine and disconnect Q13 connector and D.P7.
Measure resistance between Q13-1 and D.P7-1 (red wire).
There is continuity.
Y N
Repair harness
Measure resistance between Q13-2 and D.P7-2 (white wire).
There is continuity.
Y N
Repair harness
Measure resistance between Q13-3 and D.P7-10 (black wire).
There is continuity.
Y N
Repair harness
Replace CT-Q13 (REP 13.42)
Replace PCB “D” (PL 12.13) (REP 13.26 Stepper Motor Driver (M4) PCB “D”).

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CT-201 Entrance Sensor CT-Q1 Not activated in time CT-202 Entrance Sensor CT-Q1 Activated too long
Fault code CT-201, indicates that during a run, the Paper Entrance Sensor (Q1), Fault code indicates that at ”initialization” or during a run, the Paper Entrance Sensor (Q1),
was not blocked within timeout, was blocked exceeding timeout.
after the End of Set signal from the upstream device was detected.
Initial Actions
Initial Actions • Ensure that all connectors are properly connected.

• Ensure that all connectors are properly connected. • Ensure that the Paper Entrance Sensor (Q1) (PL 12.19) is clean.

• Ensure that the Paper Entrance Sensor (CT-Q1) (PL 12.19) is clean. • Check that there are no obstructions in the paper path.

• Check that there are no obstructions in the paper path. Procedure

Procedure Enter Service (GP 1).
Enter Service (GP 1). Check entrance sensor CT-Q1 according to GP4.
Check entrance sensor CT-Q1 according to GP4. Entrance Sensor (CT-Q1) works OK.
Entrance Sensor (CT-Q1) works OK. Y N
Y N Go to Entrance Sensor (CT-Q1) RAP.
Go to Entrance Sensor (CT-Q1) RAP. Check drive motor M1 according to GP4.
Check drive motor M1 according to GP4. Drive Motor (M1) works OK.
Drive Motor (M1) works OK. Y N
Y N Go to Drive Motor (M1) RAP.
Go to Drive Motor (M1) RAP. Go to Drive Motor (M1) RAP and
Go to Drive Motor (M1) RAP and check that transportation drive and idler rollers are in good working order.
check that transportation drive and idler rollers are in good working order. Drive and Idler Rollers are OK.
Drive and Idler Rollers are OK. Y N
Y N Fix problem.
Fix problem. Ensure that the CST is correctly installed.
Check first for paper path misalignment and Interface Cable.
Ensure that the CST is correctly installed.
Check first for paper path misalignment and Interface Cable. Installation is OK.
Installation is OK. Y N
Y N Re-install CST.

Re-install CST. Go to AF602/VF602 RAP006 ICAN Communication Entry

Go to AF602/VF602 RAP006 ICAN Communication Entry

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CT-203 Rotator Sensor CT-Q2 not activated in time
Fault code CT-203, indicates that during a run, the paper Rotator Sensor (CT-Q2),
was not blocked within timeout.
Go to Rotator Disengage Solenoid (SOL2) RAP
Initial Actions Ensure that the CST is correctly installed.
Check first for paper path misalignment and Interface Cable.
• Ensure that all connectors are properly connected.
Installation is OK.
• Ensure that the paper Rotator Sensor (CT-Q2) (PL 12.28) is clean.
Y N
• Check that there are no obstructions in the paper path.
Re-install CST
Procedure
Go to AF602/VF602 RAP006 ICAN Communication Entry
Enter Service (GP 1).
Check rotator sensor CT-Q2 according to GP4.
Rotator Sensor (Q2) works OK.
Y N
Go to Rotator Sensor (Q2) RAP.
Check drive motor M1 according to GP4.
Drive Motor (M1) works OK.
Y N
Go to Drive Motor (M1) RAP.
Check rotator motor M3 according to GP4.
Rotator Motor (M3) works OK.
Y N
Go to Rotator Motor (M3) RAP.
Go to Drive Motor (M1) RAP and Rotator Motor (M3) RAP and
check that transportation drive and idler rollers are in good working order.
Drive and Idler Rollers are OK.
Y N
Fix problem
Check rotator disengage solenoid SOL2 according to GP4.
Rotator Disengage Solenoid (SOL2) and mechanism works OK.
Y N
Go to Rotator Disengage Solenoid (SOL2) RAP.
Check rotator disengage solenoid SOL2 according to GP4.
Rotator Disengage Solenoid (SOL2) and mechanism works OK.
Y N

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CT-204 Rotator Sensor CT-Q2 activated too long Rotator Disengage Solenoid (SOL2) and mechanism works OK.
Fault code indicates that at ”initialization” or during a run, Y N
the paper Rotator Sensor (CT-Q2), was blocked exceeding timeout.
Go to Rotator Disengage Solenoid (SOL1) RAP.
Initial Actions Ensure that the CST is correctly installed.
Check first for paper path misalignment and Interface Cable.
• Ensure that all connectors are properly connected.
Installation is OK.
• Ensure that the paper Rotator Sensor (CT-Q2) (PL 12.28) is clean.
Y N
• Check that there are no obstructions in the paper path.
Re-install CST
Procedure
Go to AF602/VF602 RAP006 ICAN Communication Entry
Enter Service (GP 1).
Check rotator sensor Q2 according to GP4.
Rotator Sensor (Q2) works OK.
Y N
Go to Rotator Sensor (Q2) RAP.
Check drive motor M1 according to GP4.
Drive Motor (M1) works OK.
Y N
Go to Drive Motor (M1) RAP.
Check rotator motor M3 according to GP4.
Rotator Motor (M3) works OK.
Y N
Go to Rotator Motor (M3) RAP.
Go to Drive Motor (M1) RAP and Rotator Motor (M3) RAP and
check that transportation drive and idler rollers are in good working order.
Drive and Idler Rollers are OK.
Y N
Fix problem
Check rotator disengage solenoid SOL1 according to GP4.
Rotator Disengage Solenoid (SOL1) and mechanism works OK.
Y N
Go to Rotator Disengage Solenoid (SOL1) RAP.
Check rotator disengage solenoid SOL2 according to GP4.

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CT-205 Registration Solenoid SOL5 Trigger Sensor Rotator Disengage Solenoid (SOL2) and mechanism works OK.

CT-Q10 not activated in time Y N

The paper Registration Solenoid SOL5 Trigger Sensor CT-Q10 Go to Rotator Disengage Solenoid (SOL2) RAP
was not blocked within timeout.
Ensure that the CST is correctly installed.
Initial Actions Check first for paper path misalignment and Interface Cable.
Installation is OK.
• Ensure all connectors are properly connected.
N
• Ensure that the Registration Solenoid SOL5 Trigger Sensor CT-Q10 (PL 12.20) is clean.
Re-install CST.
• Check that there are no obstructions in the paper path.
• Check that all jam clearance baffles close properly.

Procedure

Enter Service (GP 1).

Check registration solenoid SOL5 sensor Q10 according to GP4.
Registration Solenoid SOL5 Trigger Sensor (Q10) works OK.
Y N
Go to Registration Solenoid SOL5 Trigger Sensor (Q10) RAP.
Check drive motor M1 according to GP4.
Drive Motor (M1) works OK.
Y N
Go to Drive Motor (M1) RAP.
Check rotator motor M3 according to GP4.
Rotator Motor (M3) works OK.
Y N
Go to Rotator Motor (M3) RAP.
Go to Drive Motor (M1) RAP and Rotator Motor (M3) RAP and
check that transportation drive and idler rollers are in good working order.
Drive and Idler Rollers are OK.
Y N
Fix problem
Check rotator disengage solenoid SOL2 according to GP4.
Rotator Disengage Solenoid (SOL2) and mechanism works OK.
Y N
Go to Rotator Disengage Solenoid (SOL2) RAP
Check rotator disengage solenoid SOL2 according to GP4.

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CT-206 Registration Solenoid SOL5 Trigger Sensor Rotator Disengage Solenoid (SOL2) and mechanism works OK.
CT-Q10 activated too long Y N
Fault code indicates that at ”initialization” or during a run, Go to Rotator Disengage Solenoid (SOL2) RAP
the paper Registration Solenoid SOL5 Trigger Sensor CT-Q10,
was blocked exceeding timeout. Check rotator disengage solenoid SOL2 according to GP4.
Rotator Disengage Solenoid (SOL2) and mechanism works OK.
Initial Actions
Y N
• Ensure all connectors are properly connected.
Go to Rotator Disengage Solenoid (SOL2) RAP
• Ensure that the paper Registration Solenoid SOL5 Trigger Sensor
CT-Q10 (PL 12.20) is clean. Ensure that the CST is correctly installed.
Check first for paper path misalignment and Interface Cable.
• Check that there are no obstructions in the paper path.
Installation is OK.
• Check that all jam clearance baffles close properly
N Re-install CST.
Procedure
Enter Service (GP 1).
Check registration sensor Q10 according to GP4.
Registration Solenoid SOL5 Trigger Sensor (Q10) works OK.
Y N
Go to Registration Solenoid SOL5 Trigger Sensor (Q10) RAP.
Check drive motor M1 according to GP4.
Drive Motor (M1) works OK.
Y N
Go to Drive Motor (M1) RAP.
Check rotator motor M3 according to GP4.
Rotator Motor (M3) works OK.
Y N
Go to Rotator Motor (M3) RAP.
Go to Drive Motor (M1) RAP and Rotator Motor (M3) RAP,
and check that transportation drive and idler rollers are in good working order.
Drive and Idler Rollers are OK.
Y N
Fix problem
Check rotator disengage solenoid SOL2 according to GP4.

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CT-207 Creaser Trigger Sensor CT-Q4 not activated in Rotator Disengage Solenoid (SOL2) and mechanism works OK.
time Y N
The Creaser Trigger Sensor CT-Q4 was not blocked within timeout.
Go to Rotator Disengage Solenoid (SOL1) RAP.
Initial Actions Check registration disengage solenoid SOL5 according to GP4.
• Ensure all connectors are properly connected. Registration Disengage Solenoid (SOL5) and mechanism works OK.
• Ensure that the Creaser Trigger Sensor CT-Q4 (PL 12.14) is clean. Y N
• Check that there are no obstructions in the paper path Go to Registration Disengage Solenoid (SOL5) RAP.

Procedure Ensure that the CST is correctly installed.

Check first for paper path misalignment and Interface Cable.
• Enter Service (GP 1)
Installation is OK.
Check creaser trigger sensor Q4 according to GP4.
N
Creaser Trigger Sensor (Q4) works OK.
Re-install CST
Y N
Go to Creaser Trigger Sensor (Q4) RAP
Check drive motor M1 according to GP4.
Drive Motor (M1) works OK.
Y N
Go to Drive Motor (M1) RAP
Check rotator motor M3 according to GP4.
Rotator Motor (M3) works OK.
Y N
Go to Rotator Motor (M3) RAP
Go to Drive Motor (M1) RAP and Rotator Motor (M3) RAP and
check that transportation drive and idler rollers are in good working order.
Drive and Idler Rollers are OK.
Y N
Fix problem
Check rotator disengage solenoid SOL1 according to GP4.
Rotator Disengage Solenoid (SOL1) and mechanism works OK.
Y N
Go to Rotator Disengage Solenoid (SOL1) RAP.
Check rotator disengage solenoid SOL2 according to GP4.

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CT-208 Creaser Trigger Sensor Q4 Activated too long Rotator Disengage Solenoid (SOL2) and mechanism works OK.

At ”initialization” or during a run, Y N

the Creaser Trigger Sensor CT-Q4 was blocked exceeding timeout. Go to Rotator Disengage Solenoid (SOL2) RAP

Initial Actions Check registration disengage solenoid SOL5 according to GP4.

Registration Disengage Solenoid SOL5 and mechanism works OK.
• Ensure that all connectors are properly connected.
Y N
• Ensure that the Creaser Trigger Sensor CT-Q4 (PL 12.14) is clean.
Go to Registration Disengage Solenoid (SOL5) RAP.
• Check that there are no obstructions in the paper path
Ensure that the CST is correctly installed.
• Check condition of jam clearance baffle. Check first for paper path misalignment and Interface Cable.
Installation is OK.
Procedure N
Enter Service (GP 1).
Re-install CST.
Check creaser trigger sensor Q4 according to GP4.
Creaser Trigger Sensor (Q4) works OK.
Y N
Go to Creaser Trigger Sensor (Q4) RAP.
Check drive motor M1 according to GP4.
Drive Motor (M1) works OK.
Y N
Go to Drive Motor (M1) RAP.
Check rotator motor M3 according to GP4.
Rotator Motor (M3) works OK.
Y N
Go to Rotator Motor (M3) RAP.
Go to Drive Motor (M1) RAP and Rotator Motor (M3) RAP and
check that transportation drive and idler rollers are in good working order.
Drive and Idler Rollers are OK.
Y N
Fix problem
Check rotator disengage solenoid SOL2 according to GP4.
Rotator Disengage Solenoid (SOL2) and mechanism works OK.
Y N
Go to Rotator Disengage Solenoid (SOL2) RAP
Check rotator disengage solenoid SOL2 according to GP4.

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CT-209 Exit Sensor CT-Q7 Not activated in time CT-210 Exit Sensor CT-Q7 Activated too long
The Paper Exit Sensor CT-Q7 was not blocked within timeout. At ”initialization” or during a run,
the Paper Exit Sensor CT-Q7 was blocked exceeding timeout.
Initial Actions
Initial Actions
• Ensure that all connectors are properly connected.
• Ensure that all connectors are properly connected.
• Ensure that the Paper Exit Sensor CT-Q7 (PL 12.46) is clean.
• Ensure that the Paper Exit Sensor CT-Q7 (PL 12.46) is clean.
• Check that there are no obstructions in the paper path.
• Check that there are no obstructions in the paper path.
Procedure
Procedure
Enter Service (GP 1).
Enter Service (GP 1).
Check Paper Exit Sensor Q7 according to GP4.
Check Paper Exit Sensor Q7 according to GP4.
Exit Sensor (Q7) works OK.
Exit Sensor (Q7) works OK.
Y N
Y N
Go to Paper Exit Sensor (Q7) RAP.
Go to Paper Exit Sensor (Q7) RAP.
Check drive motor M1 according to GP4.
Check drive motor M1 according to GP4.
Drive Motor (M1) works OK.
Drive Motor (M1) works OK.
Y N
Y N
Go to Drive Motor (M1) RAP.
Go to Drive Motor (M1) RAP.
Go to Drive Motor (M1) RAP and
check that transportation drive and idler rollers are in good working order. Go to Drive Motor (M1) RAP and
check that transportation drive and idler rollers are in good working order.
Drive and Idler Rollers are OK.
Drive and Idler Rollers are OK.
Y N
Y N
Fix problem.
Fix problem.
Check creaser motor M6 according to GP4.
Check creaser motor M6 according to GP4.
Creaser Motor (M6) works OK.
Creaser Motor (M6) works OK.
N
Y N
Go to Creaser Motor (M6) RAP.
Go to Creaser Motor (M6) RAP.
Ensure that the CST is correctly installed.
Check first for paper path misalignment and Interface Cable.
Installation is OK.
N
Re-install CST

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

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CT-211 Creaser Tools M6 Home Sensor CT-Q5 Not CT-212 Waste Transport Sensor CT-Q14 Activated too
activated in time long
The Creaser Tools M6 Home Sensor CT-Q5 was not blocked within timeout. The Waste Transport Sensor CT-Q14 was blocked exceeding timeout.

Initial Actions Initial Actions

• Ensure that all connectors are properly connected.
• Ensure that all connectors are properly connected.
• Ensure that the Waste Transport Sensor CT-Q14 (PL 12.10) is clean.
• Ensure that the Creaser Tools M6 Home Sensor CT-Q5 (PL 12.33) is clean.
• Check that there are no obstructions in the Waste Transport System.
• Check that there are no obstructions in the paper path.

Procedure Procedure
Enter Service (GP 1).
Enter Service (GP 1).
Check Sensor Q14 according to GP4.
Check creaser tools M6 home sensor Q5 according to GP4.
Waste Transport Sensor (Q14) works OK.
Creaser Tools M6 Home Sensor (Q5) works OK.
Y N
Y N
Go to Waste Transport Sensor (Q14) RAP.
Go to Creaser Tools M6 Home Sensor (Q5) RAP.
Check drive motor M1 according to GP4.
Check drive motor M1 according to GP4.
Drive Motor (M1) works OK.
Drive Motor (M1) works OK.
Y N
Y N
Go to Drive Motor (M1) RAP
Go to Drive Motor (M1) RAP.
Check that the Waste Transport Conveyor Belt system is properly driven and in good
Go to Drive Motor (M1) RAP and
working order when Drive Motor (M1) is operated.
check that transportation drive and idler rollers are in good working order.
Drive and Idler Rollers are OK.
The Transport Conveyor Belt System works OK.
Y N
Y N
Fix problem.
Fix problem (REP 12.24
Check creaser motor M6 according to GP4.
).
Rotator Motor (M6) works OK.
Exit
Y N
Go to Creaser Motor (M6) RAP.
Ensure that the Creaser Tool Critical parameters are correctly adjusted
(ADJ 12.57 Creaser Tools).
Parameters are correctly adjusted.
N
Go to (REP 12.57) and (ADJ 12.57 Creaser Tools).

Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)

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CT-503 Waste Bin Full Sensor CT-Q11 activated The voltage is 5 VDC ±10%?
Fault code indicates that at “initialization” or during a run, Y N
the Waste Bin Full Sensor CT-Q11 was blocked exceeding timeout.
Repair wire harness
Initial Actions
Replace Q11 from Waste Bin Full Sensor CT-Q11 (REP 12.23)
• Enter Service (GP 1)
The Waste Bin Full Sensor (CT-Q11) works OK?
• Check sensor CT-Q11 according to GP4
Y N
• Ensure that the Waste Bin Full Sensor CT-Q11 (PL 12.10) is clean.
Replace the Ribbon Cable (PL 12.12) between CPU/Controller PCB “A” and
• Ensure that the Waste Bin Full Sensor CT-Q11 is properly connected. I/O Extension PCB “G”.
• Ensure that plug A.P1 and A.P15 on the CPU/Controller PCB “A” (PL 12.12) is The Waste Bin Full Sensor (CT-Q11) works OK?
properly connected.
Y N
• Ensure that plug G.P1 and G.P2 on the I/O Extension PCB “G” (PL 12.12) is
properly connected. Replace CPU / Controller PCB “A” (REP 13.23 CPU / Controller PCB “A”)
Exit
Procedure
Disconnect plug A.P1 from CPU/Controller PCB A.
Measure between pins A.J.1-10 and A.J1-25 (5V and Ground).
The voltage is 5 VDC ±10%?
Y N
Replace CPU / Controller PCB “A” (REP 13.23 CPU / Controller PCB “A”)

Disconnect plug G.P1 from I/O extension PCB “G”.

Measure between G1-3 and G1-5 (Signal 5V and Ground).
The voltage is 5 VDC ±10%?
Y N
Replace Extension PCB “G” I/O (REP 13.29)

• Disconnect plug Q11 from Waste Bin Full Sensor (CT-Q11).

• Check wire for continuity / short circuit from the white wire at plug Q11 to G.P1-3.
• Check wire for continuity / short circuit from the black wire at plug Q11 to G.P1-5.
• Check wire for continuity / short circuit from the red wire at plug Q11 to A.P.1-10.
There is continuity and no short circuit?
Y N
Repair wire harness
Connect plug A.P1 to CPU/Controller PCB A and plug G.P1 to I/O extension PCB “G”.
Check for voltage at the P/J Q11 connector between
pins 1 (red wire, 5 V) and 3 (black wire, Ground)

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Drive Motor CT-M1 RAP
This RAP is for troubleshooting the Drive Motor CT-M1.

Initial Actions
• Enter Service (GP 1)
• Check motor CT-M1 (PL 12.8) and CT-M7 (PL 12.39) according to GP4.
• Ensure that plugs E.P2, E.P3, E.P5, E.P6 are properly connected to
Stepper Motor Driver (M1) PCB “E” (PL 12.13)

Procedure
• Turn off the main switch while turning M1 timing belt pulley by hand,
to rule out mechanical binding and/or other mechanical problems in the transmission.
• Go to Drive Motor (M1) Transmission RAP and
verify that all transmission components move as indicated.
The M1 transmission works OK?
Y N
Fix problem.
• Swap CT-M7 Stepper Motor Driver PCB “C” (PL 12.39) with
CT-M1 Stepper Motor Driver PCB ”E” (PL 12.13).
•
After swapping the Stepper Motor PCBs,
set the address dip switches to the settings in the Circuit Diagram.
• Check Motor CT-M7 functionality.
The M7 system works OK?
Y N
Replace CT-M7 Stepper Motor Driver PCB “C” (PL 12.12)
Check for continuity between pins E.P2-1 and E.P2-2.
Check for continuity between pins E.P2-3 and E.P2-4
There is continuity and no short circuit.
Y N
Repair harness.
Check for voltage at E.P3 between pins E.P3-1 and E.P3-2.
The Voltage is 48VDC±10%
Y N
Go to Stepper Motor Driver (M1) PCB “E” RAP
Replace Drive Motor CT-M1 (REP 12.8).

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Rotator Motor CT-M3 RAP
This RAP is for troubleshooting the Rotator Motor CT-M3.

Initial Actions
• Enter Service (GP 1)
• Check motor CT-M3 (PL 12.29) and M7 (PL 12.39) according to GP4
• Ensure that plugs J.P2, J.P3, J.P5, J.P6 are properly connected to
Stepper motor driver PCB “J” (PL 12.29)
• Ensure that P/J Motor situated directly on the motor chassie is properly connected.

Procedure
• Turn off the main switch while turning M3 transmission by hand to
rule out mechanical binding and/or other mechanical problems in the transmission.
• Go to Rotator Motor (M3) Transmission RAP and
verify that all transmission components move as indicated.
The M3 transmission works OK?
Y N
Fix problem.
• Swap M7 Stepper Motor Driver PCB “C” (PL 12.12) with
the Stepper Motor Driver (M3) PCB ”J” (PL 12.29).

After swapping the Stepper motor PCBs,

set the address dip switches to the settings in the Circuit Diagram.
• Check motor M7 functionality.
The M7 system works OK?
Y N
Replace the Stepper Motor Driver (M7) PCB “C” (PL 12.12)
Check for continuity between pins J.P2-1 and J.P2-2.
Check for continuity between pins J.P2-3 and J.P2-4.
There is continuity and no short circuit.
Y N
Repair harness.
Check for voltage at J.P3 between pins J.P3-1 and J.P3-2.
The Voltage is 48VDC±10%
Y N
Go to Stepper Motor Driver (M3) PCB “J” RAP.
Replace Rotator Motor (M3) REP 12.36).

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Registration Width Adjustment Motor CT-M4 RAP
This RAP is for troubleshooting the Registration Width Adjustment Motor (M4).
Initial Actions
• Enter Service (GP 1)
• Check motor CT-M4 (PL 12.8) and M7 (PL 12.39) according to GP4.
• Ensure that plugs D.P1, D.P2, D.P3, D.P4, E.P5, D.P6, D.P7 are properly connected to
Stepper motor driver PCB “D” (PL 12.13)
• Ensure that P/J Motor situated directly on the motor chassie is properly connected.

• Procedure
• Turn off the main switch while turning CT-M4 transmission by hand, to rule out severe mechanical binding and/or
other mechanical problems in the transmission.
• Go to Registration Width Adjustment Motor (CT-M4)Transmission RAP and
verify that all transmission components move as indicated.
The M4 transmission works OK?
Y N
Fix problem.
1. Swap the Stepper Motor Driver (M7) PCB “C” (PL 12.12) with the Stepper Motor M4 PCB ”D” (PL 12.13).
After swapping the Stepper motor PCBs, set the address dip switches to the settings in the Circuit Diagram.
2. Check motor M7 functionality.
The M7 system works OK?
Y N
Replace the Stepper Motor Driver (M7) PCB “C” (PL 12.12)
1. Check for continuity between pins D.P2-1 and D.P2-2.
2. Check for continuity between pins D.P2-3 and D.P2-4.
There is continuity and no short circuit.
Y N
Repair harness.
Check for voltage at C.P3 between pins D.P3-1 and D.P3-2.
The Voltage is 48VDC±10%
Y N
Go to Stepper Motor Driver (M4) PCB “D” RAP
Replace Registration Width Adjustment Motor (M4) (REP 12.39).

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Creaser Motor CT-M6 RAP The Voltage is 48VDC±10%
This RAP is for troubleshooting the Creaser Motor CT-M6. Y N
Initial Actions Go to Stepper Motor Driver (CT-M6) PCB “H” RAP

• Enter Service (GP 1) Replace Creaser Motor (CT-M6) (REP 12.55).

• Check motor CT-M6 (PL 12.14) and CT-M7 (PL 12.15) according to GP4
• Ensure that plugs H.P1, H.P2, H.P3, H.P4, H.P5, H.P6 are
properly connected to Stepper Motor Driver PCB “H” (PL 12.21)
• Check that motor CT-M7 system works OK

Procedure
• Turn off the main switch while turning M6 transmission by hand to
rule out mechanical binding and/or other mechanical problems in the transmission.
• Go to Creaser Motor CT-M6 Transmission RAP and
verify that all transmission components move as indicated.
The M6 transmission works OK?
Y N
Fix problem.
• Swap the Stepper Motor Driver (CT-M7) PCB “C” (PL 12.12) with
the Stepper Motor Driver (CT-M6) PCB ”H” (PL 12.21).

After swapping the Stepper Motor PCBs,

set the address dip switches to the settings in the Circuit Diagram.
• Check motor CT-M7 functionality.
The M7 system works OK?
Y N
Replace the Stepper Motor Driver (CT-M7) PCB “C” (PL 12.12)
Check for continuity between pins H.P2-1 and H.P2-2.
Check for continuity between pins H.P2-3 and H.P2-4.
There is continuity between pins H.P2-3 and H.P2-4.
There is continuity and no short circuit.
Y N
Repair harness.
Check for voltage at H.P3 between pins H.P3-1 and H.P3-2.

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Bleed Trimmer Width Adjustment Motor CT-M7 RAP There is continuity and short circuit.
This RAP is for troubleshooting the Bleed Trimmer Width Adjustment Motor (M7).
Y N
Initial Actions Repair harness.
• Enter Service (GP 1) Check for voltage at H.P3 between pins C-P3-1 and C.P3-1.
• Check motor M7 (PL 12.15) and M4 (PL 12.5) according to GP4 The Voltage is 48VDC±10%.
• Ensure that plugs C.P1, C.P2, C.P3, C.P4, C.P5, C.P6, C.P7 are Y N
properly connected to Stepper motor driver PCB C
Go to Stepper Motor Driver (M7) PCB “C” RAP
• Check that motor M4 system works OK
Replace Bleed Trimmer Width Adjustment Motor (M7) REP 13.4.
• Ensure that P/J Motor situated directly on the motor chassie is properly connected.

Procedure
• Turn off the main switch while turning M7 transmission by hand to
rule out severe mechanical binding and/or other mechanical problems in the transmission.
• Go to Bleed Trimmer Width Adjustment Motor (M7) Transmission RAP and
verify that all transmission components move as indicated.

The M7 transmission works OK?

Y N
Fix problem.
• Swap the Stepper Motor Driver (M4) PCB “D” (PL 12.13) with
the Stepper Motor Driver (M7) PCB ”C” (PL 12.6).

After swapping the Stepper Motor PCBs,

set the address dip switches to the settings in the Circuit Diagram.
• Check motor M4 functionality.

The M4 system works OK?

Y N
Replace the Stepper Motor Driver (M4) PCB “D” (PL 12.13)
Check for continuity between pins C.P2-1 and C.P2-2.
Check for continuity between pins C.P2-3 and C.P2-4.

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Rotator Disengage Solenoid CT-SOL1 RAP
This RAP is for troubleshooting the Rotator Disengage Solenoid (SOL1).

Initial Actions
• Enter Service (GP 1)
• Check solenoid CT-SOL1 (PL 12.28) according to GP4
• Ensure that the connectors are properly connected to the solenoid (REP 12.28 Rotator Disengage Solenoid (CT-SOL1)) .
• Ensure that plugs B.P2, B.P4, B.P5, B.11, B.12 are
properly connected to Solenoid Driver PCB “B” (PL 12.13)
• Ensure that plug / jack 31 is connected

Procedure
Power off the machine while activating the SOL1 linkage and mechanism by hand,
to rule out mechanical binding and/or other mechanical problems in the system.
The SOL1 mechanism works OK.
Y N
Fix problem.
Power off the machine.
Remove connectors from solenoid SOL1.
Place meter leads on SOL1 contacts and check for an open condition.
There is an open circuit.
Y N
Reinstall connectors. Disconnect plug B.P2 from Solenoid Driver PCB “B”.
Measure between the violet connector on the solenoid and B.P2-12.
There is continuity.
Y N
Repair Wire Harness.
Measure between the orange connector on the solenoid and B.P2-5.
There is continuity.
Y N
Repair Wire Harness.
Go to Solenoid Driver PCB “B” RAP
Replace Solenoid SOL1 (REP 12.28 Rotator Disengage Solenoid (CT-SOL1)).

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Rotator Disengage Solenoid CT-SOL2 RAP
This RAP is for troubleshooting the Rotator Disengage Solenoid CT-SOL2.

Initial Actions
• Enter Service (GP 1)
• Check solenoid CT-SOL2 (PL 12.28) according to GP4
• Ensure that the connectors are properly connected to the solenoid (REP 12.31 Rotator Disengage Solenoid (CT-SOL2))
• Ensure that plugs B.P2, B.P4, B.P5, B.11, B.12 are properly
connected to Solenoid Driver PCB “B” (PL 12.13)
• Ensure that plug / jack 31 is connected

Procedure
Power off the machine while activating the SOL2 linkage and mechanism by hand,
to rule out mechanical binding and/or other mechanical problems in the system.
The SOL2 mechanism works OK.
Y N
Fix problem.
Power off the machine. Remove connectors from solenoid SOL2.
Place meter leads on SOL2 contacts and check for an open condition.
There is an open circuit.
Y N
Reinstall connectors. Disconnect plug B.P2 from Solenoid Driver PCB “B”.
Measure between the violet connector on the solenoid and B.P2-13.
There is continuity.
Y N
Repair Wire Harness.
Measure between the orange connector on the solenoid and B.P2-6.
There is continuity.
Y N
Repair Wire Harness.
Go to Solenoid Driver PCB “B” RAP
Replace Solenoid SOL2 (REP 12.31 Rotator Disengage Solenoid (CT-SOL2)).

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Bleed Trimmer Disengage Solenoid CT-SOL3 RAP
This RAP is for troubleshooting the Bleed Trimmer Disengage Solenoid CT-SOL3.

Initial Actions
• Enter Service (GP 1)
• Check solenoid CT-SOL3 (PL 12.40) according to GP4
• Ensure that the connectors are properly connected to the solenoid
(REP 13.5 Bleed Trimmer Disengage Solenoid (CT-SOL3))
• Ensure that plugs B.P2, B.P4, B.P5, B.11, B.12 are properly
connected to Solenoid driver PCB “B” (PL 12.13)
• Ensure that plug / jack 31 is connected.

Procedure
Power off the machine while activating the SOL3 linkage and mechanism by han,
to rule out mechanical binding and/or other mechanical problems in the system.
The SOL3 mechanism works OK.
Y N
Fix problem.
Power off the machine. Remove connectors from solenoid SOL3.
Place meter leads on SOL3 contacts and check for an open condition.
There is an open circuit.
Y N
Reinstall connectors. Disconnect plug B.P2 from Solenoid Driver PCB “B”.
Measure between the violet connector on the solenoid and B.P2-14.
There is continuity.
Y N
Repair Wire Harness.
Measure between the orange connector on the solenoid and B.P2-7.
There is continuity.
Y N
Repair Wire Harness.
Go to Solenoid Driver PCB “B” RAP
Replace Solenoid SOL3
(REP 13.5 Bleed Trimmer Disengage Solenoid (CT-SOL3)).

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Transportation Disengage Solenoid CT-SOL4 RAP
This RAP is for troubleshooting the Transportation Disengage Solenoid CT-SOL4.

Initial Actions
• Enter Service (GP 1)
• Check solenoid CT-SOL4 (PL 12.27) according to GP4
• Ensure that the connectors are properly connected to the solenoid
(REP 13.11 Transportation Disengage Solenoid (CT-SOL4))
• Ensure that plugs B.P2, B.P4, B.P5, B.11, B.12 are properly
connected to Solenoid driver PCB “B” (PL 12.13)
• Ensure that plug / jack 31 is connected.

Procedure
Power off the machine while activating the SOL4 linkage and mechanism by hand,
to rule out mechanical binding and/or other mechanical problems in the system.
The SOL4 mechanism works OK.
Y N
Fix problem.
• Power off the machine.
• Remove connectors from solenoid SOL4.
• Place meter leads on SOL4 contacts and check for an open condition.
There is an open circuit.
Y N
Reinstall connectors. Disconnect plug B.P2 from Solenoid Driver PCB “B”.
Measure between the violet connector on the solenoid and B.P2-10.
There is continuity.
Y N
Repair Wire Harness.
Measure between the orange connector on the solenoid and B.P2-5.
There is continuity.
Y N
Repair Wire Harness.
Go to Solenoid Driver PCB “B” RAP
Replace Solenoid SOL4
(REP 13.11 Transportation Disengage Solenoid (CT-SOL4)).

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Registration Disengage Solenoid CT-SOL5 RAP
This RAP is for troubleshooting the Registration Disengage Solenoid CT-SOL5.

Initial Actions
• Enter Service (GP 1)
• Check solenoid SOL5 (PL 12.27) according to GP4
• Ensure that the connectors are properly connected to the solenoid
(REP 12.47 Registration Disengage Solenoid (CT-SOL5))
• Ensure that plugs B.P2, B.P4, B.P5, B.11, B.12 are properly connected to Solenoid driver
PCB “B” (PL 12.13)
• Ensure that plug / jack 31 is connected.

Procedure
Power off the machine while activating the SOL5 linkage and mechanism by hand,
to rule out mechanical binding and/or other mechanical problems in the system.
The SOL5 mechanism works OK.
Y N
Fix problem.
• Power off the machine.
• Remove connectors from solenoid SOL5.
• Place meter leads on SOL5 contacts and check for an open condition.
There is an open circuit.
Y N
Reinstall connectors. Disconnect plug B.P2 from Solenoid Driver PCB “B”.
Measure between the violet connector on the solenoid and B.P2-9.
There is continuity.
Y N
Repair Wire Harness.
Measure between the orange connector on the solenoid and B.P2-6.
There is continuity.
Y N
Repair Wire Harness.
Go to Solenoid Driver PCB “B” RAP
Replace Solenoid SOL5 (REP 12.47 Registration Disengage Solenoid (CT-SOL5))

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Entrance Sensor CT-Q1 RAP
This RAP is for troubleshooting the Paper Entrance Sensor CT-Q1.

Initial Actions
• Enter Service (GP 1)
• Check sensor Q1 according to GP4
• Ensure that the Paper Entrance Sensor CT-Q1 (PL 12.19) is clean.
• Ensure that plug / jack Q1 at the Paper Entrance Sensor (Q1) is properly connected.
• Ensure that plug A P1 on CPU/Controller PCB “A” (PL 12.12) is properly connected.

Procedure
• Disconnect plug A.P1 from CPU/Controller PCB A.
• Measure between pins A.J.1-1 and A.J1-3 (5V and Ground).
The voltage is 5 VDC ±10%?
Y N
Replace CPU / Controller PCB “A” (REP 13.23 CPU / Controller PCB “A”)
• Disconnect plug Q1 from Paper Entrance Sensor (CT-Q1).
• Check wire for continuity / short circuit from the white wire at plug Q1 to A.P1-2.
• Check wire for continuity / short circuit from the black wire at plug Q1 to A.P1-3.
• Check wire for continuity / short circuit from the red wire at plug Q1 to A.P.1-1.
There is continuity and no short circuit?
Y N
Repair wire harness
• Connect plug A.P1 to CPU/Controller PCB “A”.
• Check for voltage at the P/J Q1 connector between pins 1 (red wire, 5 V) and 3 (black wire, Ground)
The voltage is 5 VDC ±10%?
Y N
Repair wire harness
Replace Entrance Sensor (CT-Q1)REP 12.6
The Paper Entrance Sensor (Q1) works OK?
Y N
Replace CPU / Controller PCB “A” (REP 13.23 CPU / Controller PCB “A”)
Exit

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Rotator Sensor CT-Q2 RAP
This RAP is for troubleshooting the paper Rotator Sensor CT-Q2.

Initial Actions
• Enter Service (GP 1).
• Check sensor CT-Q2 according to GP4
• Ensure that the paper Rotator Sensor CT-Q2 (PL 12.28) is clean.
• Ensure that plug / jack Q2 at the paper Rotator Sensor CT-Q2 is properly connected.
• Ensure that plug A.P1 on CPU/Controller PCB “A” (PL 12.12) is properly connected.
• Ensure that plug / jack 32 is properly connected (WD CT P/J 32)

Procedure
• Disconnect plug A.P1 from CPU/Controller PCB A.
• Measure between pin A.J.1-10 and A.J1-25 (5V and Ground).
The voltage is 5 VDC ±10%?
Y N
Replace CPU / Controller PCB “A” (REP 13.23 CPU / Controller PCB “A”)
• Disconnect plug Q2 from paper Rotator Sensor CT-Q2.
• Check wire for continuity / short circuit from the white wire at plug Q2 to A.P.1-18.
• Check wire for continuity / short circuit from the black wire at plug Q2 to A.P1-25.
• Check wire for continuity / short circuit from the red wire at plug Q2 to A.P.1-10.
There is continuity and no short circuit?
Y N
Repair wire harness
• Connect plug A.P1 to CPU/Controller PCB A.
• Check for voltage at the P/J Q2 connector between pins 1 (red wire, 5 V) and 3 (black wire, Ground)
The voltage is 5 VDC ±10%?
Y N
Repair wire harness
Replace Paper Rotator Sensor Q2 (REP 12.26 Rotator Sensor (CT-Q2))
The paper Rotator Sensor (Q2) works OK?
Y N
Replace CPU / ControllerPCB “A” (REP 13.23 CPU / Controller PCB “A”)
Exit

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Registration M4 Home Sensor CT-Q3 RAP
This RAP is for troubleshooting the Registration M4 Home Sensor CT-Q3.

Initial Actions
• Enter Service (GP 1)
• Check sensor Q3 according to GP4
• Ensure that the Registration M4 Home Sensor CT-Q3 (PL 12.21) is clean.
• Ensure that plug / jack Q3 at the Registration M4 Home Sensor (CT-Q3) is
properly connected.
• Ensure that plug D, P1 on Stepper Motor Driver (M4) PCB “D” (PL 12.13) is connected.
• Ensure that plug / jack 32 is properly connected (WD CT P/J 32)

Procedure
• Disconnect plug D. P1 from Stepper Motor Driver (M4) PCB “D”.
• Measure between pins D.J1-2 and D.J1-3 (5V and Ground).
The voltage is 5 VDC ±10%?
Y N
Replace Stepper Motor Driver (M4) PCB “D” (REP 13.26 Stepper Motor Driver (M4) PCB “D”)
• Disconnect plug Q3 from Registration M4 Home Sensor (Q3).
• Check wire for continuity / short circuit from the white wire at plug Q2 to D.P1-4.
• Check wire for continuity / short circuit from the black wire at plug Q2 to D.P1-3.
• Check wire for continuity / short circuit from the red wire at plug Q2 to D.P1-2.
There is continuity and no short circuit?
Y N
Repair wire harness
Connect plug D, P1 from Stepper Motor Driver (M4) PCB “D”.
Check for voltage at the P/J Q3 connector between pins 1 (red wire, 5 V) and 3 (black wire, Ground)
The voltage is 5 VDC ±10%?
Y N
Repair wire harness
Replace the Registration M4 Home Sensor (Q3) (REP 12.40 Registration M4 Home Sensor (CT-Q3))
The paper Rotator Sensor (Q3) works OK?
Y N
Exit

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Creaser M6 Trigger Sensor CT-Q4 RAP Repair wire harness
This RAP is for troubleshooting the Creaser M6 Trigger Sensor CT-Q4.

Initial Actions Replace Creaser M6 Trigger Sensor (Q4) LED (REP 12.50)

• Enter Service (GP 1) Disconnect H.P1 from Stepper Motor Driver (M6) PCB “H”.

• Check sensor Q4 according to GP4 Check for voltage between pins H.J.1-11 and H.J.1-10 (5V and Ground).

• Ensure that the Creaser M6 Trigger Sensor CT-Q4 LED (PL 12.33) is clean. The voltage is 5 VDC ±10%?

• Ensure that the Creaser M6 Trigger Sensor CT-Q4 PHT (PL 12.33) is clean. Y N
Replace Stepper Motor Driver (M6) PCB “H” (REP 13.30 Stepper Motor Driver (M6) PCB “H”)
• Ensure that the plug / jack Q4 LED at the Creaser M6 Trigger Sensor CT-Q4 LED is
properly connected. • Disconnect plug / jack Q4 PhT at the Creaser M6 Trigger Sensor (Q4) Phototransistor
• Ensure that the plug / jack Q4 PhT at the Creaser M6 Trigger Sensor CT-Q4 PHT is • Check for continuity / short circuit between the black wire at plug Q4 Phototransistor and H.P.1-10.
properly connected.
• Check for continuity / short circuit between the red wire at plug Q4 and H.P.1-11.
• Check condition of jam clearance baffle.
• Connect plug H.P1 to Stepper Motor Driver (M6) PCB “H”.
• Ensure that plug H, P1 on Stepper Motor Driver (M6) PCB “H” (PL 12.21) is
properly connected. • Check for voltage at the P/J Q4 Phototransistor connector between
pins 1 (white wire, 5 V) and 2 (black wire, Ground)
The voltage is 5 VDC ±10%?
• Procedure
Y N
Check that light from the Creaser M6 Trigger Sensor (Q4) LED reaches
the Creaser M6 Trigger Sensor (Q4) Photo transistor. Repair wire harness
Connect plug / jack Q4 Phototransistor at the Creaser M6 Trigger Sensor (Q4) Phototransistor
The light should be visible through the Creaser M6 Trigger Sensor (Q4) Photo transistor PCB.
The Creaser M6 Trigger Sensor (Q4) works OK?
The light should also be visible through the gap in-between the creaser tools. Y N
There is light. Replace Creaser M6 Trigger Sensor (Q4) Phototransistor (REP 12.51)
Y N The Creaser M6 Trigger Sensor (Q4) works OK?
Disconnect H.P1 from Stepper Motor Driver (M6) PCB “H”. Y N
Check for voltage between pins H.J1-8 and H.J.1-6 (5V and Ground). Replace Stepper Motor Driver (M6) PCB “H”
The voltage is 5 VDC ±10%. (REP 13.30 Stepper Motor Driver (M6) PCB “H”)
Exit
Y N
Exit
Replace Stepper Motor Driver (M6) PCB “H”
(REP 13.30 Stepper Motor Driver (M6) PCB “H”)

Disconnect plug / jack Q4 LED at the Creaser M6 Trigger Sensor (Q4) LED.
Check for continuity / short circuit between the black wire at plug Q4 LED and H.P1-6.
Check for continuity / short circuit between the red wire at plug Q4 and H.P1-8.
There is continuity and no short circuit?
Y N

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Creaser Tools M6 Home Sensor CT-Q5 RAP
This RAP is for troubleshooting the Creaser Tools M6 Home Sensor CT-Q5.

Initial Actions
• Enter Service (GP 1)
• Check sensor Q5 according to GP4
• Ensure that the Creaser Tools M6 Home Sensor CT-Q5 (PL 12.33) is clean.
• Ensure that the Creaser Tools M6 Home Sensor CT-Q5 is properly connected.
• Ensure that plug H, P1 on Stepper Motor Driver PCB “H” is connected.

Procedure
• Disconnect plug H. P1 from Stepper Motor Driver PCB “H”.
• Measure between pins H.J1-5 and H.J1-3 (5V and Ground).
The voltage is 5 VDC ±10%?
Y N
Replace Stepper Motor Driver (M6) PCB “H” (REP 13.30 Stepper Motor Driver (M6) PCB “H”)
• Disconnect plug Q5 from Creaser Tools M6 Home Sensor (Q5).
• Check wire for continuity / short circuit from the white wire at plug Q5 to H.P1-4.
• Check wire for continuity / short circuit from the black wire at plug Q5 to H.P1-3.
• Check wire for continuity / short circuit from the red wire at plug Q5 to H.P1-5.
There is continuity and no short circuit?
Y N
Repair wire harness
Connect plug H, P1 from Stepper Motor Driver (M6) PCB “H”.
Check for voltage at the P/J Q5 connector between pins 1 (red wire, 5 V) and 3 (black wire, Ground)
The voltage is 5 VDC ±10%?
Y N
Repair wire harness
Replace the Creaser Tools M6 Home Sensor (Q5) (REP 12.52)
The Creaser Tools M6 Home Sensor (Q5) works OK?
Y N
Replace Stepper Motor Driver (M6) PCB “H” (REP 13.30 Stepper Motor Driver (M6) PCB “H”)
Exit

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Bleed Trimmer M7 Home Sensor CT-Q6 RAP
This RAP is for troubleshooting the Bleed Trimmer M7 Home Sensor CT-Q6.

Initial Actions
• Enter Service (GP 1)
• Check sensor CT-Q6 according to GP4
• Ensure that the Bleed Trimmer M7 Home Sensor CT-Q6 (PL 12.39) is clean.
• Ensure that the Bleed Trimmer M7 Home Sensor CT-Q6 is properly connected.
• Ensure that plug C.P1 on Stepper Motor Driver PCB “C” is connected.

Procedure
• Disconnect plug C. P1 from Stepper Motor Driver (M7) PCB “C”.
• Measure between pins C.J1-2 and C.J1-3 (5V and Ground).
The voltage is 5 VDC ±10%?
Y N
Replace Stepper Motor Driver (M7) PCB “C” (REP 13.25 Stepper Motor Driver (M7) PCB “C”)
• Disconnect plug Q6 from Bleed Trimmer M7 Home Sensor (Q6).
• Check wire for continuity / short circuit from the white wire at plug Q6 to C.P1-4.
• Check wire for continuity / short circuit from the black wire at plug Q6 to C.P1-3.
• Check wire for continuity / short circuit from the red wire at plug Q6 to C.P1-2.
There is continuity and no short circuit?
Y N
Repair wire harness
Connect plug C.P1 from Stepper Motor Driver (M7) PCB “C”.
Check for voltage at the P/J Q6 connector between pins 1 (red wire, 5 V) and 3 (black wire, Ground)
The voltage is 5 VDC ±10%?
Y N
Repair wire harness
Replace the Bleed Trimmer M7 Home Sensor (Q6) (REP 13.3)
The Bleed Trimmer M7 Home Sensor (Q6) works OK?
Y N
Replace Stepper Motor Driver (M7) PCB “C” (REP 13.25 Stepper Motor Driver (M7) PCB “C”)
Exit

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Exit Sensor CT-Q7 RAP
This RAP is for troubleshooting the Paper Exit Sensor CT-Q7.

Initial Actions
• Enter Service (GP 1)
• Check sensor Q7 according to GP4
• Ensure that the Paper Exit Sensor CT-Q7 (PL 12.16) is clean.
• Ensure that plug / jack Q7 at the Paper Exit Sensor CT-Q7 is properly connected.
• Ensure that plug A.P1 on CPU/Controller PCB “A” (PL 12.12) is properly connected.

Procedure
• Disconnect plug A.P1 from CPU/Controller PCB A.
• Measure between pins A.J.1-4 and A.J.1-6 (5V and Ground).
The voltage is 5 VDC ±10%?
Y N
Replace CPU / Controller PCB “A” (REP 13.23 CPU / Controller PCB “A”)
• Disconnect plug Q7 from Paper Exit Sensor (Q7).
• Check wire for continuity / short circuit from the white wire at plug Q7 to A.P1-5.
• Check wire for continuity / short circuit from the black wire at plug Q7 to A.P1-6.
• Check wire for continuity / short circuit from the red wire at plug Q7 to A.P1-4.
There is continuity and no short circuit?
Y N
Repair wire harness
• Connect plug A.P1 to CPU/Controller PCB A.
• Check for voltage at the P/J Q7 connector between pins 1 (red wire, 5 V) and 3 (black wire, Ground)
The voltage is 5 VDC ±10%?
Y N
Repair wire harness
Replace Paper Exit Sensor Q7 (REP 12.7)
The Paper Exit Sensor (Q7) works OK?
Y N
Replace CPU / Controller PCB “A” (REP 13.23 CPU / Controller PCB “A”)
Exit

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“Close Cover(s)”. Slide Door Interlock Switch CT-Q8/SW2 and/or Top Cover
Interlock Switch CT-Q9/SW3 Not activated
Follow this RAP if the ”Close Cover(s) message remains after
the Slide Door Interlock Switch CT-Q8 and Top Cover Interlock Switch CT-Q9 are activated by closed covers.

Initial Actions
Check whether it is the Slide Door Switch, the Top Cover Switch or both Switches
that are indicated as open in the machine mimic on the UI.

Procedure
• Enter Service (GP 1)
• Go to Sensors (GP4).
• Open both Covers and activate both Interlock switches with cheaters.

The Switch(es) indicate activated (1) state?

Y N
Go to Slide Door Interlock Switch (Q8/SW2) (REP 12.5) and/or
Top Cover Interlock Switch (Q9/SW3) RAP
• Go to corresponding cover(s) REP’s:
• Top Cover Assembly REP 12.3
• Interlock Switch Assembly Top Cover (REP 12.4)
• Interlock Switch Slide Door (REP 12.5)
• ADJ 12.6 Interlock Switch Slide Door

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Slide Door Interlock Switch CT-Q8 RAP
This RAP is for troubleshooting the Slide Door Interlock Interlock Switch CT-Q8.

Initial Actions
• Enter Service (GP 1)
• Check sensor Q8 according to GP4
• Ensure that the Slide Door Interlock Switch Q8/SW2 (PL 12.7) is
correctly installed and connected.
See Slide Door Interlock Switch (Q8/SW2) (REP 12.5) and
ADJ 12.6 Interlock Switch Slide Door
• Ensure that P/J 30 is properly connected
• Ensure that plug A.P1 on CPU / Controller PCB “A” (PL 12.12) is connected
• Ensure that plug G.P1 is connected

• Ensure that plug G, P2 and A.P15 is connected

Procedure
• Replace Slide Door Interlock Switch (Q8/SW2)
• Disconnect A.P1 from CPU/Controller PCB A. Measure between J.1-8 and J.1-12 (5V and Ground).
The voltage is 5 VDC ±10%?
Y N
Replace Controller/CPU PCB “A” REP (13.50)
• Disconnect terminal 3 (white wire) and terminal 4 (black wire) from Interlock Switch Q8.
• Check wire for continuity / short circuit from the white wire Terminal 3 to A.P1-8.

There is continuity and no short circuit?

Y N
Repair wire harness
• Connect plug A.P1 to CPU/Controller PCB “A”.
• Measure between the white wire Q8 and the black wire Q8 (5 V and Ground).

The voltage is 5 VDC ±10%?

Y N
Repair wire harness
Replace CPU/ Controller PCB “A” (REP 13.23 CPU / Controller PCB “A”).

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Top Cover Interlock Switch (Q9/SW3) RAP
This RAP is for troubleshooting the Top Cover Interlock Switch CT-Q9.

Initial Actions
• Enter Service (GP 1)
• Check sensor Q9 according to GP4
• Ensure that the Top Cover Interlock Switch CT-Q9/CT-SW3 (PL 12.6) is correctly installed and connected.
(REP 12.4 Interlock Switch Assy Top Cover CT-SW3 (CT-Q9)& Main power switch CT-SW1)
• Ensure that P/J 30 is properly connected
• Ensure that plug A.P1 on CPU/Controller PCB “A” (PL 12.12) is connected
• Ensure that plug G.P1 is connected

• Ensure that plug G, P2 and A.P15 is connected

Procedure
• Replace Interlock Switch Assembly Top Cover (REP 12.4).
• Disconnect A.P1 from CPU/Controller PCB A.
• Measure between J.1-11 and J.1-9 (5V and Ground).

The voltage is 5 VDC ±10%?

Y N
Replace CPU/ Controller PCB “A” (REP 13.23 CPU / Controller PCB “A”).
• Disconnect terminal 3 (white wire) and terminal 4 (black wire) from Interlock Sensor Q9.
• Check wire for continuity / short circuit from the white wire Terminal 3 to A.P.1-11.

There is continuity and no short circuit?

Y N
Repair wire harness
• Connect plug A.P1 to CPU/Controller PCB “A”.
• Measure between the white wire Q9 and the black wire Q9 (5 V and Ground).

The voltage is 5 VDC ±10%?

Y N
Repair wire harness
Replace CPU/Controller PCB “A” (REP 13.23 CPU / Controller PCB “A”).

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Registration Solenoid SOL5 Trigger Sensor CT-Q10 RAP
This RAP is for troubleshooting the Registration Solenoid SOL 5 Trigger Sensor CT-Q10.

Initial Actions
• Enter Service (GP 1).
• Check sensor Q10 according to GP4
• Ensure that the Registration Solenoid SOL 5 Trigger Sensor CT-Q10 (PL 12.20) is clean.
• Ensure that plug / jack Q10 at the Registration Solenoid SOL 5 Trigger Sensor (Q10) is properly connected
(REP 13.22 Registration Solenoid SOL5 Trigger Sensor (CT-Q10)).
• Ensure that plug A.P1 on CPU/Controller PCB “A” (PL 12.12) is properly connected.
• Ensure that plug / jack 32 is properly connected (WD CT P/J 32)

Procedure
• Disconnect plug A.P1 from CPU/Controller PCB “A”.
• Measure between pin A.J1-7 and A.J1-22 (5V and Ground).
The voltage is 5 VDC ±10%?
Y N
Replace CPU / Controller PCB “A” (REP 13.23 CPU / Controller PCB “A”)
• Disconnect plug Q10 from Registration Solenoid SOL 5 Trigger Sensor (Q10).
• Check wire for continuity / short circuit from the white wire at plug Q10 to A.P1-21.
• Check wire for continuity / short circuit from the black wire at plug Q10 to A.P1-22.
• Check wire for continuity / short circuit from the red wire at plug Q10 to A.P1-7.
There is continuity and no short circuit?
Y N
Repair wire harness
• Connect plug A.P1 to CPU/Controller PCB “A”.
• Check for voltage at the P/J Q10 connector between pins 1 (red wire, 5 V) and 3 (black wire, Ground)
The voltage is 5 VDC ±10%?
Y N
Repair wire harness
Replace Registration Solenoid SOL5 Trigger Sensor (CT-Q10) (REP 13.22)
The Registration Solenoid SOL 5 Trigger Sensor (Q10) works OK?
Y N
Replace CPU / ControllerPCB “A” (REP 13.23 CPU / Controller PCB “A”)
Exit

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Waste Transport Sensor CT-Q14 RAP
This RAP is for troubleshooting Waste Transport Sensor CT-Q14.

Initial Actions
• Enter Service (GP 1)
• Check sensor CT-Q6 according to GP4
• Ensure that the Waste Transport Sensor CT-Q14 (PL 12.10) is clean.
• Ensure that the Waste Transport Sensor CT-Q14 is properly connected.
• Ensure that plug D, P1 on Stepper Motor Driver (M4) PCB “D” is connected.

Procedure
• Disconnect plug D. P1 from Stepper Motor Driver (M4) PCB “D”.
• Measure between pins D.J1-9 and D.J.1-10 (5V and Ground).
The voltage is 5 VDC ±10%?
Y N
Replace Stepper Motor Driver (M4) PCB “D” (REP 13.26 Stepper Motor Driver (M4) PCB “D”)
• Disconnect plug Q14 from Waste Transport Sensor (Q14).
• Check wire for continuity / short circuit from the white wire at plug Q14 to D.P.1-11.
• Check wire for continuity / short circuit from the black wire at plug Q14 to D.P.1-10.
• Check wire for continuity / short circuit from the red wire at plug Q14 to D.P1-9.
There is continuity and no short circuit?
Y N
Repair wire harness
• Connect plug D, P1 to Stepper Motor Driver (M4) PCB “C”.
• Check for voltage at the P/JQ14 connector between pins 1 (red wire, 5 V) and 3 (black wire, Ground)
The voltage is 5 VDC ±10%?
Y N
Repair wire harness
Replace the Waste Transport Sensor (Q14) (REP 12.24)
The Waste Transport Sensor (Q14) works OK?
Y N
Replace Stepper Motor Driver (M4) PCB “D” (REP 13.26 Stepper Motor Driver (M4) PCB “D”)
Exit

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CPU / Controller PCB “A” RAP
This RAP is for troubleshooting the CPU / Controller PCB ”A” .

Initial Actions
• Ensure that all connectors to CPU / Controller PCB “A” are (PL 12.12) properly connected
(REP 13.23 CPU / Controller PCB “A”).
• Ensure that the End Termination plug J.P6 (PL 12.12) is connected to J.J6
• Ensure that the End Termination plug E.P6 (PL 12.12) is connected to E.J6

Procedure
Measure voltage between A.P2-4 andA.P2-5 (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Disconnect plugA.P2.
Measure voltage between A.P2-4 andA.P2-5 (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Measure voltage between K,J.2-2 and K,J.2-4 (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Go to 12V Power Supply Unit RAP
Repair harness
Go to Solenoid Driver PCB “B” RAP
Replace PCB “A” Controller (REP 13.23 CPU / Controller PCB “A”)

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 Y N
Solenoid Driver PCB “B” RAP

This RAP is for troubleshooting the Solenoid Driver PCB ”B”.
Measure voltage between M.P2-2 and M.P2-8 (24V and Ground).
Initial Actions
The voltage is 24 VDC ±10%.
• Ensure that all connectors to Solenoid Driver PCB “B” (PL 12.13) are properly connected
Y N
(REP 13.24 Solenoid Driver PCB “B”).
Go to 24V Power Supply Unit (1) RAP
• Ensure that the dipswitches on the PCB are set according to
REP 13.24 ). Repair harness
• Ensure that the End Termination Plug J.P6 (PL 12.12) is connected to J.J6 Replace Solenoid Driver PCB “B” (REP 13.24 Solenoid Driver PCB “B”)
• Ensure that the End Termination Plug E.P6 (PL 12.12) is connected to E.J6 Replace Solenoid Driver PCB “B” (REP 13.24 Solenoid Driver PCB “B”)

Procedure
Measure voltage between B.P4-4 and B.P4-5 (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Disconnect plug B.P5.
Measure voltage between B.P4-4 and B.P4-5 (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Disconnect plug A.P3.
Measure voltage between A.J.3-4 and A.J3-5 (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Go to CPU / Controller PCB “A” RAP
Repair harness
Go to Stepper Motor Driver (M7) PCB “C” RAP
Measure voltage between B.P11-1 and B.P11-2 (24V and Ground).
The voltage is 24 VDC ±10%.
Y N
Disconnect plug B.P11.
Measure voltage between B.P11-1 and B.P11-2 (24V and Ground).
The voltage is 24 VDC ±10%.

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Stepper Motor (M7) Driver PCB “C” RAP
The voltage is 48 VDC ±10%.
This RAP is for troubleshooting the Stepper Motor Driver (M7) PCB ”C”.
Y N
Initial Actions
Measure voltage between N.P2-1 and M.P2-9 (48V and Ground).
• Ensure that all connectors to Stepper Motor (M7) Driver PCB “C” (PL 12.12) are
properly connected (REP 13.25 Stepper Motor Driver (M7) PCB “C”). The voltage is 48 VDC ±10%.

• Ensure that the dipswitches on the PCB are set according to (REP 13.25). Y N

• Ensure that the End Termination Plug J.P6 (PL 12.12) is connected to J.J6 Go to 24V Power Supply Unit (2) RAP

• Ensure that the End Termination Plug E.P6 (PL 12.12) is connected to E.J6 Repair harness
Replace Stepper Motor Driver (M7) PCB “C”
Procedure (REP 13.25 Stepper Motor Driver (M7) PCB “C”)
Measure voltage between C.P5-4 and C.P5-5 (12V and Ground). Go to Stepper Motor Driver (M4) PCB “D” RAP
The voltage is 12 VDC ±10%.
Y N
Disconnect plug C.P6.
Measure voltage between C.P5-4 and C.P5-5 (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Disconnect plug B.P5.
Measure voltage between B.J5-4 and B.J5-5 (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Go to Solenid Driver PCB ”B” RAP
Repair harness
Go to Stepper Motor Driver (M4) PCB “D” RAP
Measure voltage between C.J5-1 and C,J.3-2 (48V and Ground).
The voltage is 48 VDC ±10%.
Y N
Disconnect plug C.P4.
Measure voltage between C.P3-1 and C.P3-2 (48V and Ground).
The voltage is 48 VDC ±10%.
Y N
Disconnect plug C.P3.
Measure voltage between C.P3-1 and C.P3-2 (48V and Ground).

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Stepper Motor Driver (M4) PCB “D” RAP

This RAP is for troubleshooting the Stepper Motor Driver (M4) PCB ”D”.
Measure voltage between C.J4-1 and C.J4-2 (48V and Ground).
Initial Actions
The voltage is 48 VDC ±10%.
• Ensure that all connectors to Stepper Motor Driver PCB “D” (PL 12.13) are
properly connected (REP 13.26 Stepper Motor Driver (M4) PCB “D”). Y N

• Set the dipswitches on the PCB according to (REP 13.26 Stepper Motor Driver (M4) PCB “D”). Go to Stepper Motor Driver (M7) driver PCB “C” RAP

• Ensure that the End Termination Plug J.P6 (PL 12.6) is connected to J.J6 Repair harness

• Ensure that the End Termination Plug E.P6 (PL 12.6) is connected to E.J6 Replace Stepper Motor Driver (M4) PCB “D”
(REP 13.26 Stepper Motor Driver (M4) PCB “D”)
Procedure
Go to Stepper Motor Driver (M1) PCB “E” RAP
Measure voltage between D.P5-4 and D.P5-5 (12V and Ground).
Replace Stepper Motor Driver (M4) PCB “D” (REP 13.26 Stepper Motor Driver (M4) PCB “D”)
The voltage is 12 VDC ±10%.
Y N
Disconnect plug D.P6.
Measure voltage between D.P5-4 and D.P5-5 (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Disconnect plug C.P6.
Measure voltage between C.J6-4 and C.J6-5 (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Go to Stepper Motor Driver (M7) PCB “C” RAP
Repair harness
Go to Stepper Motor Driver (M1) PCB “E” RAP
Measure voltage between D.J3-1 and D.J.3-2 (48V and Ground).
The voltage is 48 VDC ±10%.
Y N
Disconnect plug D.P4.
Measure voltage between D.P3-1 and D.P3-2 (48V and Ground).
The voltage is 48 VDC ±10%.
Y N
Disconnect plug D.P3.
Measure voltage between D.P3-1 and D.P3-2 (48V and Ground).
The voltage is 48 VDC ±10%.
Y N

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Stepper Motor Driver (M1) PCB “E” RAP
This RAP is for troubleshooting the Stepper Motor Driver (M1) PCB ”E”.

Initial Actions
• Ensure that all connectors to Stepper Motor Driver (M1) PCB “E” (PL 12.13) are
properly connected (REP 13.27 Stepper Motor Driver (M1) PCB “E”).
• Set the dipswitches on the PCB according to (REP 13.27 Stepper Motor Driver (M1) PCB “E”).
• Ensure that the End Termination Plug J.P6 (PL 12.6) is connected to J.J6
• Ensure that the End Termination Plug E.P6 (PL 12.6) is connected to E.J6

Procedure
Measure voltage between E.P5-4 and E.P5-5 (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Disconnect plug D.P6.
Measure voltage between D.J6-4 and D.J6-5 (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Go to Stepper Motor Driver (M4) PCB “D” RAP
Repair harness
Measure voltage between E.J3-1 and E.J.3-2 (48V and Ground).
The voltage is 48 VDC ±10%.
Y N
Disconnect plug E.P3.
Measure voltage between D.P3-1 and D.P3-2 (48V and Ground).
The voltage is 48 VDC ±10%.
Y N
Measure voltage between D.J4-1 and D.J4-2 (48V and Ground).
The voltage is 48 VDC ±10%.
Y N
Go to Stepper Motor Driver (M4) PCB “D” RAP
Repair harness
Replace Stepper Motor Driver (M1) PCB “E” (REP 13.27 Stepper Motor Driver (M1) PCB “E”)
Replace Stepper Motor Driver (M1) PCB “E” (REP 13.27 Stepper Motor Driver (M1) PCB “E”)

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I/O Extension PCB “G” RAP
This RAP is for troubleshooting the I/O Extension PCB ”G”.

Initial Actions
Ensure that all connectors to I/O Extension PCB “G” (PL 12.12) are properly connected (REP 13.29 I/O Extension PCB “G”)

Procedure
• Replace Extension PCB “G” I/O (REP 13.29).
• Enter Service (GP 1).
• Check Sensor CT-Q10 (PL 12.20) according to GP4.
• Check Sensor CT-Q11 (PL 12.10) according to GP4.
• Check Solenoid CT-REL1 (PL 12.8) (Interlock relay) according to GP4.
• Check Solenoid CT-REL2 (PL 12.20) (Optional Antistatic Kit) according to GP4.
• Check Solenoid CT-REL3 (PL 12.20) (Optional Antistatic Kit) according to GP4.
• Check Solenoid CT-COUNTER (PL 12.11) according to GP4.
All listed components operate OK.
Y N
• Replace Ribbon Cable between A.P15 and G.P2 (PL 12.12).
• Enter Service (GP 1).
• Check Sensor CT-Q10 (PL 12.20) according to GP4.
• Check Sensor CT-Q11 (PL 12.10) according to GP4.
• Check Solenoid CT-REL1 (PL 12.8) (Interlock relay) according to GP4.
• Check Solenoid CT-REL2 (PL 12.20) (Optional Antistatic Kit) according to GP4.
• Check Solenoid CT-REL3 (PL 12.20) (Optional Antistatic Kit) according to GP4.
• Check Solenoid CT-COUNTER (PL 12.5) according to GP4.

All listed components operate OK.

Y N
Replace Controller PCB “A” PL 12.12 (REP 13.23 CPU / Controller PCB “A”).
Exit
Exit

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Stepper Motor Driver (M6) PCB “H” RAP
This RAP is for troubleshooting the Stepper Motor Driver (M6) PCB ”H”.

Initial Actions The voltage is 48 VDC ±10%.

• Ensure that all connectors to Stepper Motor Driver (M6) PCB “H” (PL 12.21) are Y N
properly connected (REP 13.30 Stepper Motor Driver (M6) PCB “H”).
Measure voltage between N.P2-2 and M.P2-10 (48V and Ground).
• Set the dipswitches on the PCB according to (REP 13.30 Stepper Motor Driver (M6) PCB “H”).
The voltage is 48 VDC ±10%.
• Ensure that the End Termination Plug J.P6 (PL 12.6) is connected to J.J6
Y N
• Ensure that the End Termination Plug E.P6 (PL 12.6) is connected to E.J6
Go to 24V Power Supply Unit (2) RAP
Procedure
Repair harness
Measure voltage between H.P5-4 and H.P5-5 (12V and Ground).
Replace Stepper Motor Driver (M6) PCB “H”
The voltage is 12 VDC ±10%. (REP 13.30 Stepper Motor Driver (M6) PCB “H”)
Y N Go to Stepper Motor Driver (M3) PCB “J” RAP
Disconnect plug H.P6. Replace Stepper Motor Driver (M6) PCB “H” (REP 13.30 Stepper Motor Driver (M6) PCB “H”)
Measure voltage between H.P5-4 and H.P5-5 (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Disconnect plug H.P5.
Measure voltage between K.P2-1 and K.P2-3 (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Go to 12V Power Supply Unit RAP
Repair harness
Go to Stepper Motor Driver (M3) PCB “J” RAP
Measure voltage between H.J3-1 and H,J.3-2 (48V and Ground).
The voltage is 48 VDC ±10%.
Y N
Disconnect plug H.P4.
Measure voltage between H.P3-1 and H.P3-2 (48V and Ground).
The voltage is 48 VDC ±10%.
Y N
Disconnect plug H.P3.
Measure voltage between H.P3-1 and H.P3-2 (48V and Ground).

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Stepper Motor Driver (M3) PCB “J” RAP
This RAP is for troubleshooting the Stepper Motor Driver (M3) PCB ”J”.

Initial Actions
• Ensure that all connectors to Stepper Motor Driver (M3) PCB “J” (PL 12.29) are
properly connected (REP 13.31 Stepper Motor Driver (M3) PCB “J”).
• Ensure that the dipswitches on the PCB are set according to (REP 13.31 Stepper Motor Driver (M3) PCB “J”).
• Ensure that the End Termination Plug J.P6 (PL 12.6) is connected to J.J6
• Ensure that the End Termination Plug E.P6 (PL 12.6) is connected to E.J6

Procedure
Measure voltage between J.P5-4 and J.P5-5 (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Disconnect plug H.P6.
Measure voltage between H.J6-4 and H.J6-5 (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Go to Stepper Motor Driver (M6) PCB “H” RAP
Repair harness
Measure voltage between J.J3-1 and J.J.3-2 (48V and Ground).
The voltage is 48 VDC ±10%.
Y N
Disconnect plug J.P3.
Measure voltage between J.P3-1 and J.P3-2 (48V and Ground).
The voltage is 48 VDC ±10%.
Y N
Measure voltage between H.J4-1 and H.J4-2 (48V and Ground).
The voltage is 48 VDC ±10%.
Y N
Go to Stepper Motor Driver (M4) PCB “H” RAP
Repair harness
Replace Stepper Motor Driver (M3) PCB “J” (REP 13.31 Stepper Motor Driver (M3) PCB “J”)
Replace Stepper Motor Driver (M3) PCB “J” (REP 13.31 Stepper Motor Driver (M3) PCB “J”)

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SCP (Short Circuit Protection) PCB “K” RAP
• This RAP is for troubleshooting the SCP (Short Circuit Protection) ”K” PCB.
• If this RAP frequently ends up with blown F1,
check the primary harness for a short circuit and repair it, Y N
if you can’t find a short circuit in the primary harness replace the 12V PSU
(REP 13.36 12V Power Supply Unit). Replace SCP (Short Circuit Protection) PCB “K”

Initial Actions Locate the short circuit in the harness related to K.P2-2 and repair it
Locate the short circuit in the harness related to K.P2-1 and repair it.
• Ensure that all connectors to SCP (Short Circuit Protection) PCB “K” (PL 12.17) are
properly connected (REP 13.32).
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E” PCBs are properly connected (See Section 8).
• Ensure that plugs/jacks P29/J29, P30/J30, P25/J25, P26/J26, P28/J28, P31/J31 and P32/J32
are properly connected.
• Ensure that all connectors connecting to REL1 (PL 12.8) are properly connected.

Procedure
Measure voltage between K.P.1-1 and K.P1-2 (12V and Ground, input).
The voltage is 12 VDC ±10%.
Y N
Measure the voltage between +V and –V at 12V PSU (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Power off, disconnect K.P1, power on and measure between K.P.1-1
and K.P1-2.
The voltage is 12VDC ±10%.
Y N
Go to 12V Power Supply Unit RAP
Replace SCP (Short Circuit Protection) PCB “K”.
Repair harness between 12V PSU and SCP (Short Circuit Protection) PCB “K”.
• Power off the machine.
• Activate Slide Door Interlock Switch (SW2) (PL 12.3) and Top Cover Interlock Switch (SW3) (PL 12.3).
• Disconnect K.P2 and measure resistance between K.P2-1 and chassis.
Resistance <=500kohm.
Y N
Measure resistance between K.P2-2 and chassis.
Resistance <=100kohm.

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SCP (Short Circuit Protection) PCB “L” RAP
This RAP is for troubleshooting the SCP (Short Circuit Protection) PCB ”L”. Replace SCP (Short Circuit Protection) PCB “L”
If this RAP frequently ends up with blown F1, Locate the short circuit in the harness related to L.P2-2 and repair it.
check the primary harness for a short circuit and repair it,
if you can’t find a short circuit in the primary harness replace the 12V PSU. Locate the short circuit in the harness related to L.P2-1 and repair it
REP 13.36 12V Power Supply Unit.

Initial Actions
• Ensure that all connectors to SCP (Short Circuit Protection) PCB “L” (PL 12.17) are
properly connected (REP 13.33 SCP (Short Circuit Protection) PCB “L”).
• Ensure that all connectors to “H”, PCB “J” s are properly connected (See Section 8).
• Ensure that plugs/jacks P29/J29, P30/J30, P25/J25, P26/J26, P28/J28, P31/J31 and
P32/J32 are properly connected.
• Ensure that all connectors connecting to REL1 (PL 12.8) are properly connected.

Procedure
Measure voltage between L.P.1-1 and L.P1-2 (12V and Ground, input).
The voltage is 12 VDC ±10%.
Y N
Measure the voltage between +V and –V at 12V PSU (12V and Ground).
The voltage is 12 VDC ±10%.
Y N
Power off, disconnect L.P1, power on and
measure between L.P.1-1 and L.P1-2.
The voltage is 12VDC ±10%.
Y N
Go to 12V Power Supply Unit RAP
Replace SCP (Short Circuit Protection) PCB “L”.
Repair harness between 12V PSU and “L” SCP (Short Circuit Protection) PCB.
Power off the machine.
Disconnect L.P2 and measure resistance between L.P2-1 and chassis.
Resistance <=500kohm.
Y N
Measure resistance between L.P2-2 and chassis.
Resistance <=100kohm.
Y N

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 12V Power Supply Unit RAP
This RAP is for troubleshooting the 12V Power Supply Unit.
If this RAP frequently ends up with blown F1,
check the primary harness for a short circuit and repair it, Power off the machine.
if you can’t find a short circuit in the primary harness replace the 12V PSU (PL 12.8) (REP13.37) Disconnect K.P1 and L.P1 and red and black wires from the 12V PSU.
Measure the resistance between red wires and chassis.
Initial Actions
Resistance <=500kohm.
• Ensure that all connectors to SCP (Short Circuit Protection) PCB “K” are
properly connected (REP 13.32). Y N

• Ensure that all connectors to SCP (Short Circuit Protection) PCB “L” are Replace 12V PSU (REP 13.36)
properly connected (REP 13.33).
Repair harness between 12V PSU and SCP (Short Circuit Protection) ”K” PCB
• Ensure that plugs/jacks P29/J29, P30/J30, P25/J25, P26/J26, P28/J28, P31/J31 and and/or SCP (Short Circuit Protection) ”L” PCB.
P32/J32 are properly connected.
• Ensure that all connectors connecting to REL1 (PL 12.8) are properly connected.

WARNING!
Use caution when making the voltage measurements and always disconnect the Power
Cord when it is necessary to work inside the Power Module. AC Power is present in the Line
Module whenever the Power Cord is plugged into the Wall Outlet.

Procedure
Measure voltage between L and N on the 12V PSU (90-264VAC).
Caution, mains voltage!
The voltage is 90-264VAC.
Y N
Very Important! Failure to disconnect will result in damage to meter.
Disconnect the main power cordbut leave the AC Power Switch (SW1) on.
Measure the resistance between L (brown wire) on the 12V PSU and
outgoing black,1 wire from the Power Entry.
There is continuity.
Y N
Repair harness and / or check / replace AC Power Switch (SW1).
Measure the resistance between N (blue wire) on the 12V PSU and
outgoing black,2 wire from the Power Entry.
There is continuity.
Y N
Repair harness
Replace F1 (PL 12.5).

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 24V Power Supply Unit (1) RAP
This RAP is for troubleshooting the 24V Power Supply Unit (1).
If this RAP frequently ends up with blown F1, check the primary harness for a short circuit and repair it,
if you can’t find a short circuit in the primary harness replace the 24V PSU (REP 13.38) (PL 12.REP
13.38).

Initial Actions
• Ensure that plugs/jacks P29/J29, P30/J30, P25/J25, P26/J26, P28/J28, P31/J31 and P32/J32 are
properly connected.
• Ensure that all connectors connecting to REL1 (PL 12.8) are properly connected.
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N” PCBs are
properly connected (See Section 8).

Procedure
Activate the interlock relay (REL1) in component control GP4. Ensure Slide Door Interlock Switch (SW2)
(PL 12.3) and Top Cover Interlock Switch (SW3)(PL 12.3) are activated.
REL1 activated (look at relay contacts position (REP 13.40 Interlock Relay (CT_REL1)).
Y N
Go to Interlock Relay Circuit (REL1) RAP
Measure voltage between M,P.1-1 and M.P1-3 (24V and Ground, input).
The voltage is 24 VDC ±10%.
Y N
Measure the voltage between +V and –V on the 24V PSU (24V and Ground).
The voltage is 24 VDC ±10%.
Y N
Warning!
Use caution when making the voltage measurements and always
disconnect the Power Cord when it is necessary to work inside the
Power Module. AC Power is present in the Line Module whenever
the Power Cord is plugged into the Wall Outlet.
Measure voltage between L and N on the 24V PSU (90-264VAC),
caution, main voltage!
The voltage is 90-264VAC.
Y N
Very Important! Failure to disconnect will result in
damage to meter.
Disconnect the main power cord but leave the AC Power Switch (SW1) on.
Measure the resistance between L (brown wire) on the 24V PSU and
REL 1-34(brown wire).
There is continuity.
Y N
Repair harness and / or check / replace
A B C D AC Power Switch (SW1).

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24V Power Supply Unit (1) RAP, continued
E
A B C D
Locate the short circuit in the harness related to M.P2-1 and repair it.
Measure the resistance between REL1-31 (brown wire) and
outgoing black,1 wire from the Power Entry.
There is continuity.
Y N
Repair harness
Measure the resistance between N (blue wire) on the 24V
PSU and REL1-14 (blue wire).
There is continuity.
Y N
Repair harness
Measure the resistance between REL1-11 (blue wire) and
outgoing black,2 wire from the Power Entry.
There is continuity.
Y N
Repair harness
Replace F1 (PL 12.5).
Power off, disconnect M.P1, power on and measure
between M,P.1-1 and M.P1-3.
The voltage is 24 VDC ±10%.
Y N
Disconnect M.P1, and red and black wires from the 24V PSU.
Measure the resistance between red wires and chassis.
Resistance <=500kohm.
Y N
Replace 24V Power Supply Unit (1) (REP 13.38).
Repair harness between 24V Power Supply Unit (1)
and PCB “M” (PL 12.8).
Replace SCP (Short Circuit Protection) PCB “M” (REP 13.34).
Repair harness between 24V Power Supply Unit (1) (PL 12.8) and
SCP (Short Circuit Protection) PCB “M” (PL 12.17) .
Power off the machine.
Disconnect M.P2 and measure resistance between M.P2-1 and chassis.
Resistance <=100kohm.
Y N
Measure resistance between M.P2-2 and chassis.
Resistance <=100kohm.
Y N
Replace SCP (Short Circuit Protection) PCB “M” (REP 13.34).

E Locate the short circuit in the harness related to M.P2-2 and repair it.

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24V (48V) Power Supply Unit (2) RAP
This RAP is for troubleshooting the 24 V (48V) Power Supply Unit (2).
A B C D
If this RAP frequently ends up with blown F1, check the primary harness for a short circuit
and repair it, if you can’t find a short circuit in the primary harness replace the 24V(48V) Measure the resistance between REL1-31 (brown wire) and
PSU (2) (PL 13.38). outgoing black,1 wire from the Power Entry.
There is continuity.
Initial Actions
Y N
• Ensure that plugs/jacks P29/J29, P30/J30, P25/J25, P26/J26, P28/J28, P31/J31 and P32/ Repair harness
J32 are properly connected. Measure the resistance between N (blue wire) on the
• Ensure that all connectors connecting to REL1 (PL 12.8) are properly connected. 24V(48V) Power Supply Unit (2) and REL1-14 (blue wire).
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N” PCBs There is continuity.
are properly connected (See Section 8). Y N
Procedure Repair harness
Activate the interlock relay (REL1) in component control GP4; Ensure Slide Door Interlock Measure the resistance between REL1-11 (blue wire) and
Switch (SW2) (PL 12.3) and Top Cover Interlock Switch (SW3) (PL 12.3) are activated. outgoing black,2 wire from the Power Entry.
REL1 activated (look at relay contacts position (REP 13.40 Interlock Relay (CT_REL1)) There is continuity.
Y N Y N
Go to Interlock Relay Circuit (REL1) RAP. Repair harness
Measure voltage between N.P.1-1 and N.P1-3 (+ and -, input). Replace F1 (PL 12.5)
The voltage is 24 VDC ±10%. Power off, disconnect N.P1, power on and
measure between N.P.1-1 and N.P1-3.
Y N
The voltage is 24 VDC ±10%.
Measure the voltage between +V and –V on the 24V(48V) Power Supply Unit (2)
The voltage is 24 VDC ±10%. Y N
Y N Disconnect N.P1, and red and black wires from the
24V(48V) Power Supply Unit (2).
Warning! Measure the resistance between red wires and chassis.
Use caution when making the voltage measurements and always Resistance <=500kohm.
disconnect the Power Cord when it is necessary to work inside the
Power Module. AC Power is present in the Line Module whenever Y N
the Power Cord is plugged into the Wall Outlet. Replace 24V(48V) Power Supply Unit (2) (REP 13.38).
Measure voltage between L and N on the 24V(48V) Power Supply Unit
(2) (90-264VAC), caution, main voltage! Repair harness between 24 V Power Supply Unit (2) and
The voltage is 90-264VAC. SCP (Short Circuit Protection) PCB “N” (PL 12.17).
Y N Replace “N” PCB.
Very Important! Failure to disconnect will result in Repair harness between 24V(48V) Power Supply Unit (2) and
SCP (Short Circuit Protection) PCB “N” (PL 12.17).
damage to meter.
Power off the machine. Disconnect N.P2 and M.P2.
Disconnect (very important) the main power cord but leave Measure resistance between N.P2-1 and chassis.
the AC Power Switch (SW1) on. Measure the resistance
between L (brown wire) on the 24V(48V) Power Supply Unit Resistance <=100kohm.
(2) and REL1-34 (brown wire). Y N
There is continuity. Measure resistance between N.P2-2 and chassis.
Y N Resistance <=100kohm.
Repair harness and / or check / replace AC Power Y N
A B C D Switch (SW1). E F G

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24V (48V) Power Supply Unit (2) RAP, continued Interlock Relay Circuit (REL1) RAP
E F G This RAP is for troubleshooting the Interlock Relay Circuit (REL1).
Measure resistance between N.P2-7 and M.P2-1. Initial Actions
There is continuity.
• Ensure Service Mode GP1.
Y N
• Check solenoid REL1 action according to GP4.
Repair harness between N.P2 and M.P2.
Replace SCP (Short Circuit Protection) PCB “N” (REP 13.35). • Ensure that plug/jack P29/J29 is properly connected.
Locate the short circuit in the harness related to N.P2-2 and repair it. • Ensure that connectors are properly connected to the Interlock Relay CT-REL1 (PL 12.8).
Locate the short circuit in the harness related to N.P2-1 and repair it. • Ensure that plug A.P15 and G.P2 are properly connected (PL 12.6).
• Ensure that plug G.P3 is properly connected.
• Ensure that plug K.P2 and L.P2 are properly connected (PL 12.8).
• Ensure Slide Door Interlock Switch CT-SW2 (PL 12.7) and
Top Cover Interlock Switch CT-SW3 (PL 12.6) are activated.

Procedure
Power off the machine. Remove connectors from Relay REL1 solenoid.
Measure on the contacts on the Solenoid.
There is an open circuit.
Y N
Reinstall connectors. Disconnect plug G.P3 and L.P2 from PCBs.
Measure between the white/black wire on the Relay and L.P2-1.
Ensure Slide Door Interlock Switch CT-SW2 (PL 12.7) and
Top Cover Interlock Switch CT-SW3 are activated.
There is continuity.
Y N
Measure resistance between SW2-1 and SW2-2
There is continuity.
Y N
Replace Slide Door Interlock Switch (SW2). (REP 12.5)
Measure resistance between SW3-1 and SW3-2
There is continuity.
Y N
Replace Top Cover Interlock Switch (SW3) (REP 12.4)
Measure resistance between the white wire on the solenoid and G.P3-
2.
There is continuity.
Y N
Repair Wire Harness.
Measure resistance between SW2-3 and SW2-4
A B There is continuity.

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A B
Y N
Replace Slide Door Interlock Switch (SW2) (REP 12.5)
Measure resistance between SW3-3 and SW3-4
There is continuity.
Y N
Replace Top Cover Interlock Switch (SW3) (REP 12.4).
Measure resistance between SW2-3 and A.P1-8
There is continuity.
Y N
Repair harness
Measure resistance between SW2-4 and A.P.1-12
There is continuity.
Y N
Repair harness
Measure resistance between SW3-3 and A.P.1-11
There is continuity.
Y N
Repair harness
Measure resistance between SW3-4 and A.P1-9
There is continuity.
Y N
Repair harness
Measure between REL1-A1 and REL1-A2.
Activate REL1 in component control according to GP4 .
Activate also Top Cover Interlock Switch CT-SW3 (PL 12.6) and (Slide Door Interlock Switch CT-SW2 (PL 12.7) .
There is 12VDC±10%.
Y N
Go to I/O Extension PCB ”G” RAP.
Replace Interlock Relay (REL1) (REP 13.40)
Measure between REL1-A1 and REL1-A2.
Activate REL1 in component control according to GP4 (Slide Door Interlock Switch CT-SW2 (PL 12.7).
Activate alsoTop Cover Interlock Switch CT-SW3 (PL 12.6).
There is 12VDC±10%.
Y N
Go to I/O Extension PCB “G” RAP.
Replace Interlock Relay (REL1) (REP 13.41).
Replace Interlock Relay (REL1) (REP 13.40)

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F1 Blown Fuse RAP
This RAP is for troubleshooting when F1 (PL 12.5) frequently blows up. A There is continuity.
Y N
Initial Actions
Replace the 12V Power Supply Unit (REP 13.36) and
• Ensure that plugs/jacks P29/J29, P30/J30, P25/J25, P26/J26, P28/J28, P31/J31 and P32/ replace F1 (PL 12.5).
J32 are properly connected. Repair harness and replace F1 (PL 12.5).
• Ensure that all connectors connecting to REL1 (PL 12.8) are properly connected. Power off the machine and disconnect P28. Power on the machine.
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N” PCBs Activate Slide Door Interlock Switch (SW2) (PL 12.3) and Top Cover Interlock Switch (SW3) (PL 12.3).
are properly connected (ee Section 8). Ensure CT-REL1 activates (maybe only for a short period).
Measure voltage between L (brown wire) and N (blue wire) on the 24V Power Supply Unit (1).
• Ensure that there is proper voltage at the wall outlet.
Warning! Caution when measuring the voltage measurements.
Procedure Always disconnect the Power Cord when it is necessary to work inside the
Very Important! Failure to disconnect will result in damage to meter. Power Module. AC Power is present in the Line Module whenever
the Power Cord is plugged into the Wall Outlet.
Power off the machine and disconnect the main power cord. The voltage is 90-264VAC. Caution! Main Voltage!
Replace blown up F1 (PL 12.5). Connect the main power cord do not power on the machine.
Measure voltage between L (black,1 wire) and N (black,2 wire) on the Power Entry. Y N
The voltage is 90-264VAC. Caution! Main Voltage! Very Important! Failure to disconnect will result in damage to meter.
Y N Power off the machine and disconnect the main power cord.
Disconnect Brown wire and blue wire from the 24V Power Supply Unit (1).
Power off the machine and disconnect the main power cord (very important). Perform following three resistance measurements for the disconnected wires:
Disconnect black,1 wire and black,2 wire from the Power Entry. 1. Brown wire to blue wire.
Perform following three resistance measurements for the disconnected wires: 2. Brown wire to chassis.
1. Black,1 wire to black, 2 wire. 3. Blue wire to chassis.
2. Black,1 wire to chassis. There is continuity.
3. Black,2 wire to chassis.
Y N
There is continuity.
Replace the 12V Power Supply Unit (REP 13.36) and
Y N replace F1 (PL 12.5).
Replace the Power Entry and replace F1. Repair harness and replace F1 (PL 12.5).
Repair harness and replace F1. Very Important! Failure to disconnect will result in damage to meter.
Leave SW2 and SW3 inactivated. Power on the machine. Power off the machine, disconnect the main power cord and leave P28 disconnected.
Measure voltage between L (brown wire) and N (blue wire) on the 12V Power Supply Unit. Disconnect brown wire and blue wire from the 24V(48V) Power Supply Unit (2).
Warning! Caution when measuring the voltage measurements. Perform following three resistance measurements for the disconnected wires:
Always disconnect the Power Cord when it is necessary to work inside the 1. Brown wire to blue wire.
Power Module. AC Power is present in the Line Module whenever
the Power Cord is plugged into the Wall Outlet. 2. Brown wire to chassis.
The voltage is 90-264VAC. Caution! Main Voltage! 3. Blue wire to chassis.
Y N There is continuity.
Very Important! Failure to disconnect will result in damage to meter. Y N
Power off the machine and disconnect the main power cord (very important). Replace the 24V(48V) Power Supply Unit (2) (REP 13.38) and
replace F1 (PL 12.5).
Disconnect brown wire and blue wire from the 12V Power Supply Unit.
Perform following three resistance measurements for the disconnected wires: Repair harness and replace F1 (PL 12.5).
1. Brown wire to blue wire.
2. Brown wire to chassis.
3. Blue wire to chassis.
A

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F1 Blown Fuse RAP, continued

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Antistatic Bars Waste Transport (optional) RAP Procedure
This RAP is for troubleshooting the optional Antistatic Bars in the Waste Transport Area. Power on the machine, close cover and slide door, check that REL1 activates.
REL1 activates (check connectors position).
Initial Actions Y N
• Enter Service (GP 1) Go to Interlock Relay Circuit (REL1) RAP.
• Check Interlock Relay REL1 (PL 12.8) solenoid action according to GP4 Activate REL3 in component control.
REL3 activates (check connectors position).
• Ensure that connectors are properly connected to main power Switch CT-SW1 (PL 12.6).
Y N
• Ensure that plug/jack P29/J29, P27/J27 and P34/J34 are properly connected (WD CT). Measure VDC between REL3, A1 and REL3, A2.
• Ensure that the connectors are properly connected to the REL1 Relay. The voltage is 12 VDC ±15%?
• Ensure that the connectors are properly connected to the REL3 Relay (PL 12.20). Y N
Measure VDC between REL3, A1 and GND(chassis).
• Ensure that the connectors are properly connected to TR2 (PL 12.20).
The voltage is 12 VDC±15%?
• Ensure that the connector TR2 is properly connected.
A B
• Ensure that the connectors are properly connected to BAR2 (PL 12.20).
• Ensure that plug A.P15 and G.P2 are properly connected. (PL 12.6)
• Ensure that plug G.P3 is properly connected.
• Ensure that plug K.P2 and L.P2 are properly connected (PL 12.8).
• Ensure Slide Door Interlock Switch (SW2) (PL 12.3) and
Top Cover Interlock Switch (SW3) (PL 12.3) are activated.
• Check that the voltage selector on TR2 is put in correct position.
• Ensure that built in fuse for TR2 hasn’t tripped.
• Activate REL3 in component control according to GP4 (Slide Door Interlock Switch (SW2)(PL 12.3)
Ensure Top Cover Interlock Switch (SW3) (PL 12.3) is also activated.
Listen closely to the BAR2. If there is a 50Hz sound when REL3 is activated, the BAR2 is working.

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A B There is continuity.
Y N Y N
Measure resistance between REL3,A1 and SW3,2. Repair harness
There is continuity. Measure resistance between REL3,14 and TR2,2 (transformer connector).
Y N There is continuity.
Repair harness. Y N
Go to Interlock Relay Circuit (REL1) RAP. Repair harness
Measure resistance between REL3,A2 and G.P3-4. Change components in following order:
There is continuity.
Antistatic Bar Harness for TR2.(REP 13.39)
Y N
Repair harness. Antistatic Bar (BAR2).(REP 13.39)

Go to I/O Extension PCB “G” RAP. Transformer TR2. (REP 13.39)

Replace REL3 (REP 13.39).
Power off the machine, disconnect the main power cord.
Remove the antistatic unit from the machine.
Power on the machine, close Top Cover and Slide Door.
Measure VAC between J27-1 and J27-2.
Warning! Caution when measuring the voltage measurements.
Always disconnect the Power Cord when it is necessary to work inside the
Power Module. AC Power is present in the Line Module whenever
the Power Cord is plugged into the Wall Outlet.

The voltage is 90-264VAC. Caution! Main voltage!

Y N
Power off the machine, disconnect the main power cord.
Very Important! Failure to disconnect will result in damage to meter.
Measure resistance between J27-1 and SW1.4.
There is continuity.
Y N
Repair harness.
Repair harness between J27-2 and SW1,1.
Keep the antistatic unit outside the machine,
measure resistance between P27,1 and REL3,31.
There is continuity.
Y N
Repair harness
Measure resistance between P27,2 and REL3,11.
There is continuity.
Y N
Repair harness
Measure resistance between REL3,34 and TR2,1 (transformer connector).

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Antistatic Bars Exit (optional) RAP A B
This RAP is for troubleshooting the optional Antistatic Bars in the Exit Area. Y N
Measure resistance between REL2,A1 and SW3,2.
Initial Actions
There is continuity.
• Enter Service (GP 1) Y N
• Check Interlock Relay REL1 (PL 12.8) solenoid action according to GP4 Repair harness.
Go to Interlock Relay Circuit (REL1) RAP.
• Ensure that connectors are properly connected to main power Switch CT-SW1 (PL 12.6).
Measure resistance between REL2,A2 and G.P3-4.
• Ensure that plug/jack P29/J29, P27/J27 and P34/J34 are properly connected (WD CT).
There is continuity.
• Ensure that the connectors are properly connected to the REL1 Relay. Y N
• Ensure that the connectors are properly connected to the REL2 Relay (PL 12.20). Repair harness.
• Ensure that the connectors are properly connected to TR1 (PL 12.20). Go to I/O Extension PCB “G” RAP.
Replace REL2 (REP 13.40).
• Ensure that the connector TR1 is properly connected.
Power off the machine, disconnect the main power cord,
• Ensure that the connectors are properly connected to BAR1 (PL 12.20). remove the antistatic unit from the machine.
• Ensure that plug A.P15 and G.P2 are properly connected. (PL 12.6) Power on the machine, close Top Cover and Slide Door.
Measure VAC between J27-1 and J27-2.
• Ensure that plug G.P3 is properly connected.
Warning!
• Ensure that plug K.P2 and L.P2 are properly connected (PL 12.8).
Use caution when making the voltage measurements and always
• Ensure Slide Door Interlock Switch (SW2) (PL 12.3) and disconnect the Power Cord when it is necessary to work inside the
Top Cover Interlock Switch (SW3) (PL 12.3) are activated. Power Module. AC Power is present in the Line Module whenever
the Power Cord is plugged into the Wall Outlet.
• Check that the voltage selector on TR1 is put in correct position.
The voltage is 90-264VAC. Caution! Main voltage!
• Ensure that built in fuse for TR1 hasn’t tripped. Y N
• Activate REL2 in component control according to GP4 (Slide Door Interlock Switch (SW2) Power off the machine, disconnect the main power cord.
(PL 12.3). Ensure Top Cover Interlock Switch (SW3) (PL 12.3) is also activated. Very Important! Failure to disconnect will result in damage to meter.
Listen closely to the BAR1. If there is a 50Hz sound when REL2 is activated, the BAR1 is
working. Measure resistance between J27-1 and SW1.4.
There is continuity.
Procedure Y N
Power on the machine, close cover and slide door, check that REL1 activates.
REL1 activates (check connectors position). Repair harness.

Y N Repair harness between J27-2 and SW1,1.

Go to Interlock Relay Circuit (REL1) RAP. Keep the antistatic unit outside the machine,
measure resistance between P27,1 and REL2,31.
Activate REL2 in component control.
There is continuity.
REL2 activates (check connectors position).
Y N
Y N
Repair harness
Measure VDC between REL2, A1 and REL2, A2.
Measure resistance between P27,2 and REL2,11.
The voltage is 12 VDC ±15%?
There is continuity.
Y N
Y N
Measure VDC between REL2, A1 and GND(chassis).
Repair harness
The voltage is 12 VDC±15%?
Measure resistance between REL2,34 and TR1,1 (transformer connector).
A B
There is continuity.

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Y N Cooling Fan (FAN1) RAP
Repair harness
This RAP is for troubleshooting FAN1 Cooling Fan (PL 12.6).
Measure resistance between REL2,14 and TR1,2 (transformer connector).
There is continuity. Initial Actions
Y N • Ensure that plugs/jacks P40/J40 and CT-Q13 (PL 12.12) are properly connected.
Repair harness
• Ensure that all connectors connecting to REL1 are properly connected.
Change components in following order:
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N” PCBs
Antistatic Bar Harness for TR2.(REP 13.39) are properly connected (See Section 8).
Antistatic Bar (BAR1).(REP 13.39)
Procedure
Transformer TR1. (REP 13.39).
• Activate FAN1 (cooling fan) in component control GP4.
• Ensure top cover is closed and slide unit is in inner position.
• Measure the voltage between P40-1 (red wire) anD.P40-2 (black wire).
The voltage is 24 VDC ±10%.
Y N
Disconnect P40. Measure voltage between J40-1 and J40-2.
The voltage is 24 VDC ±10%.
Y N
Disconnect B.P2.
Measure voltage between J.2-8 and J.2-7 on the “B” PCB.
The voltage is 24 VDC ±10%.
Y N
Replace Solenoid Driver PCB ”B”
(REP 13.24 Solenoid Driver PCB “B”).
Repair harness.
Replace FAN1 (REP 13.42).

Replace FAN1 (REP 13.42).

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Counter RAP, CT
This RAP is for troubleshooting the Chassis Counter .
Replace the Extension PCB “G” I/O (REP 13.29) according to
Initial Actions “G” I/O Extension PCB RAP.

• Enter Service (GP 1) Exit

• Check solenoid CT-COUNTER (PL 12.11) according to GP4 Replace the Chassis Counter (REP 12.25).

• Ensure that the connectors are properly connected to the Counter.

• Ensure that Plug / Jack 35 is correctly connected
• Ensure that plug B.P2 is correctly connected to Solenoid driver PCB “B”

• Ensure that plug G.P3 is correctly connected to I/O Extension PCB “G”

Procedure

Power off the machine. Remove connectors from Chassis Counter.

Measure on the contacts of the Solenoid.
There is an open circuit.
Y N
Disconnect plug G, P3 from I/O Extension PCB “G”.
Measure between the white connector on the Chassis Counter and G.P3-1.
There is continuity.
Y N
Repair Wire Harness.
Disconnect plug B.P12 From solenoid driver PCB “B”.
Measure between the orange connector on the Chassis Counter and B.P12-1.
There is continuity.
Y N

Repair Wire Harness.

Connect plug B.P12 to Solenoid Driver PCB “B” and connect the plug to the Chassis Counter.
Measure between G.P3-1 and Ground.
The voltage is 24VDC±10%.
Y N
Replace the Solenoid Driver PCB “B” (REP 13.24 Solenoid Driver PCB “B”)
Replace the Chassis Counter.
The Counter functions OK.
Y N

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Bleed Trimmer Knives noisy RAP
This RAP is for troubleshooting the Bleed Trimmer knives making noise.

Initial Actions
• Enter Service (GP 1)
• Check solenoid SOL3 (PL 12.5) according to GP4
Ensure that the SOL3 action really disengage the upper knives (PL 12.15),
on both operator and non-operator side from turning with the lower knives (PL 12.15).
• Ensure that the upper and lower knife shafts on operator and non-operator side are not
binding or having excessive play

Procedure
Change knives according to:
REP 13.2 Bleed Trimmer Lower Knives and REP 13.1 Bleed Trimmer Upper Knives.

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 Drive Motor (M1) Transmission RAP
This RAP is for troubleshooting the Drive Motor (M1) Transmission.

Initial Actions
• Enter Service (GP 1)
• Check motor M1 (PL 12.5) according to GP4.

Procedure
• Switch on Drive Motor (M1).
• Check that all Drive Motor (M1) Transmission Components are moving
as indicated in Figures (1, 2, 3).
All Components are moving as indicated?
Y N
Fix problem.
Return to the RAP that directed you here.

Figure 1 Drive Motor (M1) Transmission Components

Figure 2 Drive Motor (M1) Transmission Components

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 Figure 3 Drive Motor (M1) Transmission Components

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Rotator Motor (M3) Transmission RAP
This RAP is for troubleshooting the Rotator Motor (M3) Transmission.

Initial Actions
• Enter Service (GP 1)
• Check motor M3 (PL 12.11) according to GP4.

Procedure
• Switch on Rotator Motor (M3).
• Check that all Rotator Motor (M3) Transmission Components are
moving as indicated in Figure (1).
All Components are moving as indicated?
Y N
Fix problem.
Return to the RAP that directed you here.

Figure 1 Rotator Motor (M3) Transmission Components

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Registration Width Adjustment Motor (M4) Transmission
RAP
This RAP is for troubleshooting the Registration Width Adjustment Motor (M3) Transmission.

Initial Actions
• Enter Service (GP 1)
• Check motor CT-M4 (PL 12.5) according to GP4.

Procedure
• Switch on Registration Width Adjustment Motor (M4).
• Check that all Registration Width Adjustment Motor (M4) Transmission Components are
moving as indicated in Figures (1, 2).
All Components are moving as indicated?
Y N
Fix problem.
Return to the RAP that directed you here.

Figure 2 Registration Width Adjustment Motor (M4) Transmission Components

Figure 1 Registration Width Adjustment Motor (M4) Transmission Components

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Creaser Motor (M6) Transmission RAP
This RAP is for troubleshooting the Creaser Motor (M6) Transmission.

Initial Actions
• Enter Service (GP 1).
• Check motor M6 (PL 12.14) according to GP4.

Procedure
• Switch on Creaser Motor (M6).
• Check that all Creaser Motor (M6) Transmission Components are moving
as indicated in Figure (1).
All Components are moving as indicated?
Y N
Fix problem.
Return to the RAP that directed you here.

Figure 1 Creasser Motor (M6) Transmission Components

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 Bleed Trimmer Width Adjustment Motor (M7)
Transmission RAP
This RAP is for troubleshooting the Bleed Trimmer Width Adjustment Motor (M7)
Transmission.

Initial Actions
• Enter Service (GP 1).
• Check motor CT-M7 (PL 12.15) according to GP4.

Procedure
• Switch on Bleed Trimmer Width Adjustment Motor (M7).
• Check that all Bleed Trimmer Width Adjustment Motor (M7) Transmission Components are
moving as indicated in Figures (1,2).
All Components are moving as indicated?
Y N
Fix problem.
Return to the RAP that directed you here.

Figure 2 Bleed Trimmer Width Adjustment Motor (M7) Transmission Components

Figure 1 Bleed Trimmer Width Adjustment Motor (M7) Transmission Components

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Booklet Maker (BM)
BM-001 Infeed Motor BM-M1 No Displacement Pulses
Fault code indicates that the Infeed motor BM-M1 does not receive any displacement pulses.

Initial Actions Repair/Replace wire harness.

• Enter Service Mode, and run Motor Diagnostics, that will indicate a more precise fault code. Check Q2 Sensor Disc is 0.5 mm from Sensor PWB.
Replace Motor BM-M1(PL5.3).
• Enter Service Mode and select Infeed motor BM-M1 (PL 5.3) in check motors.
Replace MD6DC PCB “B” (PL 4.0).
• Ensure that plugs B.P2, B.P12 and B.P14 on MD6DC PCB “B” in the Booklet Maker
are connected (PL 5.3).
Go to Compiler RAP
• Ensure that plug C P12 on MD6DC PCB “C” in the Booklet Maker is connected.
• Ensure that jack/plug P/J20 / P/J21 and P/J29 in the Booklet Maker is connected.

Procedure
Enter Service Mode (GP1) and select sensor BM-Q2.
BM-Q2 is toggling between 0 and 1 when rotating the Infeed Motor shaft.
Y N
Disconnect the sensor plug BM-Q2 to motor BM-M1.
Measure between the red wire Q2 and the black wire Q2 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Disconnect plug B.P14 from MD6DC “B”.
Measure between the J.14-13 and J.14-1 (5V and GND).
The voltage is 5 VDC ± 10%.

Y N
Replace MD6DC PCB “B” (PL 4.0).

Repair/Replace wire harness.

• Disconnect plug B.P14 from MD6DC “B”.
• Check wires for continuity for the white wire Q2 to B.P14-14.
• Check wires for continuity for the black wire Q2 to B.P14-13.
• Check wires for continuity for the red wire Q2 to B.P14-1.
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N

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 BM-003 Infeed Motor BM-M1 Open Circuit
BM-002 Infeed Motor M1 Short Circuit Fault code indicates that the Infeed motor BM-M1 has an open circuit.
Fault code indicates that the Infeed motor BM-M1 has a short circuit.
Initial Actions
Procedure
Ensure that plug D.P1 on SCP universal PCB “D” (PL 3.0) is connected.
• Disconnect the motor plug M1.
Procedure
• Run the Diagnostics again.
• Disconnect the motor plug M1.
Fault code BM-003 (Open circuit) is displayed.
• Enter Service Mode (GP1) and start Infeed motor (BM-M1) in (GP4) check motors.
Y N
• Measure VDC between the orange wire M1 and the violet wire M1 (Motor power +/-).
Disconnect plug B.P2 from MD6DC “B”.
Check wires for short circuit across leads, The voltage is 30 VDC ± 10%.
the orange wire M1 to B.P2-8 (violet) and the violet wire M1 to B.P2-1 (orange).
Y N
Also check short circuit between wires to chassis.
Disconnect plug B.P2 from MD6DC PCB “B”.
Is there a short circuit
Measure VDC between J.2-1 and J.2-8
Y N
The voltage is 30 VDC ± 10%.
Replace MD6DC PCB ”B” (PL 4.0).
Y N
Repair/Replace wire harness.
Replace MD6DC PCB ”B” (PL 4.0).
Replace/Repair wire Harness.
Replace motor BM-M1 (PL 5.3).

Replace motor BM-M1 (PL 5.3).

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BM-004 Back Jogger Motor sensor BM-Q45 No displacement pulses
Fault code indicates that the Back Jogger motor BM-M2 does not receive any encoder pulses
Initial Actions
Replace/Repair wire Harness.
• Enter Service Mode, and run Motor Diagnostics, that will indicate a more precise fault code.
• Enter Service Mode and select Infeed motor (BM-M1) in check motors (GP4).
• Connect plug C.P14 and C.P16 to MD6DC PCB “C”.
• Ensure that plugs C. P11 and C.P14 on MD6DC PCB “C” in the Booklet Maker are connected.
• Measure between the red wire Q45 and the black wire Q45 (5V and GND)
• Ensure that plug C P2 on MD6DC PCB “C” in the Booklet Maker is connected. Measure between the white wire Q45 and the black wire Q45 (Signal and GND).
• Ensure that jack/plug P/J20 / P/J21 and P/J29 docking sensor in the Booklet Maker is connected. The voltage is 5 VDC ± 10%.
• Ensure encoder magnet is mounted correctly.Not interfere with hallsensor at PCB. Y N
The distance should be approx. 1mm between magnet and hallsensor on PCB.
Replace/Repair wire Harness.
Procedure
Enter Service Mode and select sensor BM-Q45.
• Check Q45 Sensor Disc is 0.5 mm from Sensor PWB.
Q45 is toggling between 0 and 1 when rotating the Motor shaft.
• Replace Motor BM-M1. (PL 3.2)
Y N
• Replace MD6DC PCB “C”.(PL 3.0)
• Disconnect plug C.P14 and C.P16 from MD6DC PCB “C”.
• Measure between J.16-3 and J.14-13 (5V and GND)
Inside Booklet Maker: Check Q1, M1,M2, and M3 (GP4).
• Measure between J.14-14 and J.14-13 (Signal and GND)
Check for mechanical bindings, broken, missing or loose parts.
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “C”.(PL 3.0)

• Disconnect plug from sensor Q45.

• Check continuity for the red wire at plug Q45 to C.P16-3
• Check continuity for the white wire at plug Q45 to C.P14-14
• Check continuity for the black wire at plug Q45 to C.P14-13
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit.
Y N

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BM-005 Back Jogger Motor (M2) Cycle Timeout
Fault code indicates that the Back jogger did not reach the home position in time.
Y N
Initial Actions Replace/Repair wire Harness.

• Enter Service Mode, and run Motor Diagnostics, that will indicate a more precise fault code.
• Replace sensor Q3 (PL 5.2).
• Ensure that Back jogger home position sensor BM-Q3 (PL 5.2) is installed correctly.
• Replace MD6DC PCB “C”” (PL 4.0).
• Ensure that Back jogger home position sensor BM-Q3 (PL 5.2) is clean.
• Ensure that plug C.P13 on MD6DC PCB “C” in the Booklet Maker is connected. Turn motor M2 one and a half turn in both directions by hand.
You should be able to use about the same amount of force throughout the turn.
Procedure
The motor will turn with a small applied force.
Enter Service Mode (GP1).
Select Back jogger home position sensor BM-Q3 in (GP4) check sensors. Does the motor move freely?
Y N
The back jogger home position sensor indicates :
• Fix point of interference.
1 when the sensor is blocked, and 0 when the sensor is unblocked.
• Lubricate were needed.
Y N
• Replace motor BM-M2 (REP 3.9) (PL 5.2).
• Disconnect plug C.P13 from PCB “C”.
• Measure between J.13-13 and J.13-3 (5V and GND). • Go to Compiler RAP.
• Measure between J.13-2 and J.13-3 (Signal and GND). • Go to Stapler RAP.
• The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “C(PL 4.0).

• Disconnect plug from sensor Q3.

• Check continuity for the red wire at plug Q3 to C.P13-13
• Check continuity for the white wire at plug Q3 to C.P13-2
• Check continuity for the black wire at plug Q3 to C.P13-3
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair wire Harness.

• Connect plug C.P13 to PCB “C”.

• Measure between the red wire Q3 and the black wire Q3 (5V and GND).
• Measure between the white wire Q3 and the black wire Q3 (Signal and GND).
The voltage is 5 VDC ± 10%.

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BM-006 Back Jogger Motor BM-M2 Short circuit BM-007 Back Jogger Motor BM-M2 Open Circuit
Fault code indicates that the Back jogger motor BM-M2 has an open circuit.
Fault code indicates that the Back jogger motor BM-M2 has a short circuit.
Initial Actions
Procedure
• Ensure that plug C.P2 on MD6DC PCB “C” in the Booklet Maker is connected.
Disconnect the motor plug M2 and run diagnostics again.
• Ensure that plug D.P1 on SCP universal PCB “D” (PL 3.0) is connected.
Fault code BM-007 (Open circuit) is displayed.
Procedure
Y N
• Disconnect motor plug M2 and C.P2 from PCB “C”.
• Disconnect plug C.P2 from PCB “C”.
• Check continuity for orange wire from M2 to C.P2-1
• Check wires for short circuit across leads,
the orange wire M2 to C.P2-8 (violet). • Check continuity for violet wire from M2 to C.P2-8

• Check wires for short circuit across leads, • Check for short circuit between violet/orange wires.
the violet wire M2 to C.P2-1 (orange). • Check for short circuit between orange/violet wires to chassis/GND
• Check short circuit between wires to chassis. There is continuity for all wires and no short circuit
Is there a short circuit Y N
Y N Replace/Repair wire Harness.
Replace PCB “C” (PL 4.0). Disconnect the motor plug M2.
Enter Service Mode (GP1) and run M2 (GP4).
Replace/Repair wire Harness. Measure VDC between the orange wire M2 and the violet wire M2

The voltage is 30 VDC ± 10%.

Replace motor BM-M2 (PL 5.2). Y N
Disconnect plug C.P2 from PCB “C”.
Start Back jogger motor (BM-M2) in check motors again.
Measure VDC between J.2-1 and J.2-8

The voltage is 30 VDC ± 10%.

Y N
Replace PCB “C”(PL 4.0).

Replace/Repair wire Harness.

Replace motor BM-M2 (PL 5.2).

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BM-008 Side Jogger Motor BM-M3 no displacement
pulses
Fault code indicates that the Side jogger motor BM-M3
does not receive any displacement pulses.
Initial Actions
• Enter Service Mode, and run Motor Diagnostics,
that will indicate a more precise fault code.
• Ensure that C.P2, C.P14, J/P20 and J/P21 are properly installed.

Procedure
Enter Service Mode (GP1) and select sensor Q12A and Q12B in (GP4) check sensors.

Both Q12A and Q12B are toggling between 0 and 1,

when rotating the Side Jogger motor shaft.
Y N
Disconnect sensor plug BM-Q12 to motor BM-M3.
Measure between the red wire Q12 and the black wire Q12 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
• Disconnect plug C.P14 from MD6DC PCB “C”.
• Measure between the J14-6 and J14-9 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “C” (PL 4.0).

Replace/Repair Wire Harness.

• Disconnect plug C.P14 from MD6DC PCB “C”.

• Check continuity for the grey wire Q12 to C.P14-7, and
the white wire Q12 to C.P14-4
• Check continuity for the black wire Q12 to C.P14-6, and
the red wire Q12 to C.P14-9.
• Check for short circuits between red/white/grey/black wires,
and between red/white/grey/black to chassis/GND.

There is continuity for all wires and no short circuit.

Y N

Replace/Repair Wire Harness.

• Replace motor BM-M3 (PL 5.3).

• Replace MD6DC PCB “C(PL 4.0).

Go to Compiler RAP

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BM-009 Side Jogger Motor BM-M3 cycle timeout
Fault code indicates that the Side jogger motor BM-M3 had a Cycle timeout.
Replace/Repair wire Harness.
Initial Actions
• Ensure that plug C.P13, C.P2, C.P14 on MD6DC PCB “C” in the Booklet Maker is connected (PL 3.0). • Replace sensor Q13. (PL 5.3)

• Enter Service Mode (GP1) and check that Side jogger motor BM-M3 (PL 3.2) runs in (GP4) check motors. • Replace MD6DC PCB “C(PL 4.0).
Ensure that J/P20 and J/P21 are properly installed. Turn Sideguides / motor M3 in both directions by hand
• Ensure that the Side jogger home position sensor BM-Q13 (PL 5.3) is installed correctly. Does it move freely without binding?
Y N
Procedure
• Repair mechnical bind
Enter Service Mode (GP1) and select Side jogger home position sensor (BM-Q13) in (GP4) check sensors.
The Side jogger home position sensor indicates: • Replace motor BM-M3.(PL 5.3)
1 when the sensor is blocked, and 0 when the sensor is unblocked?
• Inside Booklet Maker:
Y N
Check BM-Q1, M1, M2, and M3 (GP4).
• Disconnect plug C.P13 and C.P14 from PCB “C”. Check for mechanical bindings, broken, missing or loose parts.
• Measure between J.14-1 and J.13-6 (5V and GND). Go to BM-011 RAP
• Measure between J.13-5 and J.13-6 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “C(PL 4.0).

• Disconnect plug from sensor Q13.

• Check wire for continuity for the red wire at plug Q13 to C.P14-1
• Check wire for continuity for the white wire at plug Q13 to C.P13-5
• Check wire for continuity for the black wire at plug Q13 to C.P13-6
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair wire Harness.

• Connect plug C.P13 to MD6DC PCB “C”.

• Measure between the red wire Q13 and the black wire Q13 (5V and GND).
• Measure between the white wire Q13 and the black wire Q13 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N

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BM-010 Side Jogger Motor BM-M3 Short Circuit
Fault code indicates that the Side jogger motor BM-M3 has a short circuit.

Procedure
Disconnect the motor plug M3. Enter Service Mode (GP1) and run M3 (GP4).
Fault code BM-011 (Open circuit) is displayed?
Y N
• Disconnect plug C.P2 from MD6DC PCB “C”.
• Check wires for Short circuit across orange wire M3 to C.P2-9 (violet).
• Check wires for Short circuit across the violet wire M3 to C.P2-2 (orange).
• Check for short circuit between wires to chassis.
Is there a short circuit
Y N
Replace MD6DC PCB ”C” (PL 3.0).

Replace/Repair wire Harness.

Replace motor BM-M3 (PL 5.3)

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BM-011 Side Jogger Motor BM-M3 Open Circuit
Fault code indicates that the Side jogger motor BM-M3 has an open circuit.

Initial Actions
• Ensure that plug C.P2 on MD6DC PCB “C” (PL 4.0) in the Booklet Maker is connected.
• Ensure that plug D.P1 on SCP universal PCB “D” (PL 3.0) is connected.

Procedure
• Disconnect motor plug M3 and C.P2 from PCB “C”.
• Check continuity for the orange wire from M3 to C.P2-2
• Check continuity for violet wire from M3 to C.P2-9
• Check for short circuit between violet/orange wires and
between orange/violet wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair wire Harness.

• Disconnect the motor plug M3.

• Enter Service mode and start Side jogger motor (BM-M3) in check motors.
• Measure VDC between the orange wire M3 and the violet wire M3.
The voltage is 30 VDC ± 10%.
Y N
• Disconnect plug C.P2 from MD6DC PCB “C”.
• Measure VDC between J.2-2 and J2-9
The voltage is 30 VDC ± 10%.
Y N

Replace MD6DC PCB ”C”. (PL 4.0)

Replace/Repair wire Harness.

Replace motor BM-M3 (PL 5.3)

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BM-012 Set Transport Motor BM-M5 Motor Sensor BM-Q40
No displacement pulses
Fault code indicates that the Set Transport motor BM-M5 (PL 5.0)
does not receive any encoder pulses Replace/Repair wire Harness.

Initial Actions
• Connect plug B.P14 to MD6DC PCB “B”.
• Enter Service Mode and run Motor Diagnostic, that will indicate a more precise fault code.
• Measure between the red wire Q40 and the black wire Q40 (5V and GND).
• Enter GP4, select Set Transport motor (BM-M5). If M5 fails to run go to BM-014 RAP.
• Measure between the white wire Q40and the black wire Q40 (Signal and GND).
• Ensure that plugs B.P12, B.P13, B.P14 and B.P2 on MD6DC PCB “B”
in the Booklet Maker are connected The voltage is 5 VDC ± 10%.
• Ensure that jack/plug P/J35 , P/J36, and P/J29 docking sensor Y N
in the Booklet Maker is connected.
Replace/Repair wire Harness.
• Ensure encoder magnet is mounted correctly and not interfering with hall sensor at PCB.
• The distance should be approx. 0.5 mm between magnet and hall sensor on PCB.
• Replace motor BM-M5(PL 5.0)
Procedure • Replace MD6DC PCB “B”.
Enter Service Mode and select sensor Q40.
Q40 is toggling between 0 and 1 when rotating the BM-M5 Motor shaft. Go to BM-014 RAP
Y N
• Disconnect plug B.P14 from MD6DC PCB “B”.
• Measure between J.14-2 and J.14-10 (5V and GND)
• Measure between J.14-11 and J.14-10 (Signal and GND)
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “B”. (PL 4.0)

• Disconnect plug from sensor Q40.

• Check continuity for the red wire at plug Q40 to B.P14-2
• Check continuity for the white wire at plug Q40 to B.P14-11
• Check continuity for the black wire at plug Q40 to B.P14-10
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N

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BM-013 Set Transport Motor BM-M5 Short Circuit
Fault code indicates that the Set Transport motor BM-M5 (PL 5.0) has a short circuit.

Procedure
Disconnect the motor plug BM-M5. Enter Service Mode (GP1) and run BM-M5 (GP4).
Fault code BM-014 (Open circuit) is displayed.
Y N
• Disconnect plug B.P2 from MD6DC PCB “B”.
• Check wires for short circuit across leads, the orange wire M5 to B.P2-9 (violet)
• Check wires for short circuit across leads, the violet wire M5 to B.P2-2 (orange).
• Check for short circuit between wires to chassis.
Is there a short circuit
Y N
Replace MD6DC PCB “B” (PL 4.0).

Replace/Repair wire Harness.

Replace motor BM-M5 (PL 5.0).

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BM-014 Set Transport Motor M5 Open Circuit
Fault code indicates that the Set Transport motor BM-M5 (PL 5.0) has an open circuit.
Initial Actions
• Ensure that plug B.P2 on MD6DC PCB “B” (PL 4.0) in the Booklet Maker is connected.
• Ensure that plug D.P1 on SCP universal PCB “D” (PL 4.0) is connected.
Procedure
• Disconnect motor plug BM-M5 and B.P2 from PCB “B”.
• Check continuity for the orange wire from M5 to B.P2-2
• Check continuity for the violet wire from M5 to B.P2-9
• Check for short circuit between violet/orange wires and between
orange/violet wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair wire Harness.

• Disconnect the motor plug BM-M5.

• Enter Service mode (GP1) and run transport motor (BM-M5) in (GP4) check motors.
• Measure VDC between the orange wire M5 and the violet wire M5
The voltage is 30 VDC ± 10%.
Y N
• Disconnect plug B.P2 from MD6DC PCB “B”.
• Measure VDC between J.2-2 and J2-9
The voltage is 30 VDC ± 10%.
Y N
Replace MD6DC PCB “B”. (PL 4.0)

Replace/Repair wire Harness.

Replace motor BM-M5.(PL 5.0)

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BM-015 Fold Roller Motor BM-M6 No Displacement Pulses Measure between the red wire Q9 and the black wire Q9 (5V and GND).
Fault code indicates that the Fold roller motor BM-M6 does not receive any displacement pulses.
The voltage is 5 VDC ± 10%.
Initial Actions Y N
• Enter Service Mode and run Motor Diagnostic, that will indicate a more precise fault code. Replace/Repair wire Harness.
• Ensure that plugs C.P11, C.P14 and C.P3 on MD6DC PCB “C”
in the Booklet Maker are connected (PL 3.0).
Replace sensor BM-Q9 (PL 6.0).
• Ensure that plug D P5 on Interlock PCB “D” in the Booklet Maker is connected.
Replace MD6DC PCB “C(PL 4.0).
• Ensure that the Fold Roller Sensor BM-Q9 (PL 6.0) is installed correctly
(REP 6.4 Fold Transmission Module, BM-M6 Fold Roller Motor, BM-Q9 Fold roller sensor & fold transmission chain).

Procedure
Enter Service Mode (GP1) and select Fold roller motor BM-M6 in (GP4) check motors.
Do the Fold Rolls turn?
Y N
• Check Fold Transmission (REP 6.4)
• Go to BM-017 RAP

Disconnect plug C.P14 from PCB “C”.

Measure between J.14-10 and J.14-2 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “C(PL 4.0).

• Disconnect plug from sensor Q9.

• Check continuity for the red wire at plug Q9 to C.P14-2
• Check continuity for the white wire at plug Q9 to C.P14-11
• Check continuity for the black wire at plug Q9 to C.P14-10
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair wire Harness.
Connect plug C.P14 to PCB “C”.

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 BM-017 Fold Roller Motor BM-M6 Open Circuit
BM-016 Fold Roller Motor BM-M6 Short Circuit Fault code indicates that the Fold roller motor BM-M6 has an open circuit.
Fault code indicates that the Fold roller motor BM-M6 has a short circuit. Initial Actions
Procedure • Ensure that plug D.P1 on SCP universal PCB “D” (PL 3.0) is connected.
• Disconnect the motor plug M6. Procedure
• Enter Service Mode (GP1) and run M6 (GP4).
• Disconnect motor plug M6 and C.P2 from PCB “C”.
Fault code BM-017 (Open circuit) is displayed.
• Check continuity for the orange wire from M6 to C.P3-2
Y N
• Check continuity for the violet wire from M6 to C.P3-3
• Disconnect plug C.P3 from PCB “C”.
• Check for short circuit between violet/orange wires and
• Check wires for short circuit across leads and to chassis. between orange/violet wires to chassis/GND

• Check wires for short circuit across the orange wire M6 to C.P3-3 (violet) There is continuity for all wires and no short circuit

• Check wires for short circuit across the violet wire M6 to C.P3-2 (orange). Y N

Is there a short circuit. Replace/Repair wire harness.

Y N Disconnect the motor plug M6.

Replace MD6DC PCB “C(PL 4.0). Enter Service mode and start Fold roller motor BM-M6 in check motors.
Measure VDC between the orange wire M6 and the violet wire M6

Replace/Repair wire Harness. The voltage is > 10 VDC.

Y N

Replace motor BM-M6 (PL 6.0). Disconnect plug C.P3 from PCB “C”.
Measure VDC between J.3-2 and J.3-3
The voltage is > 10 VDC. Should be approx. 18 VDC.
Y N
Replace MD6DC PCB “C(PL 4.0).
Replace/Repair wire Harness.
Replace motor BM-M6 (PL 3.0).

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BM-018 Fold Knife Motor BM-M7 Cycle Timeout

Fault code indicates that the Fold knife motor BM-M7 had a Cycle timeout. Replace/Repair wire Harness.

Initial Actions
• Replace sensor BM-Q15. (PL 6.2)
• Enter Service Mode and run Motor Diagnostic, that will indicate a more precise fault code.
• Replace MD6DC PCB “B” (PL 4.0).
• Enter Service Mode (GP1) and check that Fold knife motor BM-M7 (PL 6.2)
runs in (GP4) check motors. • Replace motor BM-M7.(PL 6.2)

• Ensure that Fold knife home position sensor BM-Q15 (PL 6.2) is installed correctly.
Check for mechanical bind, broken, missing or loose parts.
Procedure
Check adjustments for Fold transmission and Upper/lower Fold Roller.
Enter Service Mode and select Fold knife home position sensor (BM-Q15) in check sensors.
Go to BM-020 RAP.
The Fold knife home position sensor indicates :
1 when the sensor is blocked, and 0 when the sensor is unblocked.
Y N
• Disconnect plug B.P13 from PCB “B”.
• Measure between J.13-13 and J.13-22 (5V and GND).
• Measure between J.13-21 and J.13-22 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “B”(PL 4.0).
• Disconnect plug from sensor Q15.
• Check continuity for the red wire at plug Q15 to C.P13-13
• Check continuity for the white wire at plug Q15 to C.P13-21
• Check continuity for the black wire at plug Q15 to C.P13-22
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair wire Harness.
• Connect plug B.P13 to MD6DC PCB “B” (PL 4.0).
• Measure between the red wire Q15 and the black wire Q15 (5V and GND).
• Measure between the white wire Q15 and the black wire Q15 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N

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BM-019 Fold Knife Motor BM-M7 Short Circuit

Fault code indicates that the Fold knife motor BM-M7 has a short circuit.

Initial Actions
Ensure that plug D.P1 on SCP universal PCB “D” (PL 3.1) is connected.

Procedure
Disconnect the motor plug M7. Enter Service Mode (GP1) and run M7 (GP4).
Fault code BM-020 (Open circuit) is displayed?
Y N
• Disconnect plug B.P3 from PCB “B”.
• Check wires for Short circuit across leads and to chassis.
• Check wires for Short circuit across the orange wire M7 to B.P3-7(violet).
• Check wires for Short circuit across the violet wire M7 to B.P3-6 (orange).

Is there a short circuit

Y N
Replace MD6DC PCB “B” (PL 4.0).

Replace/Repair wire Harness.

Replace motor BM-M7 (PL 6.2).

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BM-020 Fold Knife Motor BM-M7 Open Circuit
Fault code indicates that the Fold knife motor BM-M7 (PL 6.2) has an open circuit.

Initial Actions
Ensure that plug B P3 on MD6DC PCB “B” is connected.

Procedure
• Disconnect motor plug M7 and B.P3 from PCB “B”.
• Check continuity for the orange wire from M7 to B.P3-6
• Check continuity for the violet wire from M7 to B.P3-7
• Check for short circuit between violet/orange wires.
• Check for short circuit between orange/violet wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair wire Harness.

Connect Plug B.P3 and leave M7 plug disconnected.

Enter Service mode and start Fold knife motor (M7) in check motors.
Measure VDC between the orange wire M7 and the violet wire M7.
The voltage is > 10 VDC.
Y N
Disconnect plug B.P3. Measure VDC between J.3-6 and J.3-7.
The voltage is > 10 VDC. Should be approx. 28 VDC.
Y N
Replace MD6DC PCB “B” (PL 4.0).

Replace/Repair wire Harness.

Replace motor BM-M7 (PL 6.2).

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BM-021 Stop Gate Folder Motor BM-M8 Sensor BM-Q43
No displacement pulses Replace/Repair wire Harness.
Fault code indicates the Stop Gate Folder Motor BM-M8 (PL 6.2) does not
• Connect plug H.P14 to MD6DC PCB “H”.
receive any encoder pulses
• Measure between the red wire Q43 and the black wire Q43 (5V and GND).
Initial Actions
• Measure between the white wire Q43 and the black wire Q43 (Signal and GND).
• Enter Service Mode and run Motor Diagnostic, that will indicate a more precise fault code.
The voltage is 5 VDC ± 10%.
• Enter Service Mode and select Infeed motor M8 in check motors (GP4).
Y N
• Ensure that plug H.P11, H.P13 and H.P14 on MD6DC PCB “H”
in the Booklet Maker are connected. Replace/Repair wire Harness.

• Ensure that plug H.P2, H.P4, H.P5 and H.P16 on MD6DC PCB “H”
in the Booklet Maker are connected. • Replace Motor BM-M8 (PL 6.2)
• Ensure that jack/plug P/J37, P/J38 and A.P1 in the Booklet Maker are connected. • Replace MD6DC PCB “H”. (PL 4.0)
• Ensure encoder magnet is mounted correctly and not interfering with hall sensor at PCB. • Check for mechanical bindings, broken, missing or loose parts.
The distance should be approx.0.5mm between magnet and hallsensor on PCB.
Go to BM-024 RAP
Procedure
Enter Service Mode and select sensor Q43 (GP4)
Q43 is toggling between 0 and 1 when rotating the M8 motor shaft.
Y N
• Disconnect plug H.P14 from MD6DC PCB “H”.
• Measure between J.14-2 and J.14-10 (5V and GND)
• Measure between J.14-11 and J.14-10 (Signal and GND)
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “H””.(PL 4.0)
• Disconnect plug from sensor Q43.
• Check continuity for the red wire at plug Q43 to H.P14-2
• Check continuity for the white wire at plug Q43 to H.P14-11
• Check continuity for the black wire at plug Q43 to H.P14-10
• .Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N

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BM-022 Stop Gate Folder Motor BM-M8 Sensor BM-Q44 Cycle
Timeout
Replace/Repair wire Harness.
This Fault code indicates that the Stop Gate Folder Motor BM-M8 (PL 6.2) had a Cycle timeout.
Possible failure: • Connect plug H.P13 to MD6DC PCB “H”.
• Mechnical Binding • Measure between the red wire Q44 and the black wire Q44 (5V and GND).
• Home Position Stop Gate Folder BM-Q44 is faulty • Measure between the white wire Q44 and the black wire Q44 (Signal and GND).
• Stop Gate Folder Motor BM-M8 is faulty The voltage is 5 VDC ± 10%.

Initial Actions Y N

• Enter Service Mode and check that Stop Gate Folder Motor BM-M8 runs in check motors (GP4). Replace/Repair wire Harness.

• Ensure that the Home Position Stop Gate Folder BM-Q44 is installed correctly. • Replace sensor Q44.
• Replace MD6DC PCB “H””.(PL 4.0).
Procedure
Turn the Stop Gate Folder by hand.
Enter Service Mode and select Home Position Stop Gate Folder BM-Q44 in check sensors (GP4).
The shaft turns without using force.
The Home Position Stop Gate Folder indicates :
1 when the sensor is blocked, and 0 when the sensor is unblocked. Y N

Y N Check for interference.

• Disconnect plug H.P13 from PCB “H”.

• Measure between J.13-13 and J.13-6 (5V and GND). • Inside Booklet Maker: Check Q7, Q43, Q44 and M8 ( GP4).

• Measure between J.13-5 and J.13-6 (Signal and GND). • Check for mechanical bindings, broken, missing or loose parts.

The voltage is 5 VDC ± 10%. • Go to BM-024 RAP

Y N
Replace MD6DC PCB “H””.(PL 4.0)

• Disconnect plug from sensor Q44.

• Check continuity for the red wire at plug Q44 to H.P13-13
• Check continuity for the white wire at plug Q44 to H.P13-5
• Check continuity for the black wire at plug Q44 to H.P13-6
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N

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BM-023 Stop Gate Folder Motor BM-M8 Short Circuit BM-024 Stop Gate Folder Motor BM-M8 Open Circuit
Fault code indicates that the Stop Gate Folder Motor BM-M8 has an open circuit.
Fault code indicates that the Stop Gate Folder Motor BM-M8 (PL 6.2) has a short circuit.

Procedure Initial Actions

• Ensure that jack/plug J37/P37 and H.P2 in the Booklet Maker is connected.
Disconnect the motor plug M8. Enter Service Mode and run M8 (GP1).
• Ensure that plug D.P1 on SCP universal PCB “D” (PL 3.0) is connected.
Fault code BM-024 (Open circuit) is displayed.
Y N Procedure
• Disconnect plug H.P2 from PCB “H”. (PL 4.0) • Disconnect motor plug M8 and H.P2 from PCB “H”.

• Check wires for Short circuit across leads and to chassis, • Check continuity for the orange wire from M8 to H.P2-3

• Check wires for Short circuit across the orange wire M8 to H.P2-10 (violet) • Check continuity for the violet wire from M8 to H.P2-10
and the violet wire M8 to H.P2-3 (orange).
• Check for short circuit between violet/orange wires and
Is there a short circuit between orange/violet wires to chassis/GND

Y N There is continuity for all wires and no short circuit

Replace MD6DC PCB “H”” (PL 4.0) Y N

Replace/Repair wire Harness. Replace/Repair wire Harness.

• Replace Motor BM-M8 (PL 6.2) • Disconnect the motor plug M8.
Enter Service mode and start Stop Gate Folder Motor (BM-M8) (GP1).
• Inside Booklet Maker:
• Measure VDC between the orange wire M8 and the violet wire M8.
• Check Q7, Q43, Q44 and BM-M8 (GP1).
The voltage is 30 VDC ± 10%.
• Check for mechanical bindings, broken, missing or loose parts.
Y N
• Disconnect plug P2 from PCB “H”.
• Measure VDC between J.2-3 and J.2-10
The voltage is 30 VDC ± 10%.
Y N
Replace MD6DC PCB “H””. (PL 4.0)
Replace/Repair wire Harness.
• Replace Motor BM-M8 (PL 6.2).
• Inside Booklet Maker: Check Q7, Q43, Q44 and M8 (GP4).
• Check for mechanical bindings, broken, missing or loose parts.

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BM-025 Stop Gate Folder Motor BM-M8 Max voltage exceeded

Fault code indicates that the Stop Gate Folder Motor (BM-M8) (PL 5.1) has exceeded max
voltage during operations.

Initial Actions
• Enter the Service mode and check that Stop Gate Folder Motor (BM-M8) runs in check mo-
tors ( GP1).
• Ensure that movement between end positions are smooth.
• Check for mechanical obstructions and loose screw.

If all above is OK, replace motor.

WARNING!
Turn off the Main Power Switch and disconnect the Main Power Cord before disconnecting,
removing or replacing any electrical components.

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BM-026 Staple/Fold Positioning Motor(M9) Sensor BM-Q10
No displacement pulses
Fault code indicates that the Staple / Fold positioning motor BM-M9 does not receive any There is continuity for all wires and no short circuit
encoder pulses.
Y N
Initial Actions Replace/Repair wire Harness.
• Enter Service Mode and run Motor Diagnostic,
that will indicate a more precise fault code.
• Connect plug B.P14 to MD6DC PCB “B”.
• Enter Service Mode (GP1) and
select Staple / Fold Position Motor (M9) in check motors (GP4). • Measure between the red wire Q10 and the black wire Q10 (5V and GND).

• Ensure that plug B.P14 and B.P13 on MD6DC PCB “B” in the Booklet Maker is connected. • Measure between the white wire Q10 and the black wire Q10 (Signal and GND).

• Ensure that plug B.P2 on MD6DC PCB “B” in the Booklet Maker is connected. • Measure between the grey wire Q10 and the black wire Q10 (Signal and GND).

• Ensure that plug B.P4, B.P5 and B.P16 on MD6DC PCB “B” in the Booklet Maker is con- The voltage is 5 VDC ± 10%.
nected. Y N
• Ensure encoder magnet is mounted correctly and not interfering with hallsensor at PCB. Replace/Repair wire Harness.
The distance should be approx. 0.5mm between magnet and hallsensor on PCB.
• Replace Motor BM-M9 / Q10 (PL 6.2).

Procedure • Replace MD6DC PCB “B” (PL 4.0).

Enter Service Mode and select sensor Q10A and Q10B in check sensors (GP 4). Inside Booklet Maker: Check BM-M9 (GP1).
(May need to remove lower cover.) Check for mechanical bind, broken, missing or loose parts.
Both Q10A and Q10B are toggling between 0 and 1 when rotating the M9 motor shaft. Go to BM-029 RAP.
Y N
• Disconnect plug B.P14 from MD6DC PCB “B”. (PL 4.0)
• Measure between J.14-9 and J14-6 (5V and GND)
• Measure between J14-4 and J14-6 (Signal and GND)
• Measure between J14-7 and J14-6 (Signal and GND)
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “B”.
• Disconnect plug from sensor Q10.
• Check continuity for the red wire at plug Q10 to B.P14-9
• Check continuity for the white wire at plug Q10 to B.P14-4
• Check continuity for the grey wire at plug Q10 to B.P14-7
• Check continuity for the black wire at plug Q10 to B.P14-6
• Check for short circuit between red/white/grey/black wires.
• Check for short circuit between red/white/grey/black wires to chassis/GND

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BM-027 Staple/Fold Pos. Motor (M9) Sensor BM-Q11 Cycle Timeout
Fault code indicates that the Staple / Fold positioning motor BM-M9 (PL 5.1) had a Cycle timeout.

Initial Actions Replace/Repair wire Harness.

• Enter Service Mode (GP1) and check that Staple/Fold Positioning motor BM-M9 (PL 5.0)
runs in (GP4) check motors. • Replace sensor BM-Q11 (PL 4.0)
• Ensure that the Staple / Fold home position sensor BM-Q11 (PL 4.0) is installed correctly. • Replace MD6DC PCB “B” (PL 4.0)
Procedure • Replace motor BM-M9 (PL 6.2)
Enter Service Mode and select Staple / Fold home position sensor (BM-Q11) (GP1). Turn the length transmission shaft by hand.
The Staple / Fold home position sensor indicates : The shaft turns without any binding.
1 when the sensor is blocked, and 0 when the sensor is unblocked. Y N
Y N Lubricate shaft.
• Disconnect plug B.P13 from PCB “B”. (PL 4.0) Pull the length adjustment strap down towards Stapler motor M4.
• Measure between J.16-3 and J.13-3 (5V and GND). The length adjustment strap is easy to move.
• Measure between J.13-2 and J.13-3 (Signal and GND). Y N
The voltage is 5 VDC ± 10%. • Check for interference.
Y N • Lubricate where needed.
Replace MD6DC PCB “B”. (PL 4.0) Go to BM-029 RAP

• Disconnect plug from sensor Q11.

• Check continuity for the red wire at plug Q11 to B.P16-3
• Check continuity for the white wire at plug Q11 to B.P13-2
• Check continuity for the black wire at plug Q11 to B.P13-3
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair wire Harness.
1. Connect plug B.P13 to MD6DC PCB “B”. (PL 4.0)
2. Measure between the red wire Q11 and the black wire Q11 (5V and GND).
3. Measure between the white wire Q11 and the black wire Q11
(Signal and GND).
The voltage is 5 VDC ± 10%.
Y N

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BM-028 Staple/Fold Positioning Motor BM-M9 Short BM-029 Staple/Fold Positioning Motor BM-M9 Open
Circuit Circuit
Fault code indicates that the Staple / Fold positioning motor BM-M9 has a short circuit. Fault code indicates that the Staple / Fold positioning motor BM-M9 has an open circuit.

Procedure Initial Actions

Disconnect the motor plug M9. Enter Service Mode (GP1) and run M9 (GP4). Ensure that plug D.P1 on SCP universal PCB “D” (PL 3.0) is connected.
Fault code BM-029 (Open circuit) is displayed.
Procedure
Y N
• Disconnect motor plug M9 and B.P2 from PCB “B”.
• Disconnect plug B.P2 from PCB “B”.
Check wires for Short circuit across orange wire M9 to B.P2-10 (violet) • Check continuity for the orange wire from M9 to B.P2-3
and the violet wire M9 to B.P2-3 (orange).
• Check continuity for the violet wire from M9 to B.P2-10
• Check short circuit between wires to chassis.
• Check for short circuit between violet/orange wires and
Is there short circuit between orange/violet wires between orange/violet wires to chassis/GND
and/or orange/violet wires to chassis.
There is continuity for all wires and no short circuit
Y N
Y N
Replace
Replace/Repair wire Harness.
(PL 4.0).
• Disconnect the motor plug M9.
Replace/Repair wire Harness.
• Enter Service mode and start Staple / Fold positioning motor (BM-M9) ( GP1).
• Measure VDC between the orange wire M9 and the violet wire M9
Replace motor BM-M9 (PL 6.2).
The voltage is 30 VDC ± 10%.
Y N
• Disconnect plug B.P2 from PCB “B”.
• Measure VDC between J.2-3 and J.2-10 (PWM 30V and GND).
The voltage is 30 VDC ± 10%.
Y N
Replace MD6DC PCB “B”(PL 4.0).
Replace/Repair wire Harness.
Replace motor BM-M9 (PL 6.2).

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BM-042 Primary Infeed Motor (M19) Sensor (Q43)
No displacement pulses
This Fault code indicates that the Primary Infeed motor (BM-M19) (PL 4.0) does not receive any encoder
pulses
Initial Actions
- Enter Service (GP 1). Scroll down and verify that machine is NOT set to Deburster Module.
- Enter Service Mode and run Motor Diagnostic, that will indicate a more precise fault code.
- Enter the Service mode and select Primary Infeed motor (BM-M19) in check motors (GP1).
- Ensure that plug H.P11 on MD6DC PCB “H” in the Booklet Maker is connected.
- Ensure that plug H.P14 on MD6DC PCB “H” in the Booklet Maker is connected.
- Ensure that plug H.P2 on MD6DC PCB “H” in the Booklet Maker is connected.
- Ensure that jack/plug P/J54, P/J51 in the Booklet Maker is connected.
- Ensure encoder magnet is mounted correctly and not interfering with hall sensor at PCB.
The distance should be approx. 0.5mm between magnet and hallsensor on PCB.

Procedure WARNING!
Turn off the Main Power Switch and disconnect the Main Power Cord before disconnecting,
removing or replacing any electrical components.
Enter the Service mode and select sensor Q34 (GP 1).
Q34 is toggling between 0 and 1 when rotating the Motor shaft.
Y N
Disconnect plug H.P14 from MD6DC PCB “H”.
1. Measure between J.14-1 and J.14-13 (5V and GND)
2. Measure between J.14-14 and J.14-13 (Signal and GND)
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “H”(PL4.0)

Disconnect plug from sensor Q34.

1. Check wire for continuity / short circuit from the red wire at plug Q34 to H.P14-1
2. Check wire for continuity / short circuit from the white wire at plug Q34 to H.P14-14
3. Check wire for continuity / short circuit from the black wire at plug Q34 to H.P14-13
4 .Check wire for Short circuit between red wire white wire black wire
5. Check for short circuit between red and chassis/GND, white and chassis/GND
Is there continuity and no short circuit between cables
Y N
Repair Wire Harness.

Connect plug H.P14 to MD6DC PCB “H”.

1. Measure between the red wire Q34 and the black wire Q34 (5V and GND).
2. Measure between the white wire Q34 and the black wire Q34 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Repair Wire Harness.

1. Replace Motor BM-M19 (PL 4.0).

2. Replace MD6DC PCB “H”(PL 4.0)
Go to rap BM-044

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BM-044 Primary Infeed Motor (M19) Open Circuit
Fault code indicates that the Primary Infeed motor (BM-M19) (PL 4.0) has an open circuit.
Initial Actions

- Enter Service (GP 1). Scroll down and verify that machine is NOT set to Deburster Module.

Procedure

WARNING!
Turn off the Main Power Switch and disconnect the Main Power Cord before disconnecting,
removing or replacing any electrical components.

Disconnect motor plug M19 and H.P2 from PCB “H”.

1. Check wire for continuity / short circuit the orange wire from M19 to H,P2-1
2. Check wire for continuity / short circuit from violet wire from M19 to H,P2-8
3. Check wire for Short circuit between violet wire orange wire
4. Check for short circuit between orange and chassis/GND, violet and chassis/GND
Is there continuity and no short circuit between cables
Y N
Replace/Repair wire Harness.

Disconnect the motor plug M19.

Enter Service mode and start Primary Infeed motor (BM-M19) in check motors.
Measure between the orange wire M19 and the violet wire M19.
The voltage is approximately 30 VDC?
Y N
Disconnect plug H.P2 from PCB “H”.
Start Primary Infeed motor (BM-M19) in check motors again.
Measure between J.2-1 and J.2-8.
The voltage is approximately 30 VDC?
Y N
Replace MD6PCB “H” (PL4.0)

Replace wire Harness.

Replace motor M19.

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BM-045 Stapler Home Position Left Sensor BM-Q50 Cycle
Timeout
This Fault code indicates that the Stapler Left Motor BM-M20 (PL 7.0) had a Cycle timeout.

Initial Actions
• Enter Service Mode and run Motor Diagnostic, that will indicate a more precise fault code.
• Enter Service Mode and check that Left Stapler Motor runs (GP1).

Procedure
• Enter Service mode and select Stapler Left Motor BM-M20 GP1).
The Stapler home position sensor (Q50) indicates :
1 when the Stapler is up, and 0 when the Stapler is down.
Y N
• Disconnect plug B.P16 and B.P13 from PCB “B”.
• Measure between J.16-2 and J.13-9 (5V and GND).
• Measure between J.13-8 and J.13-9 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “B”.(PL 4.0)
• Disconnect plug P43 from Stapler.
• Check continuity for the red wire at plug J43-9 to B.P16-2
• Check continuity for the white wire at plug J43-3 to B.P13-8
• Check continuity for the black wire at plug J43-10 to B.P13-9
• Check for short circuit between red wire white wire black wire
• Check for short circuit between red and chassis/GND, white and chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug B.P13 and B.P16 to MD6DC PCB “B”.
• Go to BM-048 RAP
Go to BM-018 RAP

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BM-046 Clinch Trig Sensor Left, BM-Q51, Cycle timeout
This Fault code indicates that the Stapler Left Motor BM-M20 (PL 7.0)
had a Cycle timeout for trigger sensor.

Initial Actions
• Enter Service Mode and check that Left Stapler Motor runs (GP1).

Procedure

Enter Service Mode and select Stapler Left Motor BM-M20 (GP4).
The Clinch Trigger sensor (Q51) indicates :
0 when the Stapler is up, and 1 when the Stapler is down.
Y N
• Disconnect plug B.P16 and from PCB “B”.
• Measure between J.16-1 and J.13-12 (5V and GND).
• Measure between J.13-11 and J.13-12 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “B”.(PL 4.0)
• Disconnect plug P43 from Stapler.
• Check continuity for the red wire at plug J43-8 to B.P16-1
• Check continuity for the white wire at plug J43-7 to B.P13-11
• Check continuity for the black wire at plug J43-12 to B.P13-12
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires and chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug B.P13 and B.P16 to MD6DC PCB “B”.
• Go to BM-048 RAP
Go to BM-018 RAP

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BM-047 Stapler Left Motor BM-M20 Short Circuit
This Fault code indicates that the Stapler Left Motor has a short circuit.

Initial Actions
• Ensure that both Stapler Heads are in upper position
• Ensure that Connector “Clinch Left” and “Clinch Right” are connected.
• Ensure that Connector “J39 / P39” and “J40 / P40” are connected.
• Ensure that Connector “A.P1” is connected.
• Ensure that B.P3, B.P13, B.P16, J43/P43 and J41/P41 are connected.
• Check all cables and connectors for damaged.

Procedure
• Disconnect plug B.P3 from MD6DC PCB “B” and P43
(Stapler harness goes to inside frame).
• Check wires for short between the orange wire J43-5 to B.P3-3 (violet).
• Check wires for short between the violet wire J43-11 to B.P3-2 (orange).
• Check short circuit between wires to chassis.
Is there short a circuit
Y N
• Replace Stapler Assembly Left.(PL 4.1)
• Replace MD6DC PCB “B” (PL 4.0)
Replace/Repair wire Harness.

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BM-048 Stapler Left Motor BM-M20 Open Circuit
This Fault code indicates that the Stapler Left Motor (M20) has an open circuit.

Initial Actions Replace MD6DC PCB “B”. (PL 4.0)

• Ensure that both Stapler Heads are in upper position. Replace/Repair wire Harness.
• Ensure that Connector “Clinch Left” and “Clinch Right” are connected. • Replace Stapler Left BM-M20 (PL 4.1)
• Ensure that Connector “J39 / P39” and “J40 / P40” are connected. • Replace MD6DC PCB “B”.
• Ensure that Connector “A.P1” is connected.
• Ensure that B.P3, B.P13, B.P16, J43/P43 and J41/P41 are connected.
• Check all cables and connectors for damaged.
• Ensure that plug D.P1 on SCP universal PCB “D” (PL 3.1) is connected.

Procedure
• Disconnect plug B.P3 from MD6DC PCB “B” and D.P43 (Stapler harness goes to inside frame).
• Check continuity for the orange wire from J43-5 to B.P3-2
• Check continuity for the violet wire from J43-11 to B.P3-3
• Check for short circuit between violet/orange wires
• Check for short circuit between orange/violet wires to chassis/GND
There is continuity for all wires and no short circuit.
Y N
Replace/Repair wire Harness.
• Connect B.P3 and leave P43 disconnected (Stapler harness goes to inside frame).
• Enter Service mode and start Stapler Motor (M20) in check motors (GP 4).
• Measure VDC between the orange wire J43-5 and the violet wire J43-11.
The voltage pulse is 2030 VDC?
Y N
• Disconnect plug B.P3 from PCB “B”. Stapler Motor (M20) in check motors again.
• Measure VDC between J.3-2 and J.3-3.
Is the voltage pulse 2030 VDC?
(This Pulse is short. Maybe not possible to see at Multimeter)
Y N

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BM-049 Stapler Home Pos Right Sensor BM-Q47 Cycle Timeout
This Fault code indicates that the Stapler Right Motor BM-M21 (PL 7.0) had a Cycle timeout.

Initial Actions
Enter Service Mode and run Motor Diagnostic, that will indicate a more precise fault code.

Procedure
Enter Service Mode and select Stapler Right Motor (BM-M21) in check motors ( GP4).
The Stapler home position sensor (Q47) indicates :
1 when the Stapler is up, and 0 when the Stapler is down.
Y N
• Disconnect plug C.P16 and from MD6DC PCB “C”.
• Measure between J.16-2 and J.13-9 (5V and GND).
• Measure between J.13-8 and J.13-9 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “C”. (PL 4.0)
• Disconnect plug P44 from Stapler.
• Check continuity for the red wire at plug J44-9 to C.P16-2
• Check continuity for the white wire at plug J44-3 to C.P13-8
• Check continuity for the black wire at plug J44-10 to C.P13-9
• Check for Short circuit between red/white/black wires
• Check for short circuit between red/white/black wires and chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug C.P13 and C.P16 to MD6DC PCB “C”.
• Go to theBM-052 RAP
Go to theBM-052 RAP

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BM-050 Clinch Trig Sensor Right BM-Q48 Cycle timeout
This Fault code indicates that the Stapler Right Motor BM-M21 (PL 7.0) had a Cycle timeout.

Initial Actions
Enter Service Mode and check that Stapler Right Motor BM-M21 runs (GP4).

Procedure
Enter Service mode and select Stapler Right Motor BM-M21 ( GP4).
The Stapler Right Motor ( BM-M21) Clinch Trigger Sensor (Q48) indicates :
0 when the Stapler is up, and :1 when the Stapler is down.
Y N
• Disconnect plug C.P16-1 and from MD6DC PCB “C”.
• Measure between J.16-1 and J.13-12 (5V and GND).
• Measure between J.13-11 and J.13-12 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “C”. (PL 4.0)
• Disconnect plug P44 from Stapler.
• Check continuity for the red wire at plug J44-8 to C.P16-1
• Check continuity for the white wire at plug J44-7 to C.P13-11
• Check continuity for the black wire at plug J44-12 to C.P13-12
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires and chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug C.P13 and C.P16 to MD6DC PCB “C”.
• Go to the BM-052 RAP
Go to theBM-052 RAP

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BM-051 Stapler Right Motor BM-M21 Short Circuit
This Fault code indicates that the Stapler Right Motor BM-M21 (PL 7.0) has a short circuit.

Initial Actions
• Ensure that both Stapler Heads are in upper position.
• Ensure that Connector “Clinch Left” and “Clinch Right” are connected.
• Ensure that Connector “J39 / P39” and “J40 / P40” are connected.
• Ensure that Connector “A.P1” is connected.
• Ensure that C.P3, C.P13, C.P16, J42/P42 and J44/P44 are connected.
• Check the cables and connectors for damages.
• Ensure that plug D.P1 on SCP universal PCB “D” (PL 3.1) is connected.

Procedure
• Disconnect plug C.P3 from MD6DC PCB “C” and P44 (Stapler harness goes to inside frame).
• Check wires for short circuit between the orange wire J44-5 to C.P3-7 (violet).
• Check wires for short circuit between the violet wire J44-11 to C.P3-6 (orange).
• Check short circuit between wires to chassis.
Is there a short circuit
Y N
• Replace Stapler Right BM-M21 (PL 7.0)
• Replace MD6DC PCB “C”. (PL 4.0)
Replace/Repair wire Harness.

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BM-052 Stapler Right Motor BM-M21 Open Circuit
This Fault code indicates that the Stapler Motor BM-M21 (PL 7.0) has an open circuit.

Initial Actions
• Ensure that both Stapler Heads are in upper position.
• Ensure that Connector “Clinch Left” and “Clinch Right” are connected.
• Ensure that Connector “J39 / P39” and “J40 / P40” are connected.
• Ensure that Connector “A.P1” is connected.
• Ensure that C.P3, C.P13, C.P16, J42/P42 and J44/P44 are connected.
• Check the cables and connectors for damages.

Procedure
• Disconnect plug P44 and C.P3 from PCB “C”.
• Check continuity for the orange wire from J44-5 to C.P3-6
• Check continuity for the violet wire from J44-11 to C.P3-7
• Check for short circuit between violet/orange wires
• Check for short circuit between orange/violet wires to chassis/GND
There is continuity for all wires and no short circuit.
Y N
Replace/Repair wire Harness.
• Disconnect P44 (Stapler harness goes to inside frame).
• Enter Service mode and start Stapler Motor (M21) in check motors.
• Measure VDC between the orange wire P44-5 and the violet wire P44-11.
The voltage pulse is 2030 VDC?
(This Pulse is short may not be possible to measure with Multimeter)
Y N
• Disconnect plug C.P3 from MD6DC PCB “C”.
• Enter service, GP4, check motors, Stapler Motor (M21)
• Measure VDC between J.3-6 and J.3-7.
The voltage pulse is 2030 VDC?
(This Pulse is short, maybe not possible to see with Multimeter)
Y N
Replace MD6DC PCB “C”. (PL 4.0)
Replace/Repair wire Harness.
Replace Stapler Right BM-M21 (PL 7.0)

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BM-053 Stop Gate BM-M22 Motor Sensor BM-Q41
no displacement pulses
This Fault code indicates that Stop Gate (M22) Motor Sensor BM-Q41 (PL 5.0)
does not receive any encoder pulses Replace/Repair Wire Harness.

Initial Actions • Connect plug H.P14 to MD6DC PCB “H”.

• Measure between the red wire Q41 and the black wire Q41 (5V and GND).
• Enter Service Mode and run Motor Diagnostic, that will indicate a more precise fault code.
• Measure between the white wire Q41 and the black wire Q41 (Signal and GND).
• Enter Service Mode and select Stop Gate Stapler Motor (BM-M22) in check motors ( GP1).
• Measure between the grey wire Q41 and the black wire Q41 (Signal and GND).
• Ensure that plug H.P11 on MD6DC PCB “H” in the Booklet Maker is connected.
The voltage is 5 VDC ± 10%.
• Ensure that plugs H.P14 and H.P13 on MD6DC PCB “H” in the Booklet Maker are connected.
Y N
• Ensure that plugs H. P2, H.P4, H.P5 and H.P16 on MD6DC PCB “H”
in the Booklet Maker are connected. Replace/Repair Wire Harness.
• Ensure that jack/plug P/J35 / P/J36 in the Booklet Maker are connected. Go to BM-056 RAP
• Ensure encoder magnet motor is mounted correctly (PL 5.0). Go to BM-056 RAP
The distance should be approx. 0.5 mm between magnet and hallsensor on motor PCB.

Procedure
Enter Service mode and select sensor Q41A, Q41B ( GP4).
Q41A, Q41B is toggling between 0 and 1 when rotating the Motor shaft.
Y N
• Disconnect plug H.P14 from MD6DC PCB “H” (PL 4.0).
• Measure between J.14-9 and J14-6 (5V and GND)
• Measure between J14-4 and J14-6 (Signal and GND)
• Measure between J14-7 and J14-6 (Signal and GND)
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “H””.
• Disconnect plug from sensor Q41.
• Check continuity for the red wire at plug Q41 to H.P14-9
• Check continuity for the white wire at plug Q41 to H.P14-4
• Check continuity for the grey wire at plug Q41 to H.P14-7
• Check continuity for the black wire at plug Q41 to H.P14-6
• Check for short circuit between red/white/black/grey wires
• Check for short circuit between red/white/grey/black wires and chassis/GND.
There is continuity for all wires and no short circuit.
Y N

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BM-054 Home Pos. Stop Gate Stapler BM-M22 Sensor Timeout
This Fault code indicates that Stop Gate Stapler BM-M22 Motor does not reach home position in time.

Initial Actions
• Enter Service Mode (GP1) and check that Stop Gate Stapler Motor BM-M22 (PL 5.0) Replace/Repair Wire Harness.
runs in (GP4) check motors. • Replace sensor BM-Q42 (REP 4.6) (PL 5.0)
• Ensure that Home Position Stop Gate Stapler Q42 (PL 5.0) is installed correctly. • Replace MD6DC PCB “H””. (PL 4.0)
Procedure Turn the Stop Gate Stapler Assembly by hand. (Power Off Machine)

Enter Service mode and select Home Position Stop Gate Stapler (Q42) in check sensors (GP 1). Is there a bind in the assembly?

The Stop Gate Stapler Home Position Sensor indicates : Y N

1 when the sensor is blocked, and 0 when the sensor is unblocked. Check for interference.

Y N Go to BM-056 RAP

• Disconnect plug H.P13 from MD6DC PCB “H”.

• Measure between J.16-1 and J.13-3 (5V and GND).
• Measure between J.13-2 and J.13-3 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “H””.
• Disconnect plug from sensor Q42.
• Check continuity for the red wire at plug Q42 to H.P16-1
• Check continuity for the white wire at plug Q42 to H.P13-2
• Check continuity for the black wire at plug Q42 to H.P13-3
• Check for Short circuit between red/white/black wires
• Check for short circuit between red/white/black wires and chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug H.P13 to MD6DC PCB “H”.
• Measure between the red wire Q42 and the black wire Q42 (5V and GND).
• Measure between the white wire Q42 and the black wire Q42 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N

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BM-055 Stop Gate Stapler Motor BM-M22 Short Circuit BM-056 Stop Gate Stapler Motor BM-M22 Open Circuit
Fault code indicates the Stop Gate Stapler Motor BM-M22 (PL 7.0) has a short circuit. Fault code indicates the Stop Gate Stapler Motor BM-M22 (PL 7.0) has an open circuit.

Procedure Initial Actions

• Disconnect the motor plug M22. Enter Service Mode (GP4) for Motor BM-M22. • Ensure that plug D.P1 on SCP universal PCB “D” (PL 3.1) is connected.
Fault code BM-056 (Open circuit) is displayed? Procedure
Y N • Disconnect Motor plug M22 and H.P2 from MD6DC PCB “H” (PL 4.0).
• Disconnect plug H.P2 from PCB “H”. • Check continuity for the orange wire from M22-1 to H.P2-2
• Check wires for Short circuit across orange wire M22 to H.P2-9 (violet). • Check continuity for the violet wire from M22-2 to H.P2-9
• Check wires for Short circuit across the violet wire M22 to H.P2-2 (orange). • Check for short circuit between violet/orange wires and
• Check short circuit between wires to chassis. between orange/violet wires to chassis/GND

There is a short circuit. There is continuity for all wires and no short circuit

Y N Y N

Replace MD6DC PCB “H””. (PL 4.0) Replace/Repair wire Harness.

Replace/Repair wire Harness. • Enter Service mode and start Stop Gate Stapler Motor (BM-M22) in GP4

Replace motor BM-M22 (REP 4.4) (PL 5.0). • Measure VDC between the orange wire M22-1 and the violet wire M22-2.
The voltage is approximately 30 VDC?
Y N
• Disconnect plug H.P2 from MD6DC PCB “H” and
Stop Gate Stapler Motor (BM-M22) in GP4.
• Measure VDC between J.2-2 and J2-9.
The voltage is approximately 30 VDC?
Y N
Replace MD6DC PCB “H””.(PL 4.0)
Replace/Repair wire Harness.
Replace motor BM-M22 (PL 7.0).

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BM-057 Thick Set Motor BM-M23 Sensor BM-Q37 no displacement
pulses Replace/Repair Wire Harness.
This Fault code indicates the Thick Set Motor BM-M23 (PL 7.1) does not receive any encoder pulses • Connect plug F.P3 to Addon PCB “F” (PL 3.1).

Initial Actions • Measure between the red wire Q37 and the black wire Q37 (5V and GND).

• Enter Service Mode and run Motor Diagnostic, that will indicate a more precise fault code. • Measure between the white wire Q37 and the black wire Q37 (Signal and GND).

• Enter Service Mode and select Thick Set motor (M23) in check motors (GP4) . The voltage is 5 VDC ± 10%.

• Ensure that plug C.P11, C.P14, C.P2 on MD6DC PCB “C” (PL 4.0) Y N
in the Booklet Maker are connected. Replace/Repair Wire Harness.
• Ensure that plug F.P3 on Addon PCB “F” (PL 3.1) in the Booklet Maker is connected. Go to BM-060 RAP
• Ensure that jack/plug P/J48, P/J47 in the Booklet Maker are connected. Go to BM-060 RAP
• Ensure encoder magnet is mounted correctly and not interfering with hallsensor at PCB.
The distance should be approx. 0.5 mm between magnet and hallsensor on PCB.

Procedure
Enter Service Mode (GP1) and select sensor Q37 (GP 4).
Q37 is toggling between 0 and 1 when rotating the Motor shaft.
Y N
• Disconnect plug F.P3 from Addon PCB “F” (PL 3.1).
• Measure between J.3-1 and J.3-4 (5V and GND)
• Measure between J3-3 and J.3-4 (Signal and GND)
The voltage is 5 VDC ± 10%.
Y N
Replace Addon PCB “F” . (PL 3.1)
• Disconnect plug from sensor Q37.
• Check continuity for the red wire at plug Q37-4 to F.P3-1
• Check continuity for the white wire at plug Q37-2 to F.P3-3
• Check continuity for the black wire at plug Q37-3 to F.P3-4
• Check for Short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N

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BM-058 Thick Set Motor BM-M23 home sensor BM-Q36 Cycle
Timeout
This Fault code indicates that the Thick Set Motor BM-M23
does not reach home position sensor BM-Q36 in time
Repair Wire Harness.
Initial Actions
• Enter service mode (GP1) and check that Thick Set Motor BM-M23 (PL 7.1) runs in (GP4) check • Replace sensor BM-Q36. (PL 7.1)
motors.
• Replace Addon PCB “F” (PL 3.1).
• Ensure that Thick Set Home Position Sensor BM-Q36 (PL 7.1) is installed correctly.
Turn the Thick Set Shaft by hand.
Procedure The shaft turns without using force.
• Enter Service Mode and select Thick Set Home Position (Q36) in check sensors (GP 4). Y N
Thick Set Home Position Sensor indicates : Check for interference.
1 when the sensor is blocked, and 0 when the sensor is unblocked. Go to BM-060 RAP
Y N
• Disconnect plug F.P4 and F.P6 from Addon PCB “F” (PL 3.1).
• Measure between J4-1 and J6-6 (5V and GND).
• Measure between J6-5 and J6-6 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace Addon PCB “F” . (PL 3.1)
• Disconnect plug from sensor Q36.
• Check continuity for the red wire at plug Q36 to F.P4-1
• Check continuity for the white wire at plug Q36 to F.P6-5
• Check continuity for the black wire at plug Q36 to F.P6-6
• Check for short circuit between red/white/black wires.
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Repair Wire Harness.
• Connect plug F.P4 to Addon PCB “F” (PL 3.1).
• Measure between the red wire Q36 and the black wire Q36 (5V and GND).
• Measure between the white wire Q36 and the black wire Q36 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N

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BM-059 Thick Set Motor BM-M23 Short Circuit BM-060 Thick Set Motor BM-M23 Open Circuit
Fault code indicates that the Thick Set Motor BM-M23 (PL 7.1) has a short circuit. Fault code indicates that the Thick Set Motor BM-M23 (PL 7.1) has an open circuit.

Procedure Initial Actions

Disconnect the motor plug M23. Run M23 in GP4 • Ensure that plug D.P1 on SCP universal PCB “D” (PL 3.1) is connected.

Fault code BM-060 (Open circuit) is displayed? Procedure

Y N • Disconnect motor plug M23 and H.P2 from MD6DC PCB “H” (PL 4.0).
• Disconnect plug C.P2 from MD6DC PCB “C” (PL 4.0). • Check continuity for the orange wire from M23 to C.P2-3
• Check wires for Short circuit between the orange wire M23 to violet C.P2-3. • Check continuity for the violet wire from M23 to C.P2-10
• Check wires for Short circuit between the violet wire M23 to orange C.P2-10. • Check for short circuit between violet/orange wires and
between orange/violet wires to chassis/GND
• Check short circuit between wires to chassis.
There is continuity for all wires and no short circuit
There is a short circuit
Y N
Y N
Replace/Repair wire Harness.
Replace MD6DC PCB “C(PL 4.0).
Enter Service mode and start Thick Set Motor (M23) in GP4
Replace/Repair wire Harness.
Measure VDC between the orange wire M23 and the violet wire M23
Replace motor BM-M23 (PL 7.1).
The voltage is approximately 30 VDC?
Y N
• Disconnect plug C.P2 from MD6DC PCB “C”.
• Start Thick Set Motor (M23) in GP4
• Measure VDC between J.2-3 and J.2-10
The voltage is approximately 30 VDC?
Y N
Replace MD6DC PCB “C”.
Repair wire Harness.
Replace motor BM-M23 (PL 7.1).

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BM-062 Paper infeed sensor BM-Q1 Faulty
This Fault code indicates that the Paper infeed sensor (BM-Q1) is faulty.

Initial Actions
• Ensure that the Paper infeed sensor BM-Q1 (PL 5.3) is installed correctly.

Procedure
• Enter Service Mode and select BM-Q1 Paper infeed sensor in check sensors (GP 4).
Paper Infeed Sensor indicates:
1 when the sensor is blocked, and 0 when the sensor is unblocked.
Y N
• Disconnect plug A.P1 at PCB A.
• Measure between J1-7 and J1-9 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace CPU/Controller PCB “A” (PL 3.1).
• Disconnect sensor plug Q1.
• Check continuity for the red wire at plug Q1 to A.P1-7
• Check continuity for the white wire at plug Q1 to A.P1-8
• Check continuity for the black wire at plug Q1 to A.P1-9
• Check for short circuit between red/white/black wires.
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit.
Y N
Replace/Repair Wire Harness.
• Connect plug A.P1 from PCB A.
• Measure between the red wire Q1 and the black wire Q1 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace/Repair Wire Harness.
Replace Sensor BM-Q1 (PL 5.3)
Replace CPU/Controller PCB “A” (PL 3.1).

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BM-063 Start sensor Saddle stapling BM-Q4 Faulty
This Fault code indicates that the Start sensor, Saddle stapling sensor BM-Q4 is faulty.

Initial Actions
• Ensure that the Start sensor Saddle stapling BM-Q4 (PL 5.1) is installed correctly.

Procedure
• Enter Service Mode and select Start sensor Saddle stapling (BM-Q4) in check sensors (GP4)
Start Sensor Saddle Stapling Sensor indicates :
1 when the sensor is blocked, and 0 when the sensor is unblocked.
Y N
• Disconnect plug A.P1 from Controller PCB “A”.
• Measure between J.1-4 and J.1-6 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace CPU/Controller PCB “A” (PL 3.1).
• Disconnect plug from sensor Q4.
• Check continuity for the red wire at plug Q4 to A.P1-4.
• Check continuity for the white wire at plug Q4 toA.P1-5
• Check continuity for theblack wire at plug Q4 to A.P1-6
• Check for short circuit between red/white/black wires
and between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug A.P1 to Controller PCB “A”.
• Disconnect plug at Q4.
Measure between the red wire Q4 and the black wire Q4 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace/Repair Wire Harness.
Replace Sensor BM-Q4 (PL 5.1)
Replace CPU/Controller PCB “A” (PL 3.1).

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BM-064 Stop Gate Folder sensor BM-Q7 Faulty
This Fault code indicates that the Stop Gate Folder sensor BM-Q7 is faulty.

Initial Actions
• Ensure that the Stop Gate Folder sensor BM-Q7 (PL 6.2) is installed correctly.

Procedure
• Enter Service Mode and select Stop Gate Folder sensor BM-Q7 in check sensors GP4)

Start Fold Sensor indicates:

1 when the sensor is blocked, and 0 when the sensor is unblocked.
Y N
• Disconnect plug A.P1 from Controller PCB “A” (PL 3.1) and
H.P16 at MD6DC PCB “H”
• Measure between J.1-11 and J.1-12 CPU PCB A (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace CPU/Controller PCB “A” (PL 3.1).
Measure 5VDC ±10% from H.P16-2 to A.P.1-12
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “H”” (PL 4.0)
• Connect plug A.P1 to Controller PCB “A” and H.P16 to MD6DC PCB “H”,
• Disconnect Q7.
• Measure form Q7 Pin 1 to 3 and Q7 and Pin 2 to 3.
The voltage is 5 VDC ± 10%.
Y N
Replace/Repair Wire Harness.
Replace BM-Q7 Sensor (PL 6.2)
Replace CPU/Controller PCB “A” (PL 3.1).

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BM-065 Exit Sensor BM-Q8 Faulty
This Fault code indicates that the Exit Sensor BM-Q8 is faulty.

Initial Actions
• Ensure that the Exit Sensor in the Booklet Maker BM-Q8 (PL 2.1) is installed correctly.

Procedure
• Enter Service Mode and select Exit Sensor BM-Q8 in check sensors GP4)

Exit Sensor indicates

1 when the sensor is blocked, and 0 when the sensor is unblocked.
Y N
• Disconnect plug A.P1 from Controller PCB “A” (PL 2.1).
• Measure between J.1-1 and J.1-19 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace CPU/Controller PCB “A” (PL 3.1).
• Disconnect plug from sensor Q8.
• Check continuity for the red wire at plug Q8 to A.P1-1
• Check continuity for the white wire at plug Q8 to A.P1-18
• Check continuity for the black wire at plug Q8 to A.P1-19
• Check for short circuit between red/white/black wires and
between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug A.P1 to Controller PCB A.
• Measure between the red wire Q8 and the black wire Q8 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace/Repair Wire Harness.
Replace BM-Q8 (REP 6.9) (PL 2.1)
Replace CPU/Controller PCB “A” (PL 3.1).

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BM-069 Staple Detection Clinch Left Sensor BM-Q19 Short Circuit
This Fault code indicates that the Clincher is shorted to frame or GND.
Possible failures:
• Staple or staplerhead is in contact with the clincher.
• Short in sensor cable that goes to clincher BM-Q19 (PL 7.0).

Initial Actions
• Ensure that both Stapler Heads are in upper position.
• Ensure that Connector “Clinch Left” and “Clinch Right” are connected.
• Ensure that Connector “J39 / P39” and “J40 / P40” are connected.
• Ensure that Connector “A.P1” is connected.
• Check all cables to above connectors are not damaged.

Procedure
• Disconnect plug A.P1 from CPU/Controller PCB “A”.
• Measure between J1-24 and Chassis/GND (Signal and GND)
The voltage is 5 VDC ± 10%.
Y N
Replace CPU/Controller PCB “A”.(PL 3.1)
• Disconnect plug “Clinch Left”
• Check white wire to A.P1-24 to frame.
Is there a short circuit
Y N
Check J4 at Left Clinch to frame for short circuit.
Is there a short circuit
Y N
Replace CPU/Controller PCB “A”.
Replace Clinch Left (PL 7.0)
Replace/Repair Wire Harness.
Replace/Repair wire harness.

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BM-070 Staple Detection Clinch Right Sensor BM-Q20 Short Circuit
This Fault code indicates the Clincher is in contact with frame or GND.
Possible failures:
• Staple or staplerhead is in contact with the clincher.
Short in sensor cable that goes to clincher BM-Q20 (PL 7.0).

Initial Actions
• Ensure that both Stapler Heads are in upper position.
• Ensure that Connector “Clinch Left” and “Clinch Right” are connected.
• Ensure that Connector “J39 / P39” and “J40 / P40” are connected.
• Ensure that Connector “A.P1” is connected.
• Check all cables to above connectors are not damaged.

Procedure
• Disconnect plug A.P1 from CPU/Controller PCB “A”.
• Measure between J.1-15 and Chassis/GND (Signal and GND)
The voltage is 5 VDC ± 10%.
Y N
Replace CPU/Controller PCB “A” (PL 3.1).
• Disconnect plug “Clinch Right”
• Check grey wire to A.P.1-15 to frame.
Is there a short circuit?
Y N
Check J4 at Right Clinch to frame for short circuit.
Is there a short circuit?
Y N
Replace CPU/Controller PCB “A” (PL 3.1).
• Replace Clinch Right (PL 7.0)
• Replace/Repair Wire Harness.
Replace/Repair wire harness.

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BM-071 Docking Sensor BM-Q35 faulty
This fault code indicates that Docking Sensor BM-Q35 is faulty.

Initial Actions
• Ensure that Docking Sensor BM-Q35 is installed correctly.

Procedure
• Enter Service Mode and select Docking Sensor Q35 in check sensors GP4)
Docking Sensor indicates
1 when the sensor is blocked, and 0 when the sensor is unblocked.
Y N
Disconnect plug F.P6 from ADDON PCB F
Measure between J.6-1 and J.6-3 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
• Replace cable between PCB “A” and “F”
• Replace Addon PCB “F”
• Replace CPU/Controller PCB “A” (PL 3.1).
• Disconnect plug from sensor Q35.
• Check continuity for the red wire at plug Q35 to F.P6-1
• Check continuity for the white wire at plug Q35 to F.P6-2
• Check continuity for the black wire at plug Q35 to F.P6-3.
and that F.P6 is connected to Addon PCB “F”.
• Check for short circuit between red/white/black wires
and between red/white/black wires to chassis/GND
There is Continuity on all wires and no short circuit between
red/white/black wires and red/white/black wires to chassis.
Y N
Replace/Repair Wire Harness.
Connect plug F.P6 to ADDON PCB F.
Measure between the red wire Q35 and the black wire Q35 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace/Repair Wire Harness.
Replace Q35
Replace Addon PCB “F”
Replace CPU/Controller PCB “A” (PL 3.1).

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BM-150 30VDC low at Lower MD6DC PCB “C”
This RAP is for troubleshooting a low 30VDC at Lower MD6DC PCB “C”.
If this RAP frequently ends up with blown F1, go to F1 Blown RAP

Initial Actions
• Ensure that all connectors to SCP (Short Circuit Protection) PCB “D” (PL 3.0) are connected.
• Ensure that plugs/jacks related to 30VDC PSU (PL 3.1) are properly connected.
• Ensure that all connectors connecting to REL-1 (PL 3.1) are properly connected
• Ensure that all connectors connecting to PCB “J” (PL 3.0) are properly connected.
• Ensure that connectors H.P11, B.P11, B.P12, C.P11, C.P12, A.P13, J.P12
and all connectors related to SW1 are properly connected.
• If a Square Folder/Trimmer is installed to the Booklet Maker
ensure that A.P11, B.P2, D.P11, D.P12 and connectors related to SW1 in the Square Folder/Trimmer are properly connected.
• If Square Folder/Trimmer is not installed, ensure that the Terminator is connected to Booklet maker J12.

Procedure
• Power on the machine and enter Service Mode, close the top cover,
• If there is a Square Folder/Trimmer connected close the top covers.
• Measure between +V and –V at the 30VDC PSU,
adjust the trimmer potentiometer on the 30VDC PSU (PL 3.1) until you reached a value between 29.8-30.2VDC.
• If you have no success adjusting the voltage, go to BM-154 30VDC low at Upper MD6DC PCB “H”.

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BM-151 30VDC very low at Lower MD6DC PCB “C”
This RAP is for troubleshooting a low 30VDC at Lower MD6DC PCB “C”.
If this RAP frequently ends up with blown F1, go to F1 Blown RAP

Initial Actions
• Ensure that all connectors to SCP (Short Circuit Protection) PCB “D” (PL 3.0) are connected.
• Ensure that plugs/jacks related to 30VDC PSU (PL 3.1) are properly connected.
• Ensure that all connectors connecting to REL-1 (PL 3.1) are properly connected.
• Ensure that all connectors connecting to PCB “J” (PL 3.0) are properly connected.
• Ensure that connectors H.P11, B.P11, B.P12, C.P11, C.P12, A.P13, J.P12 and
all connectors related to SW1 (PL 1.0) are properly connected.
• If a Square Folder/Trimmer is installed to the Booklet Maker Ensure A.P11, B.P2, D.P11, D.P12
and connectors related to SW1 in the Square Folder/Trimmer are properly connected.
• If a Square Folder/Trimmer is not installed, ensure the Terminator is connected to Booklet maker J12.
• If any of the 30VDC checks are between 22.0VDC and 28.9VDC
go to BM-150 30VDC Low at Lower MD6DC “C” RAP.

continued on next page

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Power Flow Chart Booklet Maker
Overview over the power distribution in the Booklet Maker system

continued on next page

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Procedure
Power on the machine, close the top cover.
If there is a Square Folder/Trimmer connected close the top covers.
Does the Interlock Relay REL-1 (PL 3.1) activate (even for a short period)
Y N
Go to Interlock Relay RAP
• Power off, disconnect C.P12 ( PL 3.0) wait 120 seconds then power on the machine, measure VDC between C.P11-1 and C.P11-2.
There might be only a short period when the voltage is present so pay attention.
• Close the top cover, if there is a Square Folder/Trimmer connected close top covers.
The voltage is 29.0-31.0VDC
N Y
Go to 30VDC low at Middle MD6DC PCB “B( PL 4.0)
• Power off, reconnect C.P12 wait 120 seconds then power on the machine, measure VDC between C.P11-1 and C.P11-2.
There might be only a short period when the voltage is present so pay attention.
• Close the top cover, if there is a Square Folder/Trimmer connected close top covers.
The voltage is 29.0-31.0VDC
Y N
• Power off the machine, disconnect D.P2 ( PL 3.0)
wait 120 seconds then power on the machine, measure VDC between J.2-3 and J2-9 on PCB “D”.
There might be only a short period when the voltage is present,so pay attention.
• Close the top cover, if there is a Square Folder/Trimmer connected close top covers.

The voltage is 29.0-31.0VDC

Y N
Go to No 30VDC from SCP PCB “D” RAP
• Power off the machine, remove the main power Cord, disconnect D.P2 and disconnect C.P11.
• Measure resistance between C.P11-1 and chassis.
There is a short circuit
Y N
• Power off the machine, remove the main power Cord, leave D.P2 and C.P11 disconnected.
• Measure resistance between D.P2-1 and chassis, and between D.P2-2 and chassis.
There is a short circuit
Y N
continued on next page
1 2 3 4

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1 2 3 4
• Power off the machine, remove the main power Cord, leave D.P2 and C.P11 disconnected,
• Measure resistance between D.P2-1 and chassis, and between D.P2-2 and chassis.
There is a short circuit
Y N
• Power off the machine, remove the main power Cord,
leave C.P11 and D.P2 disconnected.
• Measure resistance between C.P11-1 and D.P2-3,
also measure resistance between C.P11-2 and D.P2-9.
There is connectivity
Y N
Repair/replace harness
• Power off the machine, reconnect C.P11 and D.P2.
Disconnect C.P2 and C.P3. Wait 120 seconds, power on the machine. Measure VDC between C.P11-1 and C.P11-2.
There might be only a short period when the voltage is present, so pay attention.
• Close the top cover,
if there is a Square Folder/Trimmer connected close top covers.
The voltage is 29.0-31.0VDC
Y N
Replace Lower MD6DC PCB “C”
Locate the short circuit related to C.P2 and C.P3 and repair/replace.
Success
Y N
Replace Lower MD6DC PCB “C”
Exit
• If there is a Square Folder/Trimmer installed, Power off the machine,
remove the main power Cord and disconnect the Power Cable
between Booklet Maker and Square Folder/Trimmer.
• Leave D.P2 and C.P11 disconnected,
measure resistance between D.P2-1 and chassis, D.P2-2 and chassis.
There is still a short circuit
Y N
Go to Square Folder/Trimmer Service Manual, 30VDC Low RAP
Repair/replace harness
Repair/replace harness
Replace Lower MD6DC PCB “C”

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BM-152 30VDC High at Lower MD6DC PCB “C”
This RAP is for troubleshooting a high 30VDC at Lower MD6DC PCB “C”.
If this RAP frequently ends up with blown F1, go to F1 Blown Up RAP

Initial Actions
• Ensure that all connectors to SCP (Short Circuit Protection) PCB “D” (PL 3.0) are properly connected.
• Ensure that plugs/jacks related to 30VDC PSU (PL 3.1) are properly connected.
• Ensure that all connectors connecting to REL-1 are properly connected.
• Ensure that all connectors connecting to PCB “J” (PL 3.1) are properly connected.
• Ensure that connectors (Deburster K.P11) H.P11, B.P11, B.P12, C.P11, C.P12, A.P13, J/P12
and all connectors related to SW1 are properly connected.
• If a Square Folder/Trimmer is installed to the Booklet Maker,
ensure that A.P11, B.P2, D.P11, D.P12 and connectors related to SW1 in the Square Folder/Trimmer are properly connected.
• If a Square Folder/Trimmer is not installed, ensure that the short link connector is connected to Booklet maker J12.

Procedure
• Power on the machine and enter the service menu, close the top cover
• If there is a Square Folder/Trimmer connected close top covers.
• Measure between +V and –V at the 30VDC PSU,
adjust the trimmer potentiometer on the 30VDC PSU until you reached a value between 29.8-30.2VDC.

If you have no success adjusting the voltage, perform following in order:

• Load latest software version to ARM PCB “A” (PL 3.1).

• Replace ARM PCB “A”
• Replace 30VDC PSU (REP 7.8) (PL 3.0).

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BM-153 30VDC low at Middle MD6DC PCB “B”
If this RAP frequently ends up with blown F1, go to F1 Blown Up RAP Go to BM-051 30VDC very low at Lower MD6DC PCB “C”
Initial Actions • Power off the machine, leave C.P12 disconnected wait 120 seconds.
Power on the machine, measure VDC between J.12-1 and J.12-2 at PCB “C”.
• Ensure that all connectors to SCP (Short Circuit Protection) PCB “D” (PL 3.0) There might be only a short period when the voltage is present so pay attention.
are properly connected.
The voltage is 29.0-31.0VDC
• Ensure that plugs/jacks related to 30VDC PSU are properly connected.
Y N
• Ensure that all connectors connecting to REL-1 are properly connected
Replace Lower MD6DC PCB “C”
• Ensure that all connectors connecting to PCB “J” are properly connected.
• Power off the machine, remove the main power Cord.
• Ensure that connectors H.P11, B.P11, B.P12, C.P11, C.P12, A.P13, J/P12
and all connectors related to SW1 are properly connected. • Disconnect B.P12 and leave C.P12 disconnected,
measure resistance between B.P12-1 and chassis.
• If a Square Folder/Trimmer is installed to the Booklet Maker,
ensure that A.P11, B.P2,D.P11, D.P12 and connectors related to There is a short circuit
SW1 in the Square Folder/Trimmer are properly connected. Y N
• If a Square Folder/Trimmer is not installed, • Power off the machine, remove the main power Cord,
ensure that the short link connector is connected to Booklet maker J12. leave C.P12 and B.P12 disconnected,
• If any of the 30VDC measurements below ends up with • Measure resistance between C.P12-1 and B.P12-1.
30VDC being between 22.0VDC and 28.9VDC,
proceed to BM-150 30VDC Low at Lower MD6DC “C” RAP. • Measure resistance between C.P12-2 and B.P12-2.

Procedure There is connectivity

Y N
Power on the machine, close the top cover,
if there is a Square Folder/Trimmer connected close top covers. Repair/replace harness
Does the Interlock Relay activate (even for a short period) • Power off the machine, reconnect B.P12 and C.P12.
Y N • Disconnect B.P2 and B.P3. Wait 120 seconds, power on the machine.
Go to Interlock Relay RAP • Measure VDC between B.P12-1 and B.P12-2.
There might be only a short period when the voltage is present so pay attention.
• Power off, disconnect B.P11 (PL 3.0) wait 120 seconds. Power on the machine,
measure VDC between B.P12-1 and B.P12-2. • Close the top cover,
There might be only a short period when the voltage is present so pay attention. if there is a Square Folder/Trimmer connected close top covers.
• Close the top cover, if there is a Square Folder/Trimmer connected close top covers. The voltage is 29.0-31.0VDC
The voltage is 29.0-31.0VDC Y N
N Y Replace Middle MD6DC PCB “B”
Go to 30VDC low at Upper MD6DC PCB “H” Locate the short circuit related to B.P2 and B.P3 and repair/replace.
Power off the machine, disconnect C.P12 (PL 3.0) wait 120 seconds. Success
Power on the machine, measure VDC between C.P11-1 and C.P11-2.
There might be only a short period when the voltage is present so pay attention. Y N
Close the top cover, if there is a Square Folder/Trimmer connected close top covers. Replace Middle MD6DC PCB “B”
The voltage is 29.0-31.0VDC Exit
Y N Repair/replace harness
continued on next page

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BM-153 30VDC low at Middle MD6DC PCB “B”, continued

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BM-154 30VDC low at Upper MD6DC PCB “H”
This RAP is for troubleshooting a low 30VDC at Upper MD6DC PCB “H”. Replace Upper MD6DC PCB “H”

If this RAP frequently ends up with blown F1, go to F1 Blown Up RAP • Power off the machine, disconnect B.P11 wait 120 seconds then power on the machine,
• Measure VDC between B.P12-1 and B.P12-2.
Initial Actions There might be only a short period when the voltage is present so pay attention.
• Ensure that all connectors to SCP (Short Circuit Protection) PCB “D” (PL 3.0) Close the top cover, if there is a Square Folder/Trimmer connected close top covers.
are properly connected. The voltage is 29.0-31.0VDC
• Ensure that plugs/jacks related to 30VDC PSU are properly connected. Y N
• Ensure that all connectors connecting to REL-1 (PL 3.1) are properly connected. Go to BM-153 30VDC low at Middle MD6DC PCB “B”
• Ensure that all connectors connecting to PCB “J” (PL 3.0) are properly connected. • Power off the machine, leave B.P11 disconnected wait 120 second,
• Ensure that all connectors connecting to PCB “J” are properly connected. then power on the machine.

• Ensure that connectors H.P11, B.P11, B.P12, C.P11, C.P12, A.P13, J/P12 • Measure VDC between B.J11-1 and B.J11-2.
and all connectors related to SW1 are properly connected. There might be only a short period when the voltage is present so pay attention.

• If a Square Folder/Trimmer is installed to the Booklet Maker, The voltage is 29.0-31.0VDC

ensure A.P11, B.P2, D.P11, D.P12 and connectors related to SW1 Y N
in the Square Folder/Trimmer are properly connected.
Replace Middle MD6DC PCB “B” (PL 4.0).
• If a Square Folder/Trimmer is not installed,
ensure the short link connector is connected to Booklet maker J12. • Power off the machine, remove the main power Cord.
• If any of the 30VDC measurements below ends up with 30VDC • Disconnect H.P11 and leave B.P11 disconnected,
being between 22.0VDC and 28.9VDC measure resistance between H.P11-1 and chassis.
Proceed to BM-150 30VDC Low at Lower MD6DC “C” RAP.
There is a short circuit
Procedure Y N
Power on the machine, close the top cover, • Power off the machine, remove the main power Cord,
if there is a Square Folder/Trimmer connected close top covers. leave B.P11 and H.P11 disconnected,
Does the Interlock Relay activate (even for a short period)
• Measure resistance between H.P11-1 and B.P11-1.
Y N
• Measure resistance between H.P11-2 and B.P11-2.
Go to Interlock Relay RAP
There is connectivity
• Power off then power on the machine, measure VDC between H.P11-1 and H.P11-2.
Y N
• There might be only a short period when the voltage is present so pay attention.
Repair/replace harness
• Close the top cover, if there is a Square Folder/Trimmer connected close top covers.
• Power off the machine, reconnect B.P11 and H.P11.
The voltage is 29.0-31.0VDC
Disconnect H.P2 and H.P3. Wait 120 seconds, power on the machine.
N Y
• Measure VDC between H.P11-1 and H.P11-2.
There might be only a short period when the voltage is present so pay attention.
Close the top cover, if there is a Square Folder/Trimmer connected close top covers.
The voltage is 29.0-31.0VDC
Y N
continued on next page

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BM-154 30VDC low at Upper MD6DC PCB “H”, continued

Replace Upper MD6DC PCB “H” (PL 4.0).

Locate the short circuit related to H.P2 and H.P3 and repair/replace.
Success
Y N
Replace Upper MD6DC PCB “H” (PL 4.0).
Exit
Repair/replace harness

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BM-156 Relay off Timeout RAP (BM)
This RAP is for troubleshooting a not working Interlock Relay (REL-1).
If this RAP frequently ends up with blown F1, perform F1 Blown Up RAP

Initial Actions
• Ensure that all connectors to SCP (Short Circuit Protection) PCB “D” (PL 3.0) are properly connected.
• Ensure that all connectors to SCP (Short Circuit Protection) PCB “F” (PL 3.1) are properly connected.
• Ensure that all connectors to SCP (Short Circuit Protection) PCB “G” (PL 3.0) are properly connected.
• Ensure that plugs/jacks related to 30VDC PSU (PL 3.1) are properly connected.
• Ensure that plugs/jacks related to 12VDC PSU (PL 3.1) are properly connected.
• Ensure that all connectors connecting to REL1 (PL 3.1) are properly connected
• Ensure that all connectors connecting to PCB “J” (PL 3.0) are properly connected.
• Ensure that connectors H.P11, B.P11, B.P12, C.P11, C.P12, A.P13, J/P12
and all connectors related to SW1 are properly connected.
• If there is a Square Folder/Trimmer connected to the booklet maker,
ensure that A.P11, B.P2, D.P11,D.P12 and connectors related to SW1,
in the Trimmer are properly connected.
• If a Square Folder/Trimmer is not installed,
ensure the short link connector is connected to booklet maker J12

Procedure
Replace REL-1
Success
Y N
Go to SW1 Software signal (SW17) RAP

Exit.

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BM-157 Trimmer Communication Lost
Fault code indicates that there is a communication lost problem.

Initial Actions
• Ensure that the communication cable between the
Booklet Maker and the Square Folder is properly connected (see Installation).
Make sure dip/switch at PCB “V” is correctly set. Check BSD in section 8.
• Ensure that the communication cable between the
Square Folder and the Trimmer is properly connected (see Installation).
• Ensure the power to Booklet Maker and Square Folder is connected (see Installation).
• Ensure the power between Square Folder and Trimmer is connected (see Installation).

Procedure
Power on the machine, inside Trimmer, measure 12VDC between A.P4-4 and A.P4-5.
The voltage is 12VDC ± 10%
Y N
Go to No 12VDC RAP in Trimmer section
• Power off, inside Trimmer disconnect A.P6 and A.P7,
uninstall communication cable(s) between machines and disconnect both CAN terminations.

• Use the BSD to locate connectors/pins and measure continuity

between all wires from A.P6 to J23 and between A.P7 to P24.
• Check for short circuit between all wires from A.P6 and A.P7 to chassis and
between different pins at J23. Check for short circuit between different pins at P24.
There is connectivity and no short circuit
Y N
Repair/replace harness
• Measure continuity for all wires in the communication cable(s),
it could be one or two communication cables depending on system setup,
pin 1 to 1, 2 to 2, 3 to 3, 5 to 5 and 7 to 7.
• Check for short circuits between the different pins,
and from pin 1, 2, 5 and 7 to the connector housing (not pin3).
There is connectivity and no short circuit
Y N
Replace the failed communication cable(s) (PL 10.7).
Leave CAN terminations disconnected, at both CAN terminations measure resistance between pin 2 and pin 7.
The resistance is 120R ± 10%
Y N
Replace the failed CAN termination connector(s)
There is a Square Folder installed
Y N
continued on next page

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BM-157 Trimmer Communication Lost, continued

• Power off:
Inside Booklet Maker:
Disconnect A.P4
Uninstall the communication cable between Booklet Maker and Trimmer
Disconnect both CAN terminations.
• Use the BSD to locate connectors/pins, and
measure continuity between all wires from A.P4 to J23.
• Check for short circuit between all wires from A.P4 to chassis and
between different pins at J23.
There is connectivity and no short circuit
Y N
Repair/replace harness
Replace the MD6DC PCB “A” in the Trimmer

• Power off
Inside Square Folder:
Disconnect D.P6
Uninstall the communication cable between Square Folder and Trimmer
Disconnect both CAN terminations.
• Use the BSD to locate connectors/pins and
measure continuity between all wires from D.P6 to J23.
• Check for short circuit between all wires from D.P6 to chassis and
between different pins at J23.
There is connectivity and no short circuit
Y N
Repair/replace harness
Replace the MD6DC PCB “A” in the Trimmer

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BM-158 Square Folder Communication Lost
Fault code indicates that there is a communication lost problem. Replace the failed CAN termination connector(s)
Initial Actions • Power off.
Inside Booklet Maker:
• Ensure that the communication cable between the Booklet Maker and the Square Folder Disconnect A.P4
is properly connected (see Installation). Make sure dip/switch at PCB “V” is correctly set. Uninstall the communication cable between Booklet Maker and Square Folder
Check BSD. Disconnect both CAN terminations.
• Ensure that the communication cable between the Square Folder and the Trimmer is • Use the BSD to locate connectors/pins and
properly connected (see Installation). measure continuity between all wires from A.P4 to J23.
• Ensure the power to Booklet Maker and Square Folder is connected (see Installation). • Check for short circuit between all wires from A.P4 to chassis and
• Ensure the power between Square Folder and Trimmer is connected (see Installation). between different pins at J23.
There is connectivity and no short circuit
Y N
Procedure
Repair/replace harness
Power on the machine, inside Square Folder, measure 12VDC between D.P4-4 and D.P4-5.
Replace the MD6DC PCB “D” in the Square Folder
The voltage is 12VDC ± 10%
Y N
Go to No 12VDC RAP in Square Folder section
• Power off.
Inside Square Folder:
Disconnect D.P6 and D.P7.
Uninstall communication cable(s) between machines
Disconnect both CAN terminations.
• Use the BSD to locate connectors/pins and
measure continuity between all wires from D.P6 to J23 and between D.P7 to P24.
• Check for short circuit between all wires from D.P6 and D.P7 to chassis and
between different pins at J23. Check for short circuit between different pins at P24.
There is connectivity and no short circuit
Y N
Repair/replace harness
• Measure continuity for all wires in the communication cable(s),
it could be one or two communication cables depending on system setup,
pin 1 to 1, 2 to 2, 3 to 3, 5 to 5 and 7 to 7.
• Check for short circuits between the different pins,
and from pin 1, 2, 5 and 7 to the connector housing (not pin3).
There is connectivity and no short circuit
Y N
Replace the failed communication cable(s) (PL 10.7).
Leave CAN terminations disconnected,
at both CAN terminations measure resistance between pin 2 and pin 7.
The resistance is 120R ± 10%
Y N

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BM-159 PCB MD6DC “B” Not Connected
Fault code indicates that the MD6DC B is not connected.

Initial Actions
• Ensure that all connectors are properly connected to PCB MD6DC B (REP 7.1).
• Ensure that the dipswitches on the PCB are set correctly (REP 7.1 MD6DC PCB ”B” (middle)).

Procedure
• Power off the machine.
• Measure for continuity between
P4-1 on MD6DC B (PL 3.0) and P5-1 on MD6DC C (PL 3.0).

There is continuity.
Y N
Replace/Repair Wire Harness.

Measure for continuity between P4-2 on MD6DC PCB “B” and P5-2 on MD6DC PCB “C”.
There is continuity.
Y N
Replace/Repair Wire Harness.
Replace MD6DC PCB “B” (PL 4.0).

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BM-160 PCB MD6DC “C” Not Connected
Fault code indicates that the PCB MD6DC C is not connected.

Initial Actions
• Ensure that all connectors are properly connected to MD6DC C (REP 7.2 MD6DC PCB ”C” (lower)).
• Ensure that the dipswitches on the PCB are set correctly (REP 7.2 MD6DC PCB ”C” (lower)).

Procedure
• Power off the machine.
• Measure for continuity between P4-1 on MD6DC PCB “C” (PL 4.0)
• Measure for continuity between P2-1 on CPU/Controller PCB “A” (PL 3.0).

There is continuity.
Y N
Replace/Repair Wire Harness.
Measure for continuity between
P4-2 on MD6DC C and P2-2 on CPU/Controller PCB “A” (PL 3.0).
There is continuity.
Y N
Replace/Repair Wire Harness.

Replace MD6DC PCB “C(PL 4.0).

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BM-161 PCB MD6DC “H” Not Connected
Fault code indicates that the PCB MD6DC H is not connected.

Initial Actions
• Ensure that all connectors are properly connected to PCB MD6DC H (REP 7.0 MD6DC PCB ”H” (upper)).
• Ensure that the dipswitches on the PCB are set correctly (REP 7.0 MD6DC PCB ”H” (upper)).

Procedure
• Power off the machine.
• Measure for continuity between
P4-1 on MD6DC H (PL 3.0) and P5-1 on MD6DC B (PL 3.0).

There is continuity.
Y N
Replace/Repair Wire Harness.

Measure for continuity between P4-2 on MD6DC PCB “H” and

P5-2 on MD6DC PCB “B”.
There is continuity.
Y N
Replace/Repair Wire Harness.

Replace MD6DC PCB “H”” (PL 4.0).

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PCB MD3DC “O” Not Connected (Option)
Fault code indicates that the PCB MD6DC K is not connected.

Initial Actions
• Ensure that all connectors are properly connected to PCB MD3DC O (REP 7.0).
• Ensure that the dipswitches on the PCB are set correctly (REP 7.0).

Procedure
• Power off the machine.
• Measure for continuity between
P4-1 on MD3DC “O” (PL 3.0) and P3-1 on ARM PCB A (PL 3.0).

There is continuity.
Y N
Replace/Repair Wire Harness.

Measure for continuity between P4-2 on MD3DC PCB “O” and P3-2 on ARM PCB A.
There is continuity.
Y N
Replace/Repair Wire Harness.

Replace MD3DC PCB “O” .

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BM-164 Addon PCB “F”Not connected BM-165 Cover sensor SW1 (Interlock) faulty
Fault code indicates that at power on, Fault code indicates that the two circuits in the interlock switch do not havwe the same
the ADDON PCB ”F” had no communication with Controller PCB ”A”. status (open or closed)
Initial Actions
Initial Actions - Check that power cavle to SQF is connected or that termination plug is mounted
• Check that Ribbon Cable from A.P10 on - Check that cables are connected to switch
Controller PCB “A” (PL 3.1) to F.P5 on the Addon PCB “F” (PL 3.1) is connected. - Check connection of white cable from pin 2 switch SW1 to D-sub connector J12 pin 3 (on
connection plate)
Procedure - Check connection of black cable from pin 4 switch SW1 to (J, P1)pin 5
- Check connection of white cable from pin 3 switch SW1 to (J, P1)pin 1
Replace the Addon PCB “F” (PL 3.1). - Check connection of black cable from pin 1 switch SW1 to (F, P2)pin 2
The communication fault remains.
Procedure
Y N Replace interlock switch SW 1 or Harness
Exit.

Replace Ribbon Cable between A.P10 and F.P5.

The communication fault remains.
Y N
Exit.

Replace PCB “A” Controller (PL 3.1).

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BM-168 Stacker Motor ST-M1 Short Circuit BM-169 Stacker Motor ST-M1 Open Circuit
Fault code indicates that the Stacker motor (ST-M1) has a short circuit. Fault code indicates that the Stacker motor (ST-M1) has an open circuit.

Initial Actions Initial Actions

• Ensure that the connectors are properly installed on the Stacker Motor (PL 6.0). • Ensure that the connectors are properly installed on the Stacker Motor (PL 6.0).
• If a Trimmer is installed:
Procedure Ensure that plug B.P2, J/PM1 and J/P28 are connected.
Disconnect the motor plug M1. Enter Service Mode (GP1) and run M1 (GP4). • Check that the Belt Stacker cable is connected to the Booklet Maker.

Fault code BM-169 (Open circuit) is displayed. Procedure

Y N • Disconnect the motor plug M1.

• Disconnect plug P2 from PCB “B” (PL 4.0). • Enter Service (GP1) mode and start Stacker motor (ST-M1) in (GP4) check motors.

• Check wires for Short circuit between • Measure VDC between the red wire M1 and the black wire M1 (PWM 30V and GND).
the red wire M1 to P2-11 (violet) and the black wire M1 to P2-4 (orange).
The voltage is 24 VDC ± 10%.
• Check short circuits between wires and chassis. Y N
There is no short circuit • Disconnect plug P2 from PCB “B”. (PL 4.0)
Y N • Measure VDC between J.2-4 and J.2-11 (PWM 30V and GND).
Replace MD6DC PCB “B” (PL 4.0).
The voltage is 24 VDC ± 10%.
Replace/Repair wire Harness.
Y N
Replace motor BM-M1 (PL 5.3). Replace MD6DC PCB “B” (PL 4.0).

Replace/Repair Wire Harness.

Replace motor BM-M1 (PL 5.3).

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BM-170 Incompatible CST Software
Fault code indicates that the software in the CST is not compatible with the Booklet Maker
software.

Initial Actions

Procedure
Follow instructions in below GP’s to check and update software in the CST.
• GP 18 Checking Versions of Installed Software
• GP 19 Update Software

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BM-201 Sensor BM-Q1 Not activated in time BM-202 Sensor BM-Q1 Activated too long
Fault code indicates that during a run, BM-Q1 Paper infeed sensor, Fault code indicates that at “initialization” or during a run,
was not blocked within timeout after the start signal the BM-Q1 Paper infeed sensor, was blocked exceeding timeout.
from the Deburster (optional) was detected.
Initial Actions
Initial Actions
• Ensure that BM-Q1 (PL 5.3) Paper infeed sensor is installed correctly.
• Ensure that BM-Q1 (PL 5.3) Paper infeed sensor is properly connected.
• Ensure that BM-Q1 Paper infeed sensor is clean.
• Ensure there are no obstructions in the paper path.
Procedure
• Ensure that BM-Q1 Paper infeed sensor is clean.
• Check for obstructions in the paper path.
• Reference GP4 Check Motors / Solenoids / Sensors for correct operation.
• Ensure that the Booklet maker is correctly installed (see Installation).
Procedure
• Go to Compiler RAP.
• Check for obstructions in the paper path.
• If cover feeder is used in the job that caused the problem Go to Cover Feeder RAP.
• Ensure that the Booklet maker is correctly installed (see Installation).
• Go to Length Adjustment Unit RAP.
• Go to Compiler RAP.
• Got to Stapler RAP.
• Go to Length Adjustment Unit RAP.

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BM-203 Sensor BM-Q4 Not activated in time BM-204 Sensor BM-Q4 Activated too long
Fault code indicates that during a run BM-Q4, Start Sensor Saddle Stapling, Fault code indicates that at “initialization” or during a run BM-Q4 was blocked,
was not blocked within timeout. exceeding timeout.

Initial Actions Initial Actions

• Ensure that sensor BM-Q4 (PL 5.1) is installed correctly. • Ensure that BM-Q4 (PL 5.1) is installed correctly.
• Ensure that sensor BM-Q4 is clean. • Ensure that BM-Q4 is clean.
• Ensure that jack/plug J49/P49 in the Booklet Maker is connected. Procedure
Procedure • Check for obstructions in the paper path.
• Check for obstructions in the paper path. • Ensure that the Booklet maker is correctly installed.
• Ensure that the Booklet maker is correctly installed. • Go to Prefold Transport RAP.
• Go to BM-Q4 REP, continue with step 4 if no succes with BM-Q4 REP. • If cover feeder is used in the job that caused the problem Go to Cover Feeder RAP.
• If cover feeder is used in the job that caused the problem Go to Cover Feeder RAP. • Go to Folding Unit RAP.
• Go to Compiler RAP. • Go to Compiler RAP.
• Go to Length Adjustment Unit RAP. • Go to Length Adjustment Unit RAP.
• Go to Prefold Transport RAP. • Got to Stapler RAP.
• Go to Stapler RAP.

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BM-205 Sensor BM-Q7 Not activated in time BM-206 Sensor BM-Q7 Activated too long
Fault code indicates that during a run, the Stop Gate Folder sensor BM-Q7, Fault code indicates that at “initialization” or during a run,
was not blocked within timeout. the Stop Gate Folder sensor (BM-Q7), was blocked exceeding timeout.
Initial Actions Initial Actions
• Ensure that the Stop Gate Folder sensor BM-Q7 (PL 6.2) is installed correctly. • Ensure that the Stop Gate Folder sensor BM-Q7 (PL 6.2) is installed correctly.
• Ensure that the Stop Gate Folder sensor BM-Q7 is clean. • Ensure that the Stop Gate Folder sensor BM-Q7 is clean.
Procedure Procedure
• Check for obstructions in the paper path. • Check for obstructions in the paper path.
• Ensure that the Booklet maker is correctly installed (see Installation). • Ensure that the Booklet maker is correctly installed (see Installation).
• Go to Prefold Transport RAP. • Go to Folding Unit RAP.
• If cover feeder is used in the job that caused the problem Go to Cover Feeder RAP. • Go to Prefold Transport RAP.
• Go to Folding Unit RAP. • If cover feeder is used in the job that caused the problem Go to Cover Feeder RAP.
• Go to Compiler RAP. • Go to Length Adjustment Unit RAP.
• Go to Length Adjustment Unit RAP.
• Go to Stapler RAP.

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BM-207 Sensor BM-Q8 not activated in time BM-208 Sensor BM-Q8 Activated too long
The fault code indicates that during a run, Fault code indicates that at “initialization” or during a run,
the Exit sensor BM-Q8 was not blocked within timeout. the Exit sensor BM-Q8 was blocked exceeding timeout.

Initial Actions Initial Actions

• Ensure communication cable is properly installed (see Entry RAP)
• Ensure that the Exit sensor BM-Q8 (PL 2.1) is installed correctly.
• Ensure that the Exit sensor BM-Q8 (PL 2.1) is installed correctly.
• Ensure that the Exit sensor BM-Q8 is clean.
• Ensure that the Exit sensor BM-Q8 is clean.
Procedure
Procedure
• Check for obstructions in the paper path.
Is a SQF installed?
• Ensure that the Booklet maker is correctly installed (see Installation).
Y N
• Go to Folding Unit RAP.
• Check for obstructions in the paper path.
• Go to Length Adjustment Unit RAP
• Go to Folding Unit RAP.
• Go to Length Adjustment Unit RAP.
• Go to Belt Stacker RAP.

• Check for obstructions in the paper path.

• Go to SQF Transport RAP.
• Go to Folding Unit RAP.
• Go to Length Adjustment Unit RAP.

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BM-211 Infeed unit sensor BM-Q53 Not activated in time

Fault code indicates that during a run, BM-Q53, Infeed unit sensor, was not blocked within timeout
after the start signal from the printer was detected.
Initial Actions
-- Ensure that BM-Q53 (PL 5.3) Upper bypass unit infeed sensor is properly connected.
-- Ensure there are no obstructions in the paper path.
-- Ensure that BM-Q53 Upper bypass unit infeed sensor is clean.
-- Reference GP4 Check Motors / Solenoids / Sensors for correct operation.
Procedure
1. Check for obstructions in the paper path.
2. Ensure that the Booklet maker is correctly installed (see Installation).

BM-212 Infeed unit sensor BM-Q53 Activated too long

Fault code indicates that at “initialization” or during a run, the BM-Q53 Infeed unit sensor, was
blocked exceeding timeout.
Initial Actions
- Ensure that BM-Q53 (PL 5.3) Upper bypass unit infeed sensor is installed correctly.
- Ensure that BM-Q53 Upper bypass unit infeed sensor is clean.

Procedure
1. Check for obstructions in the paper path.
2. Ensure that the Booklet maker is correctly installed (see Installation).
3. Go to Compiler RAP.

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BM-401 Staple Miss Right Stapler (BM-Q20)
This Fault code indicates that the staple does not reach the clincher.
Possible failure:
• Staple stucked in stapler head
• Bad mounted staple cartridge/ Bad Staple cartridge
• Very greasy clinch, bad connection.
• Clinch or Stapler wrong mounted.
• Broken Clinch/ Stapler
• Activated PTC resistor to Clinch. PTC resistor explained below.

Initial Actions
• Ensure that both Stapler Heads are in upper position.
• Ensure that Connector “Clinch Left” and “Clinch Right” are connected (PL 4.0).
• Ensure that the PTC to Clinch is not warm.
• Ensure that Connector “J39 / P39” and “J40 / P40” are connected.
• Ensure that Connector “A.P1” are connected (PL 3.0).
• Ensure that Connector “ H.P3” are connected (PL 3.0).
• Check that all cables to above connectors, are not damaged.
• In service menu, check that the function of Clinch Right and Clinch Left are working.
A sound like “Bang” for less than 0.5 second, PTC resistor
indicates that the electrical function of the clinch is working. The PTC resistor, commonly
• Check also that the clinch metal tongue is not broken. known as a resettable fuse, acts
The tongue is visible straight down between the beam and clinch. like a circuit breaker to protect
If it’s broken the metal tongue might be hard to spot. against overcurrent in electronic
circuits. If to much current is
passed through (short circuit), the
PTC will become hot and break
the circiut. Allowed to cool off, the
circuit will be closed again.

WARNING!
The PTC can become very hot!

PTC resistors

continued on next page

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BM-401 Staple Miss Right Stapler (BM-Q20), continued
Procedures
• Disconnect plug A.P1 from CPU/Controller PCB “A” (PL 3.0).
• Measure between J1-15 and Chassis/GND (Signal and GND)
The voltage is 5 VDC ± 10%.
Y N
Replace CPU/Controller PCB “A” (PL 3.1).
• Disconnect plug “Clinch Right” from Clinch Right and plug H.P3
• Check continuity for the grey wire at plug “CLINCH RIGHT” Pos.-4 to A.P.1-15
• Check continuity for the orange wire at plug “CLINCH RIGHT” Pos.-2 to H.P3-3
• Check continuity for the violet wire at plug “CLINCH RIGHT” Pos.-3 to H.P3-8
• Check for short circuit between orange/violet/grey wires and Chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Measure the diode 1N4002 between
“CLINCH RIGHT” Pos.-2 and “CLINCH RIGHT” Pos.-3 (PL 4.0).
• The diode shall only lead current one direction: from Pos.-3 to Pos-2.
Is there continuity only from Pos.-3 to Pos-2, and not from Pos.-2 to Pos-3?
Y N
Replace Wire Harness/Diode
• Connect plug A.P1 to CPU/Controller PCB “A”.
• Measure between the white wire “CLINCH RIGHT” and the Chassis/GND (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
• Replace/Repair Wire Harness.
• Replace CPU/Controller “A” (PL 3.0).
• Replace MD6DC PCB “H”” (PL 4.0).

• Replace Stapler cartridge (PL 4.1).

• Replace CPU/Controller PCB “A” (PL 3.1).
• Replace MD6DC PCB “H”” (PL 4.0).
• Replace Right Clincher. (PL 4.1).

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BM-402 Staple Miss Left Stapler (BM-Q19) Procedures
This Fault code indicates that the staple does not reach the clincher. • Disconnect plug A.P1 from CPU/Controller PCB “A” (PL 3.0).
Possible failure:
• Measure between J1-24 and Chassis/GND (Signal and GND)
• Staple stucked in stapler head
The voltage is 5 VDC ± 10%.
• Bad mounted staple cartridge/ Bad Staple cartridge
Y N
• Very greasy clinch, bad connection.
Replace CPU/Controller PCB “A” (PL 3.1).
• Clinch or Stapler wrong mounted.
• Disconnect plug “Clinch Right”. from Clinch Right and plug H.P3
• Broken Clinch/ Stapler
• Check continuity for the white wire at plug “CLINCH LEFT” Pos.-4 to A.P1-24
• Activated (warm/ hot) PTC resistor to Clinch.
PTC resistor explained at Fault code BM-401. • Check continuity for the orange wire at plug “CLINCH LEFT” Pos.-2 to H.P3-2
• Check continuity for the violet wire at plug “CLINCH LEFT” Pos.-3 to H.P3-8
Initial Actions
• Check for short circuit between orange/violet/white wires and Chassis/GND
• Ensure that both Stapler Heads are in upper position.
There is continuity for all wires and no short circuit
• Ensure that Connector “Clinch Left” and “Clinch Right” are connected (PL 4.0).
Y N
• Ensure that the PTC to Clinch is not warm.
Replace/Repair Wire Harness.
• Ensure that Connector “J39 / P39” and “J40 / P40” are connected.
• Measure the diode 1N4002 between “CLINCH LEFT” Pos.-2 and “CLINCH LEFT” Pos.-3 (PL 4.0).
• Ensure that Connector “A.P1” are connected (PL 3.0).
• The diode shall only lead current one direction. From Pos.-3 to Pos-2.
• Ensure that Connector “ H.P3” are connected (PL 3.0).
Is there continuity only from Pos.-3 to Pos-2, and not from Pos.-2 to Pos-3?
• Check that all cables to above connectors, are not damaged.
Y N
• Check that the function of Clinch Right and Clinch Left are working.
A sound like “Bang” for less than 0.5 second, Replace Wire Harness/Diode
indicates that the electrical function of the clinch is working.
• Connect plug A.P1 to CPU/Controller PCB “A”.
• Check also that the clinch metal tongue is not broken.
• Measure between the white wire “CLINCH LEFT and the Chassis/GND (Signal and GND).
The tongue is visible straight down between the beam and clinch.
If it’s broken the metal tongue might be hard to spot. The voltage is 5 VDC ± 10%.
Y N
• Replace/Repair Wire Harness.
• Replace CPU/Controller “A” (PL 3.1).
• Replace MD6DC PCB “H”” (PL 4.0).
• Replace Stapler cartridge (PL 4.1).
• Replace CPU/Controller PCB “A” (PL 3.1).
• Replace MD6DC PCB “H”” (PL 4.0).
• Replace Left Clincher (PL 4.1).

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BM-403 Staple Miss Both Staplers (BM-Q19, BM-Q20) BM-405 Remove Purged Set
Go to fault codes and perform the procedures given there: This Fault code indicates that a purged set must be removed.

• BM-401 Staple Detection Clinch Right Sensor(BM-Q20) Procedure

• BM-402 Staple Miss Left Stapler (BM-Q19) • Remove set and try again
• Check type of job
BM-404 Set too thick • Check type of paper
This Fault code indicates too thick set reached the infeed unit.
Procedure BM-407 Too many sheets
This Fault code indicates that to many sheets was fed into the Booklet Maker
• Check job and Ensure that less sheets are programmed in the job.
• Check operator mode with . Procedure
• Check type of paper. • Check job and Ensure no more than 35 or 50 sheets are programmed in the job.

Initial Actions • Check type of paper

• Remove set and try again. Initial Actions

• Check type of job. • Remove set and try again

• Check type of paper. • Check type of job

• Check type of paper

Note: This fault can also occur if a job is paused / cancelled in the middle of a set and
the Booklet Maker is not purged before new job is submitted to the Booklet Maker.
Note: This fault can also occur if a job is paused / cancelled in the middle of a set and
the Booklet Maker is not purged before new job is submitted to the Booklet Maker.

BM-409 Unfinished set in compiler

This Fault code indicates that an unfinished set must be removed from BM compiler

Procedure
• Remove set and try again
• Check type of job
• Check type of paper

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BM-501 Staples, Low Stapler Right BM-Q46
This Fault Code indicates that the Right Stapler has a low level of staples.
Procedures
Possible failure: The Staples Right Low Sensor (Q46) indicates :
Low Staple Right. 1=Staples low. 0=Staples inside the cartridge.
• Staples in Cartridge low Staples press the plastic tongue down, inside the stapler.
• Staple Cartridge is not mounted correctly Y N
• Low staple sensor is broken/broken stapler • Disconnect plug C.P16 and from PCB “C” (PL 4.0).
• Harness to stapler is broken • Measure between J.16-2 and J.13-9 (5V and GND).
• PCB failure • Measure between J.13-24 and J.13-9 (Signal and GND).

Initial Actions The voltage is 5 VDC ± 10%.

Change Staple cartridge. Y N

Enter Service Mode and select Right Staples low sensor in check sensors. Replace MD6DC PCB “C(PL 4.0).
• Disconnect plug P44 from Stapler.
• Check continuity for the red wire at plug J44-9 to C.P16-2
• Check continuity for the grey wire at plug J44-1 to C.P13-24
• Check continuity for the black wire at plug J44-10 to C.P13-9
• Check wire for Short circuit between red/grey/black wires
• Check for short circuit between red/grey/black wires and chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug C.P13 and C.P16 to MD6DC PCB “C”.
• Measure between the red wire J44-9 and the black wire J44-10 (5V and GND).
• Measure between the grey wire J44-1 and the black wire J44-10 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace/Repair Wire Harness.
• Replace Stapler Right.
• Replace MD6DC PCB “C(PL 4.0).
• Replace Stapler Right.
• Replace MD6DC PCB “C(PL 4.0).
• Replace/Repair Wire Harness.

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BM-502 Staples, Low Stapler Left, BM-Q49 Procedures
This Fault Code indicates that the Left Stapler has a low level of staples. The Staples Left Low Sensor (Q46) indicates :
Low Staple Left. 1=Staples low. 0=Staples inside the cartridge.
Possible failure: Staples press the plastic tongue down, inside the stapler.
• Staples in Cartridge low Y N
• Staple Cartridge is not mounted correctly • Disconnect plug C.P16 and from PCB “C” (PL 4.0).
• Low staple sensor is broken/broken stapler • Measure between J.16-2 and J.13-9 (5V and GND).
• Harness to stapler is broken • Measure between J.13-24 and J.13-9 (Signal and GND).
• PCB failure The voltage is 5 VDC ± 10%.
Initial Actions Y N
Change Staple cartridge. Replace MD6DC PCB “C(PL 4.0).
Enter Service Mode and select Left Staples low sensor in check sensors. • Disconnect plug P43 from Stapler.
• Check continuity for the red wire at plug J43-9 to B.P16-2
• Check continuity for the grey wire at plug J43-1 to B.P13-24
• Check continuity for the black wire at plug J43-10 to B.P13-9
• Check wire for Short circuit between red/grey/black wires
• Check for short circuit between red/grey/black wires and chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug B.P13 and B.P16 to MD6DC PCB “B”.
• Measure between the red wire J43-9 and the black wire J43-10 (5V and GND).
• Measure between the grey wire J43-1 and the black wire J43-10 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace/Repair Wire Harness.
• Replace Stapler Left.
• Replace MD6DC PCB “B” (PL 4.0).
• Replace Stapler Left.
• Replace MD6DC PCB “C(PL 4.0).
• Replace/Repair Wire Harness.

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BM-503 Staples, Low both stapler (BM-Q46, BM-Q49) BM-504 Stacker Full/Empty Stacker
See below RAP’s: This Fault code indicates that the Belt Stacker is full.
• BM-501 “Staples Low Stapler Right (Q46)
Procedure
• BM-502 ”Staples Low Stapler Left (Q49)
Empty Belt Stacker and press done on the UI.
Note: This function can also be turned off under the Tools menu on the UI.

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Booklet Maker Communication Lost (UI: “No Com”)
Fault code indicates that there is a communication lost problem.

Initial Actions
• Ensure that the communication cable between the Booklet Maker and
the Square Folder is properly connected (see Installation).
Make sure dip/switch at PCB “V” is correctly set. Check BSD in section 8.
• Ensure that the communication cable between the Square Folder and the Trimmer is
properly connected (see Installation). Make sure the microSD memory is installed.
• Ensure the power to Booklet Maker and Square Folder is connected (see Installation).

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Booklet Maker Communication Lost (UI: “No Com”), continued
Y N
• Ensure the power between Square Folder and Trimmer is connected (see Installation).
Repair/replace harness
Procedure
• Power off, uninstall Square Folder, move CAN termination to Trimmer.
• Disconnect A.P5 and P107, leave communication cable(s) and
• Power on. You may need to change system setup in the UI. both CAN terminations disconnected.
There is still “No Com” message displayed on UI? • Use the BSD (section 8) to locate connectors/pins.
Measure continuity between all wires from A.P5 to P107.
Y N
Go to Square Folder Communication Lost RAP • Check for short circuit between all wires from A.P5 to chassis and
between different pins at A.P5.
• Power off, uninstall Trimmer, move CAN termination to Booklet Maker. There is connectivity and no short circuit
• Power on. You may need to change system setup in the UI. Y N
There is still “No Com” message displayed on UI? Repair/replace harness
Y N
Go to Trimmer Communication Lost RAP • Leave communication cable(s), P107 and both CAN terminations disconnected.
• Use the BSD to locate connectors/pins
• Power off, measure continuity for all wires in the communication cable(s),
Measure continuity between all wires from P24 to P107.
it could be one or two communication cables depending on system setup,
pin 1 to 1, 2 to 2, 3 to 3, 5 to 5 and 7 to 7. • Check for short circuit between P107-5, P107-6, P107-7 and P107-8 to chassis and
between different pins at P24.
• Check for short circuits between the different pins,
and from pin 1, 2, 5 and 7 to the connector housing (not pin3). There is connectivity and no short circuit
There is connectivity and no short circuit Y N
Y N Repair/replace harness
Replace the failed communication cable(s) (PL 10.7).
Do following, check functionallity between the steps:

Disconnect CAN terminations, at CAN terminations measure resistance between pin 2 and 7. • Load new software to UI and ARM CPU PCB “A”.

The resistance is 120R ± 10% • Replace microSD memory, and load new UI software.
Y N • Replace ARM CPU PCB “A”.
Replace the failed CAN termination connector(s) • Replace UI module.

• Disconnect A.P4, leave communication cable(s) and both CAN terminations disconnected.
• Use the BSD to locate connectors/pins and
measure continuity between all wires from A.P4 to J23.
• Check for short circuit between all wires from A.P4 to chassis and
between different pins at J23.
There is connectivity and no short circuit

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Blank UI (no backlight) Procedure
Power on, measure VDC between +(red) and (black) on the 12V PSU.
This RAP is for troubleshooting a Blank (no backlight) UI.
Careful Main Voltage nearby!
Initial Actions
The voltage is 12V ± 10%?
• Ensure Line Voltage is present,
Power Cable is connected, machine is powered On. Y N

• Ensure that the Power Supply RS-35-12 (PL 3.1) has 12 VDC. Go to No 12VDC machine not starting RAP
(Refer to power supply RS-35-12 LED, Chapter 6, section Power Supply RS-35-12 LED) • Power off, disconnect P107 (connecor to UI-module)
• Check Fuse F1 (PL 3.1). • Power on
• Check that G.P1, G.P2, A.P5, J/P107 and connectors inside UI-module • Measure VDC between P107-1 and P107-3 and between P107-2 and P107-4.
V.P6, VP7, P2 (BM/RD), 4P FFC cable and 40P FFC cable are connected.
The voltage is 12V ± 10%?
• Check that Ribbon Cable from A.P10 on CPU/Controller PCB “A” to F P5 on
the Addon PCB “F” is connected (PL 3.0). Y N
Make sure the microSD memory is installed properly.
• Reconnect P107, disconnect Trimmer and/or Square Folder,
• Check that cable from A .P2 on CPU/Controller PCB “A” to C P5 on connect the short link connector to Booklet maker J12.
MD6DC PCB “C” is connected (PL 3.0).
• Move CAN termination to Booklet Maker. Power on.
The UI starts up.
Y N

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 • Power off, disconnect P107 and G.P2
measure continuity between P107-1 to G.P2-1
measure continuity between P107-2 to G.P2-1
measure continuity between P107-3 to G.P2-3
measure continuity between P107-4 to G.P2-3.
• Check for short circuit between all wires at G.P2 to chassis
and between all different wires at G.P2.
There is continuity for all wires and no short circuit
Y N
Replace/Repair wire harness
Reconnect all connectors, power on
measure VDC between G.P1-1 and G.P1-2.
The voltage is 12V ± 10%?
Y N
Replace/Repair harness between PSU 12V and PCB “G”
Measure VDC between G.P2-1 and G.P2-3.
The voltage is 12V ± 10%?
Y N
Replace PCB “G”
Do following, check functionallity between the steps:
• Load new software to UI-module.
• Replace microSD memory, and load new UI software.
• Replace UI module.

• Perform following, check functionallity between steps:

• Perform SQF No 12VDC (Square Folder)
• Perform TR No 12VDC (Trimmer)

Do following, check functionallity between the steps:

• Load new software to UI-module.
• Replace microSD memory, and load new UI software.
• Replace UI module.

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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Compiler RAP Stapler RAP
This RAP is for troubleshooting the Compiler. This RAP is for troubleshooting the Stapler.

You should have been re-directed to this RAP from another Status indicator RAP. You should have been re-directed to this RAP from another Status indicator RAP.

Procedure Procedure
Check Sensor BM-Q1 (PL 5.3) according to GP4. Check stapler left (M20) (Pl 4.1) and stapler right (M21) (PL 4.1) according to GP4.

Is Sensor Q1 working correctly? Is the stapler working correctly?

Y N Y N

Go to BM-062 Paper Infeed sensor BM-Q1 Faulty. • Check for mechanical bindings, broken, missing or loose parts.
• Check staple position to clincher (BQ 4).

Are the two outer back joggers finger in their right position (REP 3.7). • Go to BM-401

Y N
Position the two outer back jogger fingers in their correct position Return to the previous RAP.
(See REP 3.7 Back Jogger assembly).

Check Motor M2 (PL 3.2) according to GP4.

Is the back jogger working correctly?
Y N
Check for mechanical bindings, broken, missing or loose parts.

Check Motor M1 (PL 3.2) according to GP4.

Is the M1 feed roller working correctly?
Y N
Check for mechanical bindings, broken, missing or loose parts.

Check Motor M3 (PL 3.2) according to GP4.

Are the side joggers working correctly?
Y N
Check for mechanical bindings, broken, missing or loose parts.

Return to the previous RAP.

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Pre Fold Transport RAP Length adjustment Unit RAP
This RAP is for troubleshooting the Pre Fold Transport. This RAP is for troubleshooting the Length Adjustment Unit.
You should have been re-directed to this RAP from another Status indicator RAP. You should have been re-directed to this RAP from another Status indicator RAP.

Procedure Initial Actions

Check Sensor BM-Q4 (PL 5.1) according to GP4. • Check that the actual paper size corresponds to settings in the UI.
Is Sensor Q4 working correctly? Procedure
Y N
Check Motor BM-M9 (PL 6.2) according to GP4.
Go to BM-063 Start sensor saddle stapling BM-Q4 faulty
Is the staple/fold positioning working correctly?
Check Sensor BM-Q7 (PL 6.2) according to GP4.
Y N
Is Sensor Q7 working correctly?
• Check for mechanical bindings, broken, missing or loose parts.
Y N
• Select paper size 8.5 x 11”.
Go to BM-064 Stop gate folder sensor BM-Q7 faulty Slide the Motor BM-M1 (PL 5.3) assembly (see figure below) upstreams and
check that the assembly slides back into the previous position by itself,
when released.
Check Motor BM-M5 (PL 5.0) according to GP4.
• Perform Paper Size reset (GP11).
Are the drive roller tires working correctly?
Y N
Return to the previous RAP.
• Check for mechanical bindings, broken, missing or loose parts.
• Check adjustment of set transport drive (ADJ 4.3).
• Check Set Transport Calibration (ADJ 4.2)

Return to the previous RAP.

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Folding Unit RAP
This RAP is for troubleshooting the Folding Unit.
You should have been re-directed to this RAP from another Status indicator RAP.

Procedure
Check Sensor BM-Q8 (PL 2.1) according to GP4.
Is Sensor Q8 working correctly?
Y N
Go to BM-065 Exit sensor BM-Q8 faulty.

Check Motor BM-M6 (PL 6.2) according to GP4.

Are the fold rollers working correctly?
Y N
• Check for mechanical bindings, broken, missing or loose parts.
• Check adjustment of the fold transmission chain (ADJ 6.4).
• Check adjustment of the Upper Fold Roller (ADJ 6.6).
• Check adjustment of the Lower Fold Roller (ADJ 6.7).

Check Motor BM-M7 (PL 6.2) according to GP4.

Is the fold knife working correctly?
Y N
Check for mechanical bindings, broken, missing or loose parts.

Check Motor BM-M8 (PL 6.2) according to GP4.

Is the fold stop gate working correctly?
Y N
Check for mechanical bindings, broken, missing or loose parts.

Return to the previous RAP.

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MD6DC PCB RAP
This RAP is for troubleshooting a problem in Booklet Maker with components
connected to the MD6DC PCB ”H”, “B” , “C” (PL 4.0) located in the Booklet Maker • If a CF is installed check for binding / shorted motor CF-M15 (PL 9.2)

You should have been re-directed to this RAP from another Status indicator RAP. • If a CF is installed check for shorted motor CF-M17 (PL 9.0)
• If a CF is installed check for shorted motor CF-M18 (PL 9.0)
Initial Actions
• Check for shorted motor BM-M8 (PL 6.2)
• Ensure that all dip switches are set correctly.
• Check for shorted motor BM-M22 (PL 5.0)
• Ensure all connectors are properly connected.
Exit
Procedure
• Disconnect P12 on MD6DC “C” (PL 4.0).
• Power on machine and close covers.
A different fault code than BM-150 is displayed.
Y N
• Check for shorted counter (PL 3.1).
• Check for shorted Thick Set Motor BM-M23 (PL 7.1).
• Check for mechanical bindings / shorted motor BM-M2 (PL 5.2).
• Check for mechanical bindings / shorted motor BM-M3 (PL 5.3).
• Check for mechanical bindings / shorted motor BM-M6 (PL 3.0).
• If a CF is installed check for shorted motor CF-M16 (PL 9.2).
• Check for shorted Stapler Right Motor BM-M21 (PL 7.0).
Power machine off and re-connect P12 on MD6DC “C” (PL 4.0).
Disconnect P11 on MD6DC “B” (PL 4.0). Power on machine and close covers.
A different fault code than BM-153 is displayed.
Y N
• Check for shorted Stapler Left Motor BM-M20 (PL 7.0).
• Check for mechanical bindings / shorted motor BM-M1 (PL 5.3).
• Check for mechanical bindings / shorted motor BM-M7 (PL 6.2).
• Check for mechanical bindings / shorted motor BM-M9 (PL 6.2).
• Check for mechanical bindings / shorted motor ST-M1 (PL 8.0).
• Check for mechanical bindings / shorted motor BM-M5 (PL 5.0).
Power machine off and re-connect P11 on MD6DC “B” (PL 4.0).
Disconnect P11 on MD6DC “H” (PL 4.0). Power on machine and close covers.

A different fault code than BM-154 is displayed.

Y N

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Counter RAP, Booklet Maker RS232 Program Loading Chassis 9-P, D-sub RAP
This RAP is for troubleshooting the Electromechanical Counter. This RAP is for troubleshooting the RS232 Program Loading Chassis 9-P, D-sub

Initial Actions Initial Actions

• Check the COUNTER. • Ensure that connector P11 anD.P7 at Controller/CPU PCB “A” that goes to J47
are properly connected.
• Ensure that the connector is properly connected to the Counter.
• Check that the crimp sockets in D-sub are not damage.
• Ensure that connector C.P2 at PCB “C” (PL 4.0) is propertly connected.
Procedure
Procedure
• Disconnect plug P11 and P7 from Controller/CPU PCB “A” (PL 3.1).
• Disconnect plug C.P2 from MD6DC PCB “C” (PL 4.0).
• Check continuity for the white wire A.P11-1 and (J.47-7 and J.47-8)
• Measure between VDC J.2-7 and C.P11-2 (GND)
• Check continuity for the white wire A.P11-2 and J.47-4
The voltage is 30 VDC ± 10%.
• Check continuity for the white wire A.P7-1 and J.47-2
Y N
• Check continuity for the white wire A.P7-2 and J.47-3
Replace MD6DC PCB “C”.
• Check continuity for the white wire A.P7-3 and J.47-5
• Disconnect plug from counter.
• Check for Short circuit between wires (J.47-7 and J.47-8 are supposed to be shorted)
• Check continuity for the orange wire at plug Counter to C.P2-7
• Check for short circuit between all wires and chassis/GND
• Check continuity for the violet wire at plug Counter to C.P2-14
There is continuity for all wires and no short circuit
• Check for short circuit between violet/orange wires and
between orange/violet wires to chassis/GND Y N

There is continuity for all wires and no short circuit Replace/Repair Wire Harness.

Y N
Replace/Repair Wire Harness. Replace Controller/CPU PCB “A” (PL 3.1).

• Connect plug C.P2 to MD6DC PCB “C” (PL 4.0).

• Measure VDC at the counter connector between the orange and C.P11-2 (GND)
The voltage is 30 VDC ± 10%.
Y N
• Repair Wire Harness.
• Replace MD6DC PCB “C(PL 4.0)
• Replace Counter.
• Replace MD6DC PCB “C(PL 4.0).

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F1 Blown Up RAP
This RAP is for troubleshooting a dead machine,
no mains voltage present and F1 frequently blows up.

This RAP assumes there is no Trimmer or Square Folder installed.

If the problem is related only when the Trimmer or Square Folder are installed,
please see Trimmer or Square Folder service manuals.
Initial Actions

• Ensure that J/P45 is properly connected.

• Ensure that all connectors related to SW3 (mains switch) are properly connected.
• Ensure that all connectors related to mains power inlet are properly connected.
• Ensure that all connectors connecting to REL-1 are properly connected.

Procedure
• Power off the machine and disconnect the main power cord (Very Important!).
• Replace blown up F1. Connect the main power cord (do not power on the machine).
• Measure voltage between L (black,1 wire) and N (black,2 wire) on the Power Entry.
The voltage is 90-264VAC.
Y N
• Power off the machine and disconnect the main power cord
(Very Important! Failure to disconnect will result in damage to meter.)
• Disconnect black,1 wire and black, 2 wire from the Power Entry.
• Perform following three resistance measurements for the disconnected wires:
• black,1 wire to black, 2 wire.
• black,1 wire to chassis.
• black, 2 wire to chassis.
There is continuity.
Y N
Replace the Power Entry and replace F1 (PL 3.1).
Repair harness and replace F1.
• Leave SW1 interlock switch inactivated. Power on the machine.
• Measure voltage between L (brown wire) and N (blue wire) on the 12V PSU (PL 3.1).
The voltage is 90-264VAC.
Y N
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 • Power off the machine and disconnect the main power cord
(Very Important! Failure to disconnect will result in damage to meter.)
• Disconnect brown wire and blue wire from the12VDC PSU.
• Perform following three resistance measurements for the disconnected wires:
• brown wire to blue wire.
• brown wire to chassis.
• blue wire to chassis.
There is continuity.
Y N
Warning!
Replace the 12VDC PSU and replace F1.
Use caution when making the voltage measurements and always disconnect the Power Cord
Repair harness and replace F1. when it is necessary to work inside the Power Module. AC Power is present in the Line Module
• Activate SW. Ensure REL-1 activates (maybe only for a short period). whenever the Power Cord is plugged into the Wall Outlet.

• Measure voltage between L (brown wire) and N (blue wire) on the 30VDC PSU (PL 3.1).
The voltage is 90-264VAC.
Y N
• Power off the machine and disconnect the main power cord (Very Important!)
• Disconnect brown wire and blue wire from the 30VDC PSU.

• Perform following three resistance measurements for the disconnected wires:

• brown wire to blue wire.
• brown wire to chassis.
• blue wire to chassis.
There is continuity.
Y N
Replace the 30VDC PSU and replace F1.
Repair harness and replace F1.
Exit (bad fuse)

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No 30VDC from SCP PCB “D” RAP Procedure
This RAP is for troubleshooting a low 30VDC from SCP PCB “D”. Power on the machine, close the top cover.
If this RAP frequently ends up with blown F1, go to F1 Blown Up RAP If there is a Trimmer or Square Folder connected close the Square Folder/Trimmer top cover.
Does the Interlock Relay activate (even for a short period)
Initial Actions
Y N
• Ensure that all connectors to SCP (Short Circuit Protection) PCB “D” (PL 3.1) (PL 3.1)
are properly connected. Go to Interlock Relay RAP
• Ensure that plugs/jacks related to 30VDC PSU are properly connected.
• Power off, disconnect D.P2 wait 120 seconds then power on the machine,
• Ensure that all connectors connecting to REL-1 are properly connected
measure VDC between D.J.2-1 and D.J.2-7.
• Ensure that all connectors connecting to PCB “J” are properly connected. There might be only a short period when the voltage is present so pay attention.

• Ensure that connectors H.P11, B.P11, B.P12, C.P11, C.P12, A.P13, J/P12, J/P46 • Close the top cover, if there is a Square Folder/Trimmer connected, close the top covers.
and all connectors related to SW1 are properly connected.
The voltage is 29.0-31.0VDC
• If a Square Folder is installed,
N Y
ensure D.P11, D.P12, B.P2 and connectors related to SW1 in the Square Folder
are properly connected. • Power off and leave D.P2 disconnected
• If a Trimmer is installed, • Measure resistance between D.P2-5 and D.P2-11.
ensure A.P11, A.P12, B.P2 and connectors related to SW1 in the Trimmer
are properly connected. There is continuity.

• If a Trimmer/Square Folder is not installed, ensure the short link connector is Y N

connected to the correct position. Repair/replace harness
• If any of the 30VDC measurements below ends up with 30VDC
being between 22.0VDC and 28.9VDC, • Go to 30VDC low at Upper MD6DC PCB “H” RAP
proceed to 30VDC Low at Lower MD6DC “C” RAP.
• If there is no success with 30VDC low at Upper MD6DC PCB “H” RAP,
Replace SCP PCB “D” (PL 3.1).
Leave D.P2 disconnected and measure VDC between D.P.1-1 and D.P1-3.
The voltage is 29.0-31.0VDC
Y N
• Power off, disconnect D.P1 wait 120 seconds then power on the machine,
measure VDC between D.P.1-1 and D.P1-3.
There might be only a short period when the voltage is present so pay attention.
• Close the top cover, if there is a Square Folder/Trimmer connected,
close the top covers.
The voltage is 29.0-31.0VDC
Y N

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 • Power off,
disconnected all red and black wires from 30VDC PSU outputs.
WARNING! MAIN VOLTAGE
• Wait 120 seconds and power on,
measure VDC between +V and –V on 30VDC PSU.
The voltage is 29.0-31.0VDC
Y N
Measure VAC between L and N at the 30VDC PSU input.
The voltage is 90-264VAC
Y N
Repair/replace harness between 30VDC PSU and
Interlock Relay REL-1.
Replace 30VDC PSU (REP 7.8) (PL 3.0).

Repair/replace harness between 30VDC PSU and SCP PCB “D”.

Replace SCP PCB “D” (PL 3.1).

Replace SCP PCB “D” (PL 3.1).

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Mains Voltage connectivity check RAP
This RAP is for troubleshooting a dead machine, no mains voltage present.
If this RAP frequently ends up with blown F1 (PL 3.1), go to F1 Blown Up RAP.
This RAP assumes there is no Trimmer or Square Folder installed.
If the problem is related only when the Trimmer or Square Folder are installed,
please see Trimmer or Square Folder service manuals.

Initial Actions
• Ensure that J/P45 is properly connected.
• Ensure that all connectors related to SW3 (mains switch) (PL 2.0) are properly connected.
• Ensure that all connectors related to mains power inlet are properly connected.
• Ensure that all connectors connecting to REL-1 are properly connected.
• The mains power cord must be disconnected during the whole test!

Procedure

Disconnect the main power Cord. Check F1.

F1 blown
N Y
Go to F1 Blown Up RAP

• Disconnect the main power Cord.

• Set SW3 to 0
• Measure resistance between L on the 12VDC PSU (PL 3.1) and 11 on REL-1 (PL 3.1).
There is continuity.
Y N
Repair/replace harness

• Disconnect the main power Cord.

• Set SW3 to 0
• Measure resistance between N on the 12VDC PSU and 31 on REL-1.
There is continuity.
Y N

continued on next page

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 Repair/replace harness

Repair/replace harness

• Disconnect the main power Cord.

• Disconnect the main power Cord. • Set SW3 to 1

• Set SW3 to 0 • Measure resistance between SW3-2 and SW3-1.

• Measure resistance between REL-1 11 and J45-1. There is continuity

There is continuity Y N

Y N Replace SW3

Repair/replace harness • Disconnect the main power Cord.

• Disconnect the main power Cord. • Set SW3 to 1

• Set SW3 to 0 • Measure resistance between SW3-4 and SW3-5.

• Measure resistance between REL-1 31 and J45-2. There is continuity

There is continuity Y N

Y N Replace SW3

Repair/replace harness • Disconnect the main power Cord.

• Disconnect the main power Cord. • Set SW3 to 0

• Set SW3 to 0 • Measure resistance between SW3-2 and N on the mains power inlet.

• Measure resistance between P45-1 and SW3-4. There is continuity

There is continuity Y N

Y N Repair/replace harness

Repair/replace harness • Disconnect the main power Cord.

• Disconnect the main power Cord. • Set SW3 to 0

• Set SW3 to 0, • Measure resistance between SW3-5 and L on the mains power inlet.

• Measure resistance between P45-2 and SW3-1. There is continuity

There is continuity Y N

Y N Repair/replace harness

Replace Mains Power Inlet

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BM-SW1 Interlock circuit (SW16) RAP
This RAP is for troubleshooting a not working Interlock
Relay (no activation) or other problems related to SW1.
If this RAP frequently ends up with blown F1, perform F1 Blown Up RAP

Initial Actions
• Ensure that all connectors to SCP PCB “D” (PL 3.1) are properly connected.
• Ensure that all connectors to SCP PCB “F” (PL 3.1) are properly connected.
• Ensure that all connectors to SCP PCB “G” (PL 3.0) are properly connected.
• Ensure that plugs/jacks related to 30VDC PSU (PL 3.1) are properly connected.
• Ensure that plugs/jacks related to 12VDC PSU (PL 3.1) are properly connected.
• Ensure that all connectors connecting to REL-1 (PL 3.1) are properly connected.
• Ensure that all connectors connecting to PCB “J” (PL 3.1) are properly connected.
• Ensure that connectors H.P11, B.P11, B.P12, C.P11, C.P12, A.P13, J/P12
and all connectors related to SW1 are properly connected.
• If a Square Folder is installed,
ensure D.P11, D.P12, B.P2 and connectors related to SW1 in
the Square Folder are properly connected.
• If a Trimmer is installed,
ensure A.P11, A.P12, B.P2 and connectors related to SW1 in the
Trimmer are properly connected.
• If a Square Folder/Trimmer is not installed,
ensure the short link connector is connected to Booklet maker J12.
• Disconnect the Square Folder/Trimmer and connect the short link connector to Booklet maker J12,
if the problem disappears when the Square Folder/Trimmer is disconnected,
go to Square Folder/Trimmer Service Manual.

continued on next page

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BM-SW1 Interlock circuit (SW16) RAP, continued
Procedure
• Power off the machine, remove the mains power cord,
disconnect F.P2 related to the SCP PCB “F” (PL 3.1) and J.P3 related to 4IN / 4OUT PCB “J”
• Close the top cover, measure resistance between F.P2-2 and BM-SW1-1 (PL 2.0). Repair/replace harness

There is continuity
Y N • Keep the machine power off, the mains power cord disconnected,
keep F.P2 related to the SCP PCB “F” and J.P3 related to 4IN / 4OUT PCB “J” disconnected
Repair/replace harness
• Close the top cover, measure resistance between J46-1 and A1 on REL-1.
• Keep the machine power off, the mains power cord disconnected,
keep F.P2 related to the SCP PCB “F” and J.P3 related to 4IN / 4OUT PCB “J” disconnected There is continuity

• Close the top cover, measure resistance between SW1-2 and SW1-1. Y N

There is continuity Repair/replace harness

Y N • Keep the machine power off, the mains power cord disconnected,
keep F.P2 related to the SCP PCB “F” and J.P3 related to 4IN / 4OUT PCB “J” disconnected,
Replace SW1
• Open the top cover, measure resistance between SW1-1 and SW1-2.
• Keep the machine power off, the mains power cord disconnected,
keep F.P2 related to the SCP PCB “F” and J.P3 related to 4IN / 4OUT PCB “J” disconnected There is continuity

• Close the top cover, measure resistance between SW1-2 and J12-3. Y N

There is continuity Go to SW1 Software signal (SW17) RAP

Y N Replace SW1

Repair/replace harness

• Keep the machine power off, the mains power cord disconnected,
keep F.P2 related to the SCP PCB “F” and J.P3 related to 4IN / 4OUT PCB “J” disconnected
• Close the top cover, measure resistance between J12-3 and J12-4.
There is continuity
Y N
Repair/replace short link connector
• Keep the machine power off, the mains power cord disconnected,
keep F.P2 related to the SCP PCB “F” and J.P3 related to 4IN / 4OUT PCB “J” disconnected
• Close the top cover, measure resistance between J12-4 and P46-1.
There is continuity
Y N

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SW1 Software signal SW17 RAP
This RAP is for troubleshooting SW1 Software signal, this fault results in software doesn’t register that top cover is closed/opened.
If this RAP frequently ends up with blown F1, Go to F1 Blown Up RAP

Initial Actions
• Ensure that all connectors to SCP PCB “D” (PL 3.1) are properly connected.
• Ensure that all connectors to SCP PCB “F” (PL 3.1) are properly connected.
• Ensure that all connectors to SCP PCB “G” (PL 3.0) are properly connected.
• Ensure that plugs/jacks related to 30VDC PSU (PL 3.1) are properly connected.
• Ensure that plugs/jacks related to 12VDC PSU (PL 3.1) are properly connected.
• Ensure that all connectors connecting to BM-REL1 (PL 3.0) are properly connected
• Ensure that all connectors connecting to PCB “J” (PL 3.1) are properly connected.
• Ensure that connectors H.P11, B.P11, B.P12, C.P11, C.P12, A.P13, J/P12 and all connectors related to SW1 are properly connected.
• If a Square Folder is installed,
ensure D.P11, D.P12, B.P2 and connectors related to SW1 in the Square Folder are properly connected.
• If a Trimmer is installed,
ensure A.P11, A.P12, B.P2 and connectors related to SW1 in the Trimmer are properly connected.
• If a Square Folder/Trimmer is not installed,
ensure the short link connector is connected to Booklet maker J12.

continued on next page

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SW1 Software signal SW17 RAP, continued
Procedure
• Power off the machine, remove the mains power cord.
• Disconnect J.P1 related to the related to 4IN / 4OUT PCB “J” (PL 3.1)
• Close the top cover, measure resistance between J.P.1-1 and SW1-3.
There is continuity
Y N
Repair/replace harness
• Power off the machine, remove the mains power cord.
• Disconnect J.P1 related to the related to 4IN / 4OUT PCB “J”.
• Close the top cover, measure resistance between J.P1-5 and SW1-4.
There is continuity
Y N
Repair/replace harness
• Power off the machine, remove the mains power cord.
• Disconnect J.P1 related to the related to 4IN / 4OUT PCB “J”.
• Open the top cover, measure resistance between SW1-3 and SW1-4.
There is continuity
Y N
• Power off the machine, remove the mains power cord.
• Disconnect J.P1 related to the 4IN / 4OUT PCB“J”.
• Open the top cover
• Disconnect white wire from SW1-3, measure resistance between white wire and chassis.
There is a short circuit
Y N
• Replace components in following order:
Ribbon cable between 4IN / 4OUT PCB “J” and ARM PCB “A”.
4IN / 4OUT PCB “J”
ARM PCB “A”
Repair/replace harness
Replace SW1 (PL 1.0).

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Interlock Relay REL-1 RAP Procedure
This RAP is for troubleshooting a not working Interlock Relay (No 30VDC in machine). Power on the machine, close the top cover, measure VDC between A1 and A2 on REL-1.
This RAP assumes there is no activation for REL-1 when the interlock switches are closed. The REL-1 may be mechanical removed to be able to make this measurement,
If this RAP frequently ends up with blown F1, Go to F1 Blown Up RAP CAUTION: Mains voltage connected to REL-1!
The voltage is 12VDC±10%
Initial Actions
Y N
• Ensure that all connectors to SCP PCB “D” (PL 3.1) are properly connected.
Keep the top cover closed,
• Ensure that all connectors to SCP PCB “F” (PL 3.1) are properly connected.
measure VDC between A1 on the REL-1 and F.P2-3 on the SCP PCB “F”.
• Ensure that all connectors to SCP PCB “G” (PL 3.0) are properly connected.
The voltage is 12VDC±10%
• Ensure that plugs/jacks related to 30VDC PSU are properly connected (PL 3.1).
Y N
• Ensure that plugs/jacks related to 12VDC PSU are properly connected (PL 3.1).
Go to SW1 Software signal (SW17) RAP
• Ensure that all connectors connecting to REL-1 are properly connected (PL 3.1).
• Power off the machine
• Ensure that all connectors connecting to PCB “J” (PL 3.1) are properly connected.
• Disconnect J.P3 and F.P2 related to SCP PCB “F”,
• Ensure that connectors H.P11, B.P11, B.P12, C.P11, C.P12, A.P13, J/P12 and measure resistance between J.P3-2 and P46-2,
all connectors related to SW1 are properly connected. also measure between J46-2 and A2 on REL-1.

• If a Square Folder is installed ensure D.P11, D.P12, B.P2 and There is continuity
connectors related to SW1 in the Square Folder are properly connected.
Y N
• If a Trimmer is installed,
Repair/replace harness
ensure A.P11, A.P12, B.P2 and connectors related to SW1
in the Trimmer are properly connected. Go to SW1 Software signal (SW17) RAP
• If a Square Folder/Trimmer is not installed, Perform the Mains voltage connectivity check RAP
ensure the short link connector is connected to Booklet maker J12. Warning!
• Disconnect the Square Folder/Trimmer and Use caution when making the voltage measurements,
connect the short link connector to Booklet maker J12, and always disconnect the Power Cord when it is necessary to work inside the Power Module.
if the problem disappears when the Square Folder/Trimmer is disconnected, AC Power is present in the Line Module whenever the Power Cord is plugged into the Wall Outlet.
go to Square Folder/Trimmer Service Manual.
Success
Y N
Replace REL-1 (PL 3.1)
Exit

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No 12VDC, machine not starting RAP
This RAP is for troubleshooting loss of 12VDC.
If this RAP frequently ends up with blown F1 (PL 3.1), go to F1 Blown Up RAP
This RAP assumes there is no Trimmer or Square Folder installed.

If the problem is related only when the Trimmer or Square Folder are installed,
please see Trimmer or Square Folder service manuals.

Initial Actions
• Ensure that all connectors to SCP (Short Circuit Protection) PCB “F” (PL 3.1)
are properly connected.
• Ensure that all connectors to SCP (Short Circuit Protection) PCB “G” (PL 3.0)
are properly connected.
• Ensure that plugs/jacks related to 12VDC PSU are properly connected (PL 3.1).
• Ensure that all connectors connecting to REL-1 are properly connected (PL 3.1).
• Ensure that connectors: H.P5, H.P4, B.P5, B.P4, C.P5, C.P4, A.P2 and A.P3
are properly connected.
• Ensure all connectors related to LED LAMP PCBs “L” and “M” are properly installed.

continued on next page

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No 12VDC, machine not starting RAP, continued
Procedure Repair/replace harness

• If the 12V PSU turns on and off LEDs in machine and 12V PSU LED activates/deactivates
with 4-5 seconds interval, there is a short circuit related to the 12V and • Power off the machine, remove the main power Cord.
the PSU tries to turn on the power outputs (12V).
• Leave the cover open
• If this happens perform this RAP,
if there is no succes, perform UI Blank RAP, No 12V TR RAP and No 12V SQF RAP. • Disconnect F.P1on the SCP PCB

• Power on the machine, measure voltage between L and N on the 12V PSU (90-264VAC), • Measure resistance between F,P.1-1 and +V, F.P1-2 and -V
CAUTION: main voltage! There is connectivity
The voltage is 90-264VAC. Y N
Y N Repair/replace harness
Disconnect the main power Cord ( very important ! ) Replace SCP PCB “F (PL 3.0).
Check F1.
Measure VDC between F.P2-1 and F.P2-3 related to the SCP PCB.
F1 blown
The voltage is 12VDC±10%
N Y
N Y
Go to F1 Blown Up RAP
Measure VDC between H.P5-4 and H.P5-5.
Go to Mains voltage connectivity check RAP
The voltage is 12VDC±10%
Measure VDC between F,P.1-1 and F.P1-2 related to the SCP PCB “F”.
Y N
The voltage is 12VDC±10%
• Repair harness between F.P2 related to the SCP PCB and H.P5
Y N Warning! Use caution when making the voltage measurements.
Measure VDC between +V and -V on the output of the 12VDC PSU (PL 3.1). Always disconnect the Power Cord when
it is necessary to work inside the Power Module.
The voltage is 12VDC±10% AC Power is present in the Line Module whenever
the Power Cord is plugged in.
Y N
• Power off the machine, remove the main power Cord.
• Leave the cover open
• Disconnect F.P1on the SCP PCB
• Disconnect G.P1, red and black wires from 12VDC PSU
• Measure resistance between F,P.1-1 and chassis, G.P.1-1 and chassis.
There is a short circuit
Y N
Replace 12V PSU
Success
Y N
Replace SCP PCB “F” and SCP PCB “G” (PL 3.0).
continued on next page
Exit

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No 12VDC, machine not starting RAP, continued

Measure VDC between H.P4-4 and H.P4-5. Replace upgradekit for OPTION 500, harness and PCBs “O” and “N”
The voltage is 12VDC±10% Disconnect L.P1, wait 120 seconds, power on the machine.
Measure VDC between F.P2-1 and F.P2-3 related to the SCP PCB.
Y N
The voltage is 12VDC±10%
Replace Upper MD6DC PCB “H” (PL 4.0).
N Y
Measure VDC between B.P5-4 and B.P5-5.
Replace PCB “L”
The voltage is 12VDC±10%
Power off, disconnect J/P50 and L.P1, check for short circuit between L.P1-1 chassis.
Y N There is a short circuit
Repair harness between H.P4 and B.P5 N Y
Measure VDC between B.P4-4 and B.P4-5. Repair/replace harness
The voltage is 12VDC±10% Reconnect L.P1 and disconnect M.P1, wait 120 seconds, power on the machine,
Y N measure VDC between F.P2-1 and F.P2-3 related to the SCP PCB.

Replace Middle MD6DC PCB “B” (PL 4.0). The voltage is 12VDC±10%

Measure VDC between C.P4-4 and C.P4-5. N Y

The voltage is 12VDC±10% Replace PCB “M”

Y N Power off, disconnect J/P50 and M.P1, check for short circuit between M.P1-1 chassis.
There is a short circuit
Repair harness between B.P4 and C.P4
N Y
Measure VDC between C.P5-4 and C.P5-5.
The voltage is 12VDC±10% Repair/replace harness

Y N Reconnect M.P1 and J/P50, disconnect A.P3.

Check for short circuit between A.P3-4 to chassis and between A.P3-4 to A.P3-5.
Replace Lower MD6DC PCB “C” (PL 3.1).
There is a short circuit
Measure VDC between A.P2-4 andA.P2-5.
N Y
The voltage is 12VDC±10%
Repair/replace harness
Y N
Reconnect connectors from previous step, disconnect C.P5, wait 120 seconds,
Repair harness between C.P5 andA.P2 power on the machine, measure VDC between F.P2-1 and F.P2-3 related to the SCP PCB.
Replace ARM PCB “A” (PL 3.1). The voltage is 12VDC±10%
Is there an OPTION 500 installed. N Y
N Y
Power off, disconnect O.P4, power on.
Measure VDC between F.P2-1 and F.P2-3 related to the SCP PCB.
The voltage is 12VDC±10%
N Y continued on next page

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No 12VDC, machine not starting RAP, continued

Power off the machine, keep H.P5 disconnected.

Disconnect F.P2 on SCP PCB.
Power off the machine, keep C.P5 disconnected, disconnect A.P2. Measure resistance between H.P5-4 and chassis and H.P5-4 to H.P5-5.
Measure resistance between A.P2-4 and chassis and between A.P2-4 to A.P2-5.
There is a short circuit
There is a short circuit
Y N
Y N
Replace Upper MD6DC PCB “H” (PL 4.0).
Replace ARM PCB “A” (PL 3.1).
Repair/replace harness
Repair/replace harness
Power off the machine and disconnect F.P2 on SCP PCB. Close the top cover if applicable.
Reconnect connectors from previous step, disconnect B.P4. Measure resistance between F.P2-2 related to the SCP PCB and chassis.
Wait 120 seconds, power on the machine. Measure between SW1-2 and chassis.
Measure VDC between F.P2-1 and F.P2-3 related to the SCP PCB.
There is a short circuit
The voltage is 12VDC±10%
Y N
N Y
Replace SCP PCB “F (PL 3.0).
Power off the machine, keep B.P4 disconnected, disconnect C.P4.
Measure resistance between C.P4-4 and chassis and C.P4-4 to C.P4-5. Repair/replace harness

There is a short circuit

Y N
Replace MD6DC PCB “C(PL 3.1).
Repair/replace harness
Reconnect connectors from previous step, disconnect H.P4.
Wait 120 seconds, power on the machine.
Measure VDC between F.P2-1 and F.P2-3 related to the SCP PCB.
The voltage is 12VDC±10%
N Y
Power off the machine, keep H.P4 disconnected, disconnect B.P5.
Measure resistance between B.P5-4 and chassis and B.P5-4 to B.P4-5.
There is a short circuit
Y N
Replace MD6DC PCB “B” (PL 4.0).
Repair/replace harness
Reconnect connectors from previous step, disconnect H.P5
Wait 120 seconds. Power on the machine,
measure VDC between F.P2-1 and F.P2-3 related to the SCP PCB.
The voltage is 12VDC±10%
N Y

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User Interface (Display) not working RAP
• This RAP is for troubleshooting the display. If this RAP frequently ends up with blown F1, go to F1 Blown Up RAP. This RAP assumes there is no Trimmer or Square Folder installed.
• If the problem is related only when the Trimmer or Square Folder are installed, please see Trimmer or Square Folder service manuals.

Initial Actions
• Ensure that all connectors to SCP (Short Circuit Protection) PCB “F” (PL 3.1) are properly connected.
• Check that G.P1, G.P2, A.P5, J/P107 and connectors inside UI-module V.P6, VP7, P2 (BM/RD), 4P FFC cable and 40P FFC cable are connected
• Ensure that plugs/jacks related to 12VDC PSU are properly connected (PL 3.1).
• Ensure that all connectors connecting to REL-1 are properly connected (PL 3.1).
• Ensure that connectors: H.P5, H.P4, B.P5, B.P4, C.P5, C.P4, A.P2 and A.P3 are connected.

Procedure
There is a No Com message displayed.
N Y
Go to Booklet Maker Communication Lost (UI: “No Com”) RAP
Go to UI Blank RAP

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Booklet Maker, Top Cover LED Lamp Faulty
This RAP is for troubleshooting the LED Lamp PCB “L” and “M”

Initial Actions
• Check functionallity between steps.
• Enter Service Mode
• Replace 4IN / 4OUT PCB “J” (PL 3.1).
• Check the LED Lamp
• Replace ARM PCB “A” (PL 3.0).
• Ensure that the connector is properly connected to the LED Lamp PCBs “L” and “M”.
• Deactivate LED Lamp in service mode.
• Ensure that connectors J/P50, J/P53, J/P56 are connected.
• Measure VDC at the LED Lamp L.P1 and M.P1 connector,
• Ensure that connectors A.P3 at PCB “A” and J.P3 at PCB “J” are properly connected (PL 3.0). between the red and white (12VDC and GND)

Procedure The voltage is 12 VDC ± 10%.

• Disconnect plug A.P3 from ARM PCB “A”. Y N

• Measure VDC between J.3-4 and J3-5 (12 VDC and GND) Replace LED Lamp PCB “L” and/or “M” (PL 2.0).

The voltage is 12 VDC ± 10%. • Check functionallity between steps.

Y N • Replace 4IN / 4OUT PCB “J” (PL 3.1).

Replace ARM PCB “A” (PL 3.0). • Replace ARM PCB “A” (PL 3.0).

• Disconnect L.P1, M.P1 and J.P3 from 4IN / 4OUT PCB “J”.
Leave A.P3 disconnected.
Check continuity for the red wire at Plug L.P1-1 to A.P3-4.
• Check continuity for the white wire at plug L.P1-4 to J.P3-3
• Check continuity for the red wire at Plug M.P1-1 to A.P3-4
• Check continuity for the white wire at plug M.P1-4 to J.P3-4
• Check all wires for short circuit to chassis,
also check short circuit between red to white wires
Is there continuity and no short circuit
Y N
Replace/Repair wire Harness.
• Connect plug A.P3 and J.P3
• Enter Service Mode and activate LED Lamp.
Measure VDC at the LED Lamp L.P1 and M.P1 connector,
between the red and white (12VDC and GND)
The voltage is 12 VDC ± 10%.
Y N

continued on next page

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 XCAN and ICAN OVERVIEW

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Power Save Mode RAP Close Cover/s RAP
This RAP is for troubleshooting the condition where the Cover Open message persist.
This RAP is for troubleshooting the system
when the UI does not wake up after Power Save mode. Initial Actions

Procedure • Ensure that all Top Covers on the system are closed (PL 1.0, PL 9.0 and PL 11.0).

Press the Touch Screen. • If a Square Folder and / or Trimmer Module is installed,
The UI wakes up. ensure that the Communication Power Cables (PL 10.7 and 11.9) are properly installed
(See Entry RAP).
Y N
• Open then close any Cover on the machine. • Ensure that the Interlock Jumper and Terminator Plugs (PL 7.0) are properly installed
• Power Off then On the system. (See Entry RAP).

Procedure
• Go to SW1 Interlock circuit (SW16) RAP (Booklet Maker).
Test pressing various options on the screen. • Go to SW1 Interlock circuit (SQF-SW3) RAP (if Square Folder is installed).
If it is hard to make selections, power off then on.
• Go to SW1 Interlock circuit (TR-SW9,TR-SW10) RAP (if TR is installed).
• Go to TR-153 RAP Interlock sensor faulty TR-Q1.

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Stacker (ST)
ST-001 Stacker Motor ST-M1 Short circuit
Belt Stacker RAP
This RAP is for troubleshooting the Belt Stacker.
(Stacker installed on Square Folder)
You should have been re-directed to this RAP from another Status indicator RAP. Fault code indicates that the Stacker motor ST-M1 has a short circuit.

Procedure Initial Actions

Check Motor ST-M1 (PL 8.0) in the Belt Stacker according to GP4. Ensure that the connectors are properly installed on the Stacker Motor (PL 8.0).
Is the Belt Stacker working correctly?
Procedure
Y N
Disconnect the motor plug M1. Enter Service Mode (GP1) and run M1 (GP4).
• Check for mechanical bindings, broken, missing or loose parts. Fault code ST-002 (Open circuit) is displayed.
• Check adjustment of Belt Stacker Module (ADJ 8.0). Y N
• Check adjustment of Belt Stacker Module (ADJ 8.0). • Disconnect plug P2 from MD6DC PCB “D” .
• Return to the previous RAP. • Check wires for Short circuit between the red wire M1 to P2-11 (violet)
• Check wires for Short circuit between the black wire M1 to P2-4 (orange).
Also check short circuit between wires to chassis.

There is a Short circuit.

Y N
Replace MD6DC PCB “D” .
Replace/repair harness
Replace motor ST-M1 (PL 8.0).

Wiring diagram for Stacker attached to Booklet Maker

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ST-001 Stacker Motor ST-M1 Short circuit ST-002 Stacker Motor ST-M1 Open Circuit
(Stacker installed on Trimmer) (Stacker installed on SQF)
Fault code indicates that the Stacker motor ST-M1 has an open circuit.
Fault code indicates that the Stacker motor ST-M1 has a short circuit.
Initial Actions
Initial Actions
• Ensure that the connectors are properly installed on the Stacker Motor (PL 8.0).
Ensure that the connectors are properly installed on the Stacker Motor ST-M1 (PL 8.0).
• Check that the Belt Stacker cable is connected to the Square Folder.
Procedure
Procedure
Disconnect the motor plug M1. Enter Service Mode (GP1) and run M1 (GP4).
• Disconnect the motor plug M1.
Fault code ST-002 (Open circuit) is displayed.
• Enter Service (GP1) mode and start Stacker motor (ST-M1) in (GP4) check motors.
Y N
• Measure VDC between the red wire M1 and the black wire M1
• Disconnect plug P2 from MD6DC PCB “A”.
The voltage is 24 VDC ± 10%.
• Check wires for Short circuit across the red wire M1 to P2-10 (violet)
and the black wire M1 to P2-3 (orange). Y N

• Check short circuit between wires to chassis. • Disconnect plug P2 from PCB “D”.

There is a short circuit. • Measure VDC between J.2-4 and J.2-11

Y N The voltage is 24 VDC ± 10%.

Replace MD6DC PCB “A”. Y N

Replace/Repair Wire Harness. Replace MD6DC PCB “D” .

Replace motor ST-M1 (PL 8.0). Replace/repair harness

Replace
.

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ST-002 Stacker Motor ST-M1 Open Circuit If a Square Folder not is installed :

(Stacker installed on Trimmer) • Check that the Belt Stacker cable is connected to the Trimmer.
Fault code indicates that the Stacker motor ST-M1 has an open circuit. • Disconnect the motor plug M1.
Enter Service (GP1) mode and start Stacker motor (ST-M1) in (GP4).
Initial Actions
• Measure Vdc between the red wire M1 and the black wire M1 (30V PVM and GND).
• Ensure that the connectors are properly installed on the Stacker Motor ST-M1 (PL 8.0).
The voltage is 24 VDC ± 10%.
• Ensure P30/J30 is connected and connector A.P2.
Y N
• Disconnect plug P2 from MD6DC PCB “A”.
If a Square Folder is installed:
• Measure VDC between J.2-3 and J.2-10
• Ensure that plug A.P6 on MD6DC PCB “A” in the Trimmer is connected (PL 11.4). The voltage is 24 VDC ± 10%.
• Ensure that plug D.P4 on MD6DC PCB “D” in the Square Folder is connected (PL 10.2). Y N
• Ensure that plug D.P7 on MD6DC PCB “D” in the Square Folder is connected (PL 10.2). Replace MD6DC PCB (PL 11.4)
• Ensure that the communication cable between Trimmer and Square Folder is connected. • Check continuity for wire between A.P2-3 to Plug M1
• Check that the power cable between Booklet Maker and Square Folder is connected. • Check continuity for wire between A.P2-10 wire to Plug M1
• Check for short circuit between A.P2-3 to A.P2-10
• Check for short circuit between A.P2-3 and chassis/GND
• Check for short circuit between A.P2-10 and chassis/GND
There is continuity for all wires and no short circuit
Y N
• Replace/Repair Wire Harness.
• Replace MD6DC PCB “A”.
Replace motor ST-M1 (PL 8.0).
Replace motor ST-M1 (PL 8.0).

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Square Folder (SQF)
SQF-001 Transport Belt Motor SQF-M1 Short circuit SQF-002 Transport Belt Motor SQF-M1 Open circuit
Fault code indicates that the Transport Belt Motor SQF-M1 has a short circuit. Fault code indicates that the Transport Belt Motor SQF-M1 has an open circuit.

Procedure Procedure
Disconnect the motor plug M1. Enter Service Mode (GP1) and run M1 (GP4). • Disconnect the motor plug M1.
Fault code SQF-002 (Open circuit) is displayed.
• Enter Service mode (GP1) and start Transport Belt Motor SQF-M1 in (GP4) check motors.
Y N
• Measure VDC between the orange wire M1 and the violet wire M1.
• Disconnect plug D.P3 from MD6DC PCB ”D”.
• Check wires for Short circuit between the orange wire M1 to D.P3-6 (violet) The voltage is 18 VDC ± 10%.
• Check wires for Short circuit between the violet wire M1 to D.P3-7 (orange). Y N
• Check for short circuit between wires to chassis • Disconnect plug D.P3 from MD6DC PCB ”D”.
Is there a short circuit • Measure VDC between J.3-6 and J.3-7
Y N
The voltage is 18 VDC ± 10%.
Replace MD6DC PCB ”D”.
Y N
Replace/Repair wire Harness.
Replace MD6DC PCB ”D”.
Replace motor SQF-M1 (PL 10.7).
Replace/Repair wire Harness.

Replace motor SQF-M1 (PL 10.7).

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SQF-003 Stop Gate Motor SQF-M2 Pulse timeout
Fault code indicates that the Stop Gate Motor SQF-M2 (PL 10.7)
does not receive any displacement pulses. • Disconnect plug D.P14 from MD6DC PCB “D”.
Initial Actions • Check continuity for the red wire at plug Q10 to D.P14-9.

• Ensure that the Stop gate sensor SQF-Q1 (PL 10.1) is installed correctly (REP 11.10). • Check continuity for the white wire at plug Q10 to D.P14-7

• Ensure that plug D.P14 on MD6DC PCB “D” in the Square Folder is connected. • Check continuity for the grey wire at plug Q10 to D.P14-4

• Ensure that plug D.P2 on MD6DC PCB “D” in the Square Folder is connected. • Check continuity for the black wire at plug Q10 to D.P14-3

• Ensure that jack/plug J20/P20 are connected. • Check for Short circuit between red/ white/black/grey wires.

• Ensure that jack/plug J21/P21 are connected. • Check for short circuit between red/white/grey/black wires and chassis/GND

• Enter Service Mode (GP1) and There is continuity for all wires and no short circuit
check Stop Gate Motor (SQF-M2) (PL 10.7) in (GP4) check motors. Y N
Procedure Replace/Repair harness
The Stop Gate is working correctly • Replace motor SQF-M2 (PL 10.7).
Y N • Replace MD6DC PCB “D” .
• Check for mechanical bindings, broken, missing or loose parts. Inside Square Folder:
• Disconnect the sensor plug Q10 to motor M2. • Check SQF-Q5, SQF-Q6, SQF-Q7, SQF-M1 and SQF-SOL1-4 (GP1).
• Measure between the red wire Q10 and the black wire Q10 (5V and GND). • Check for mechanical bindings, broken, missing or loose parts.
The voltage is 5 VDC ± 10%. • Clean the transport belts.
Y N
• Disconnect plug D.P14 from PCB “D”.
• Measure between the J.14-9 and J14-3 (5V and Signal GND).

The voltage is 5 VDC ± 10%.

Y N
Replace MD6DC PCB “D” .

Replace/Repair wire Harness.

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SQF-004 Stop Gate Motor SQF-M2 Cycle timeout Procedure
Fault code indicates that the Stop Gate Motor SQF-M2 had a Cycle timeout. Enter Service Mode (GP1) and check Stop Gate Motor (SQF-M2) in (GP4) check motors.
The Stop Gate is working correctly
Initial Actions
Y N
• Ensure that the Stop gate sensor SQF-Q1 (PL 10.1) is installed correctly (REP 11.10).
Check for mechanical bindings, broken, missing or loose parts.
• Ensure that plug D.P13, D.P16, D.P2 on MD6DC PCB “D”
Enter Service Mode (GP1).
in the Square Folder is connected.
Select (M2) Stop gate sensor (SQF-Q1) in (GP4) check sensors.
• Ensure that jack/plug J20/P20, J21/P21, in the Square Folder is connected.
The (M2) Stop gate sensor (SQF-Q1) indicates :
• Ensure the allen screw to the white cam is 1 when the sensor is blocked, and 0 when the sensor is unblocked.
tightened against the flat on the motor shaft (REP 11.7).
Y N
Disconnect the sensor plug Q1.
Measure between the red wire Q1 and the black wire Q1 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Disconnect plug D.P13 and D.P16 from PCB “D”.
Measure between the J.16-2 and J13-3 (5V and Signal GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “D” .
Repair wire harness.
• Disconnect plug D.P14 from MD6DC PCB “D”.
• Check continuity for the red wire at plug Q1 to D.P16-2.
• Check continuity for the white wire at plug Q1 to D.P13-2
• Check continuity for the black wire at plug Q1 to D.P13-3
• Check wire for short circuit between red/white/black wires.
• Check for short circuit between red/white/black wires to chassis/GND.
There is continuity for all wires and no short circuit
Y N
Replace/Repair harness
Replace sensor Q1(REP11.10)
Replace MD6DC PCB “D” .
Inside Square Folder:
Check Q5, Q6, Q7, M1 and SOL1-4.
Check for mechanical bindings, broken, missing or loose parts.
Clean the Transport belts.

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SQF-005 Stop Gate Motor SQF-M2 Short Circuit SQF-006 Stop Gate Motor SQF-M2 Open Circuit
Fault code indicates that the Stop Gate Motor SQF-M2 has a short circuit. Fault code indicates that the Stop Gate Motor SQF-M2 has an open circuit.

Procedure Procedure
Disconnect the motor plug M2. Enter Service Mode (GP1) and run M2 (GP4). • Disconnect the motor plug M2 and D.P2.
• Check continuity for theorange wire from M2 to D.P2-2
Fault code SQF-006 (Open circuit) is displayed.
• Check continuity for the violet wire from M2 to D.P2-9
Y N
• Check for short circuit between violet/orange wires
• Disconnect plug D.P2 from MD6DC PCB ”D”.
• Check for short circuit between between orange/violet wires to chassis/GND
• Check wires for short circuit between the orange wire M2 to D.P2-9 (violet).
There is continuity for all wires and no short circuit
• Check wires for short circuit between the violet wire M2 to D.P2-2 (orange).
Y N
• Check for short circuit between wires to chassis.
Replace/Repair wire Harness.
Is there a short circuit.
• Replace motor SQF-M2 (PL 10.7).
Y N
• Replace MD6DC PCB ”D”.
Replace MD6DC PCB ”D”.
Replace/Repair wire Harness.
Replace motor SQF-M2 (PL 10.7).

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SQF-007 Clamp Motor SQF-M3 Short circuit SQF-008 Clamp Motor SQF-M3 Open circuit
Fault code indicates that Clamp Motor SQF-M3 has a short circuit. Fault code indicates that Clamp Motor SQF-M3 has an open circuit.

Procedure Procedure
• Disconnect the motor plug M3 (PL 10.5). • Disconnect the motor plug M3 (PL 10.5). Disconnect plug D.P3.

• Enter Service Mode (GP1) and run M3 (GP4). • Check wire for continuity / short circuit the orange wire from M3 to D.P3-2

Fault code SQF-008 (Open circuit) is displayed. • Check wire for continuity / short circuit from violet wire from M3 to D.P3-3

Y N • Check for short circuit between violet/orange wires

• Disconnect plug D.P3 from MD6DC PCB ”D”. • Check for short circuit between orange/violet wires to chassis/GND.

• Check wires for short circuit between the orange wire M3 and D.P3-3 (violet). There is continuity for all wires and no short circuit

• Check wires for short circuit between the violet wire M3 and D.P3-2 (orange). Y N

• Check short circuit between wires and chassis. Replace/Repair wire Harness.

Is there a short circuit • Check for mechanical bindings or worn/broken parts.

Y N • Replace motor SQF-M3 (PL 10.5).

Replace MD6DC PCB ”D”. • Replace MD6DC PCB ”D”.

Replace/Repair wire Harness.

Replace motor (PL 10.5).

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SQF-009 Clamp Motor SQF-M3 Pulse Timeout
Fault code indicates that the Clamp Motor SQF-M3 had a Pulse timeout.

Initial Actions

• Enter Service mode (GP1) and run Clamp Motor SQF-M3 in (GP4) check motors.
Replace/Repair wire Harness
• Ensure that Clamp motor Encoder sensor SQF-Q4 is installed correctly and
not damaged (REP 11.12). • Replace sensor SQF-Q4 (PL 10.5).

• Ensure that plug D.P3, D.P14 and D.P16 on MD6DC PCB “D” • Replace MD6DC PCB ”D”.
in the Square Folder are connected. Inside Square Folder:
Procedure • Check motor SQF-M3.

Enter Service Mode and select Clamp motor Encoder sensor (Q4) in check sensors. • Check for mechanical bindings, broken, missing or loose parts.

Sensor Q4 working correctly • Replace theSQF-M3.

Y N
• Check for mechanical bindings, broken, missing or loose parts.
• Disconnect plug D.P16 and D.P14 from MD6DC PCB ”D”.
• Measure between J.16-5 and J14-6 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB ”D”.
• Disconnect plug from sensor Q4.
• Check continuity for the red wire at plug Q4 to D.P16-5.
• Check continuity for the white wire at plug Q4 to D.P14-11
• Check continuity for the black wire at plug Q4 to D.P14-6
• Check for short circuit between red/white/black wires.
• Check for short circuit between red/white/black wires to chassis/GND.
There is continuity for all wires and no short circuit
Y N
Replace/Repair harness
• Connect plug D.P16 and D.P14 to MD6DC PCB ”D”.
• Measure between the red wire Q4 and the black wire Q4 (5V and GND).

The voltage is 5 VDC ± 10%.

Y N

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SQF-010 Roll Motor SQF-M4 Short circuit SQF-011 Roll Motor SQF-M4 Open circuit
Fault code indicates that the Roller motor SQF-M4 has a short circuit. Fault code indicates that the Roller motor SQF-M4 has an open circuit.

Procedure Procedure
Disconnect the motor plug M4. Enter Service Mode (GP1) and run M4 (GP4). • Disconnect the motor plug M4. Disconnect plug D.P2.
Fault code SQF-011 (Open circuit) is displayed. • Check continuity for the orange wire from M4 to D.P2-3
Y N • Check continuity for the violet wire from M4 to D.P2-10
• Disconnect plug D.P2 from MD6DC PCB ”D”. • Check for short circuit between violet and the orange wires
• Check for short circuit between the orange wire M4 and D.P2-10 (violet) • Check for short circuit between orange/violet wires to chassis/GND
• Check for short circuit between the violet wire M4 and D.P2-3 (orange). There is continuity for all wires and no short circuits.
• Check short circuit between wires to chassis. Y N
Is there a short circuit Replace/Repair wire Harness.
Y N • Replace motor SQF-M4.
Replace MD6DC PCB ”D”. • Replace MD6DC PCB ”D”.
Replace/Repair wire Harness
Replace motor SQF-M4.

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SQF-012 Roll Motor SQF-M4 cycle timeout
Fault code indicates that the Roll motor SQF-M4 had a Cycle timeout.

Initial Actions
• Ensure that jack/plug J27/P27, J26/P26 in the Square Folder is connected.
• Ensure that Roller motor Right Home position sensor (SQF-Q2) is
installed correctly (REP 11.11).
• Ensure that Roller motor Left Home position sensor (SQF-Q3) is
installed correctly (REP 11.11).

Procedure
Enter Service mode (GP1) and run Roller motor (M4) in (GP4) check motors.
Is the Roller working correctly?
Y N
Enter Service Mode and select
Roller motor Right Home position sensor (Q2) in check sensors.
The Roller motor Right Home position sensor indicates:
1 when the sensor is blocked, and 0 when the sensor is unblocked.
Y N
Disconnect plug D.P13 and D.P14 from MD6DC PCB ”D”.
Measure between J.14-2 and J13-6 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB ”D”.
• Disconnect plug from sensor Q2.
• Check continuity for the red wire at plug Q2 to D.P14-2.
• Check continuity for the white wire at plug Q2 to D.P13-5
• Check continuity for the black wire at plug Q2 to D.P13-6
• Check for Short circuit between red/white/black wires.
• Check for short circuit between red/white/black wires to chassis/GND.
There is continuity for all wires and no short circuit
Y N
Replace/Repair harness
Connect plug D.P13 and D.P14 to MD6DC PCB ”D”.
Measure between the red wire Q2 and the black wire Q2 (5V and GND).

The voltage is 5 VDC ± 10%.

continued on next page
Y N

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SQF-012 Roll Motor SQF-M4 cycle timeout, continued

Replace/Repair wire Harness Pull the motor gently by hand.

• Replace sensor SQF-Q2. Are you able to pull the motor back and forth without using a lot of force.

• Replace MD6DC PCB ”D”. Y N

Enter Service mode (GP1) and Lubricate where needed.

select Roller motor Left position sensor (Q3) in check sensors.
The Roller motor Left Home position sensor indicates : Replace motor SQF-M4.
1 when the sensor is blocked, and 0 when the sensor is unblocked.
Y N Inside Square Folder:

Disconnect plug D.P13 from MD6DC PCB ”D”. • Check Q5, Q6, Q7, M1, M2, M3 and SOL1-4.
Measure between J.13-13 and J13-9 (5V and GND). • Check for mechanical bindings, broken, missing or loose parts.
• Clean the Transport belts.
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB ”D”.
• Disconnect plug from sensor Q3.
• Check continuity for th red wire at plug Q3 to D.P13-13.
• Check continuity for th white wire at plug Q3 to D.P13-8
• Check continuity for th black wire at plug Q3 to D.P13-9
• Check for Short circuit between red/white/black wires.
• Check for short circuit between red/white/black wires to chassis/GND.
There is continuity for all wires and no short circuit
Y N
Replace/Repair harness
Connect plug D.P16 and D.P14 to MD6DC PCB ”D”.
Measure between the red wire Q3 and the black wire Q3 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace/Repair wire Harness
Replace sensor SQF-Q2 .
Replace MD6DC PCB ”D”.

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SQF-013 Roll Motor SQF-M4 Pulse timeout
Fault code indicates that the Roll motor (SQF-M4) had an pulse timeout.

Initial Actions
Ensure that jack/plug J27/P27, J26/P26 in the Square Folder are connected.

Procedure
Enter Service mode (GP1) and check sensor Q8 in (GP4) check sensors.
Sensor Q8 is toggling between 1 and 0 when rotating the motor
Y N
Disconnect the sensor plug Q8 to motor M4.
Measure between the yellow wire Q8 and the grey wire Q8 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Disconnect plug D.P14 from MD6DC PCB ”D”.
Measure between the J.16-4 and J.14-13 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB ”D”.
Replace/Repair wire Harness
• Disconnect plug D.P14 from MD6DC PCB ”D”.
• Check continuity for the red wire from Q8 to D.P16-4
• Check continuity for the white wire from Q8 to D.P14-14
• Check continuity for the black wire from Q8 to D.P14-13
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit.
Y N
Replace/Repair wire Harness
• Replace motor SQF-M4.
• Replace MD6DC PCB ”D” .
Inside Square Folder:
Check Q5, Q6, Q7, M1, M2, M3 and SOL1-4.
Check for mechanical bindings, broken, missing or loose parts.
Clean the Transport belts.

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SQF-014 Infeed Sensor SQF-Q5 Faulty
Fault code indicates that the Infeed Sensor SQF-Q5 is faulty.

Initial Actions
• Ensure that the sensor SQF-Q5 (PL 10.4) is clean.
• Ensure that Q5 is properly installed (REP 11.13 SQF-Q5 Infeed Sensors).
• Ensure P/J33, P/J32, P20/J20 and P13 is connected.

Procedure
Disconnect plug D.P13 from PCB ”D”.
Measure between J.13-23 and J.13-16 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB ”D”.
Disconnect plug from Infeed LED sensor Q5.
Check continuity for the black wire Q5 to D.P13-16 and for the red wire Q5 to D.P13-23.
Check for short circuit between red/black wires and between red/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair wire Harness.
Connect plug D.P13 to MD6DC PCB ”D”. Disconnect plug from Infeed photo transistor sensor Q5.
Measure between black wire Q5 and white wire Q5 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Disconnect plug J/P20.
Measure between P20-2 and P20-3 (Signal and GND) in the plug P20.
The voltage is 5 VDC ± 10%.
Y N
Disconnect plug D.P13 from MD6DC PCB ”D”.
Measure between J.13-24 and J.13-25 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB ”D”.
Replace/Repair wire Harness
Repair wire Harness to Infeed photo transistor sensor SQF-Q5 (PL 10.4).
Replace Infeed LED sensor SQF-Q5.
Replace Infeed LED sensor SQF-Q5.

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SQF-015 Clamp Sensor SQF-Q6 Faulty
Fault code indicates that the Clamp Sensor SQF-Q6 is faulty.

Initial Actions
• Ensure that the sensor Q6 is clean (REP 11.15 SQF-Q6 Clamp Sensor).
• Ensure that Q6 is properly installed (REP 11.15 SQF-Q6 Clamp Sensor).

Procedure
Enter Service Mode and select Clamp Sensor (SQF-Q6) in check sensors.
Clamp Sensor indicates
1 when the sensor is blocked, and 0 when the sensor is unblocked.
Y N
Disconnect plug D.P16 and D.P13 from MD6DC PCB ”D” (PL 11.2).
Measure between J.16-3 and J.13-22 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB ”D”.
• Disconnect plug from sensor Q6.
• Check continuity for the red wire at plug Q6 to D.P16-3
• Check continuity for the white wire at plug Q6 to D.P13-21
• Check continuity for the black wire at plug Q6 to D.P13-22
• Check for short circuit between red/white/black wires
and between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug D.P16 and D.P13 from MD6DC PCB ”D”.
• Measure between the red wire Q6 and the black wire Q6 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace/Repair Wire Harness.
Replace SQF-Q6 Clamp Sensor.
Replace MD6DC PCB ”D” .

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SQF-016 Exit Sensor SQF-Q7 Faulty
Fault code indicates that the Exit Sensor SQF-Q7 is faulty.

Initial Actions
• Ensure that the sensor Q7 is clean (PL 11.14).
• Ensure that Q7 is properly installed (REP 11.14 SQF-Q7 Exit Sensors).
• Ensure that jack/plug J29/P29, J20/P20, J27/P27 in the Square Folder is connected.
Procedure
• Disconnect plug D.P13 and D.P14 from MD6DC PCB ”D”.
• Measure between J.13-17 and J.14-10 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB ”D”.
• Disconnect plug from Exit LED sensor Q7.
Check wire for continuity for black wire Q7 to D.P14-10 and the red wire Q7 to D.P13 17.
• Check for short circuit between red/black wires and between red/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug D.P13 and D.P14 to PCB ”D”.
• Disconnect plug from Exit photo transistor sensor Q7.
• Measure between black wire Q7 and white wire Q7 (Signal and GND).

The voltage is 5 VDC ± 10%.

Y N
Disconnect plug D.P13 from PCB ”D”.
Measure between J.13-18 and J.13-19 (Signal and GND).

The voltage is 5 VDC ± 10%.

Y N
Replace MD6DC PCB ”D”.
Replace/Repair Wire Harness.
• Replace Exit LED sensor (REP 11.14 SQF-Q7 Exit Sensors)
• Replace Exit photo transistor sensor Q7 (REP 11.14 SQF-Q7 Exit Sensors).

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SQF-017 SOL1 / 3 Open circuit SQF-018 SOL2 / 4 Open circuit
Fault code indicates that there is an open circuit on SOL 1 / 3. Fault code indicates that there is an open circuit on SOL 2 / 4.

Initial Actions Initial Actions

• Ensure that SOL2 and SOL4 connector are properly connected (PL 10.4).
• Ensure that SQF-SOL1 and SQF-SOL3 connector are properly connected (PL 10.3).
• Ensure that P2/J2 on the MD6DC “D” is properly connected (PL 10.2). • Ensure that P2/J2 on the MD6DC “D” is properly connected (PL 10.2).
• Ensure that P21/J21 is properly connected.
• Ensure that P32/J32 is properly connected
Procedure
Procedure
• Disconnect the SOL 2 and SOL 4 connectors. Disconnect plug D.P2.
• Disconnect the SOL 1 and SOL 3 connectors. Disconnect plug D.P2.
• Measure continuity between the orange wire SOL2 to D.P2-6.
• Measure continuity between the orange wire SOL1 to D.P2-5.
• Measure continuity between the orange wire SOL4 to D.P2-6.
• Measure continuity between the orange wire SOL3 to D.P2-5.
• Measure continuity between the violet wire SOL2 to D.P2-13.
• Measure continuity between the violet wire SOL1 to D.P2-12.
• Measure continuity between the violet wire SOL4 to D.P2-13.
• Measure continuity between the violet wire SOL3 to D.P2-12.
There is continuity.
There is continuity.
Y N
Y N
Repair wire Harness.
Repair wire Harness.
• Replace SOL 2 / 4 (PL 10.4).
• Replace SOL 1 / 3 (PL 10.3).
• Replace MD6DC PCB ”D”.
• Replace MD6DC PCB ”D”.

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SQF-150 30V Input low The voltage is 29.0-31.0VDC
N Y
This RAP is for troubleshooting a low 30VDC in Square Folder.

Initial Actions • Power off, reconnect A.P11 and A.P12

• Ensure connectors related to TR-Q1 are properly connected. • Disconnect A.P2 and A.P3 wait 120 seconds then power on the machine,
• Ensure that all connectors to MD6DC PCB “D” are properly connected. measure VDC between A.P11-1 and A.P11-2.
There might be only a short period when the voltage is present so pay attention.
• Ensure that all connectors to LED PCB “B” (PL 10.2) are properly connected. Close all top covers.
• Ensure that all connectors to BM-SW1. SQF-SW1 and TR-SW1 are properly connected. The voltage is 29.0-31.0VDC
• Ensure the Power Connection Cable between the BM, SQF and TR N Y
are properly connected and not damaged.
Locate short circuit related to A.P2 and A.P3 and repair/replace.
Procedure Success
• Power off, disconnect the Power Connection Cable between the BM, SQF and TR, Y N
• Connect the Short link connector to Booklet Maker J12. Replace MD6DC PCB “D”
• Disconnect com. cables and move CAN termination to Booklet Maker. Exit
Wait 120 seconds then power on the machine. The system setup in UI may need to be changed.
Replace MD6DC PCB “D”
• Measure VDC between J.12-1 and J.12-2.
There might be only a short period when the voltage is present so pay attention. • Power off, disconnect A.P11, A.P12 and the two Power Connection Cables.
Close all top covers.
• Check continuity for the red wire between A.P11-1 to J25-1
The voltage is 29.0-31.0VDC
• Check continuity for the red wire between A.P12-1 to J25-7
Y N
• Check continuity for the black wire between A.P12-2 to J25-8
Go to No 30VDC from SCP PCB “D” in Booklet Maker service manual
• Check continuity for the black wire between A.P11-2 to J25-2
• Power off. Leave the Power Connection Cable between the
• Check for short circuit between red/black wires and between red wires to chassis/GND
Booklet Maker, Square Folder and Trimmer disconnected
• Measure resistance between pin 1 to pin 1, pin 2 to pin 2 and so on for both cables. There is Continuity on all wires and no short circuit between red/black wires and red
Is there connectivity for all 12 pins wires to chassis.

Y N Y N

Replace/repair the Power Connection Cables

Below measurements shall all be performed inside the Trimmer

• Reconnect Power Connection Cable between the BM, SQF and TR

• Disconnect A.P11 and A.P12, power on the machine
• Measure VDC between A.P11-1 and A.P11-2.
There might be only a short period when the voltage is present so pay attention.
Close all top covers.
continued on next page

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SQF-150 30V Input low, continued

Replace/repair harness
Below measurements shall be performed inside Square Folder

• Power off, reconnect everything from earlier steps, disconnect D.P11 and D.P12.
• Check continuity for the red wire between D.P11-1 to J13-1
• Check continuity for the red wire between D.P12-1 to J30-1
• Check continuity for the black wire between D.P12-2 to J30-2
• Check continuity for the black wire between D.P11-2 to J31-2
• Check continuity for the red wire between J31-7 to J30-7
• Check continuity for the black wire between J31-8 to J30-8
• Check for short circuit between red/black wires and between red wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/repair harness
• Power off, reconnect D.P12 and D.P11
• Disconnect D.P2 and D.P3 wait 120 seconds
then power on the machine, measure VDC between D.P12-1 and D.P12-2.
There might be only a short period when the voltage is present so pay attention.
• Close all top covers.
The voltage is 29.0-31.0VDC
N Y
Locate short circuit related to D.P2 and D.P3 and repair/replace.
Success
Y N
Replace MD6DC PCB “D”
Exit
Replace MD6DC PCB “D”
Success
Y N
Go to No 30VDC from SCP PCB “D” in Booklet Maker service manual

Exit

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SQF-151 30V Input high
This RAP is for troubleshooting a high 30VDC.

Initial actions
• Ensure that all connectors to MD6DC PCB “A” in Trimmer and
MD6DC PCB “D” (PL 11.2) in Square Folder are properly connected.
• Ensure the Power Connection Cable between the BM, SQF and TR
are properly connected and not damaged.

Procedure
Perform BM-152 30VDC High at Lower MD6DC PCB “C” in Booklet Maker RAP
Success
Y N
• Replace MD6DC “D” in Square Folder
• Replace MD6DC “A” in Trimmer

Exit

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SQF-201 Infeed Sensor SQF-Q5 Not activated in time SQF-202 Infeed Sensor SQF-Q5 Activated to long
Fault code indicates that during Run (Operation) the Infeed sensor SQF-Q5 (PL 10.4), Fault code indicates that at ”initialization” or during Run the Infeed sensor SQF-Q5 (PL 10.4),
was not blocked within timeout, after detection of the Booklet Maker exit signal. was blocked exceeding timeout.

Initial Actions
Initial Actions
• Ensure that the sensor (SQF-Q5) is clean (REP 11.13 SQF-Q5 Infeed Sensors).
• Ensure that the sensor (SQF-Q5) is clean (REP 11.13 SQF-Q5 Infeed Sensors).
• Ensure that the Infeed Sensor (SQF-Q5), is installed correctly (REP 11.13 SQF-Q5 Infeed Sensors).
• Ensure that the Infeed Sensor (SQF-Q5), is installed correctly
(REP 11.13 SQF-Q5 Infeed Sensors). Procedure
Procedure • Inside Booklet Maker: Check BM-Q8, BM-M5, BM-M22, BM-M8,
BM-Q40, BM-Q41, BM-Q42, BM-Q7, BM-Q43, BM-Q44 , BM-M6, BM-Q9.
• Inside Booklet Maker:
Check Q8, M5, M22, M8, Q40, Q41, Q42, Q7, Q43, Q44 , M6, BM-Q9. • Inside Square Folder:
Check SQF-Q5, SQF-Q6, SQF-Q7, SQF-M1 and SOL1-4 .
• Inside Square Folder: Check Q5, Q6, Q7, M1 and SOL1-4.
• Inside Booklet Maker and Square Folder:
• Inside Booklet Maker and Square Folder: Check for mechanical bindings, broken, missing or loose parts, clean the Transport belts.
Check for mechanical bindings, broken, missing or loose parts, clean the Transport belts.
• Ensure that nothing interferes with the paper path.
• Ensure that nothing interferes with the paper path direction between the Booklet Maker,
and the Square Folder.
• Ensure that the Square Folder is correctly installed (see chapter 1, Installation).

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SQF-203 Clamp Sensor SQF-Q6 Not activated in time SQF-204 Clamp Sensor (SQF-Q6) Activated too long
During Run the Clamp Sensor SQF-Q6 (PL 10.7) was not blocked within timeout. At ”initialization” or during Run the Clamp sensor SQF-Q6 (PL 10.7)
was blocked exceeding timeout.
Initial Actions
Initial Actions
• Ensure that the sensor SQF-Q6 is clean (REP 11.15 SQF-Q6 Clamp Sensor).
• Ensure that the sensor SQF-Q6 is clean (REP 11.15 SQF-Q6 Clamp Sensor).
• Ensure that the Clamp sensor SQF-Q6,
is installed correctly (REP 11.15 SQF-Q6 Clamp Sensor). • Ensure that the Clamp sensor SQF-Q6,
is installed correctly (REP 11.15 SQF-Q6 Clamp Sensor).
• Ensure J/P20 is connected.
• Ensure J/P20 is connected.
Procedure
Procedure
• Inside Square Folder: Check Q5, Q6, Q7, M1 and SOL1-4.
• Inside Square Folder: Check Q5, Q6, Q7, M1, M2, M3 and SOL1-4.
• Inside Booklet Maker Check BM-M6, BM-Q9
• Check Belt stacker motor M1.
• Inside Booklet Maker and Square Folder:
Check for mechanical bindings, broken, missing or loose parts, clean the Transport belts. • Inside Bookler Maker: Check BM-M6, BM-Q9.
• Ensure that nothing interferes with the paper path. • Inside Booklet Maker and Square Folder:
• Check for mechanical bindings, broken, missing or loose parts, clean the Transport belts.
• Ensure that nothing interferes with the paper path BM-062

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SQF-205 Exit Sensor SQF-Q7 not activated in time SQF-206 Exit Sensor SQF-Q7 activated too long
At ”initialization” or during Run the Exit Sensor SQF-Q7 (PL 10.5) At ”initialization” or during Run the Exit Sensor SQF-Q7 (PL 10.5)
was not blocked within timeout. was blocked exceeding timeout.

Initial Actions Initial Actions

• Ensure that Exit Sensor SQF-Q7 is clean (REP 11.14 SQF-Q7 Exit Sensors). • Ensure that Exit Sensor SQF-Q7 is clean (REP 11.14 SQF-Q7 Exit Sensors).
• Ensure that Exit Sensor SQF-Q7 is installed correctly (REP 11.14 SQF-Q7 Exit Sensors). • Ensure that Exit Sensor SQF-Q7 is installed correctly (REP 11.14 SQF-Q7 Exit Sensors).
• Ensure that jack/plug J27/P27 in the Square Folder is connected. • Ensure that jack/plug J27/P27 in the Square Folder is connected.
• Ensure that jack/plug J29/P29, P20/J20 in the Square Folder is connected. • Ensure that jack/plug J29/P29, P20/J20 in the Square Folder is connected.

Procedure Procedure
• Inside Square Folder: Check Q5, Q6, Q7, M1, M2, M3 and SOL1-4. • Inside Square Folder: Check Q5, Q6, Q7, M1, M2, M3 and SOL1-4.
• Inside Booklet Maker: Check BM-M6, BM-Q9 • Check Belt stacker motor M1.
• Inside Booklet Maker and Square Folder: • Inside Trimmer and Square Folder:
Check for mechanical bindings, broken, missing or loose parts, clean the Transport belts. Check for mechanical bindings, broken, missing or loose parts, clean the Transport belts.
• Ensure that nothing interferes with the paper path. • Ensure that nothing interferes with the paper path.

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SQF-501 Stacker Full Square Folder Transport RAP
Fault code indicates that the Belt Stacker is full. This RAP is for troubleshooting the Square Folder Transport.

Procedure You should have been re-directed to this RAP from another Status indicator RAP.

Empty Belt Stacker and press Done on the UI. Procedure

Note: This function can also be turned off under the Tools menu on the UI. Check Sensor SQF-Q5 (PL 10.4) according to GP4.
Is Sensor Q5 working correctly?
Y N

Clamp RAP Go to SQF-014.

This RAP is for troubleshooting the Clamp motor. Check Sensor SQF-Q6 (PL 10.7) according to GP4.

You should have been re-directed to this RAP from another Status indicator RAP. The sensor Q6 is working correctly
Y N
Procedure
Go to SQF-015.
Check Motor SQF-M3 (PL 10.5) according to GP4.
Check Sensor SQF-Q7 (PL 10.5) according to GP4.
Are the clamps working correctly?
Is Sensor SQF-Q7 working correctly?
Y N
Y N
Check for mechanical bindings, broken, missing or loose parts.
Go to SQF-016.
Return to the previous RAP
Check Motor SQF-M1 (PL 10.7), SQF-SOL1 (PL 10.3), SQF-SOL 3 (PL 10.3) , SQF-SOL 2
(PL 10.4) and SQF-SOL4 (PL 10.4) according to GP4.
Are the Upper and Lower Transport belts working correctly?

Square Folder Stop Gate RAP Y N

This RAP is for troubelshooting the Square Folder Stop Gate. Check for mechanical bindings, broken, missing or loose parts.

You should have been re-directed to this RAP from another Status indicator RAP. Check that both Springs (PL 10.3) on the upper Transport belts are in the upper position.
Is the Square Folder Transport working correctly?
Procedure
Y N
Check Motor SQF-M2 (PL 10.7) according to GP4.
Clean the transport belts.
The Stop Gate is working correctly
Return to the previous RAP.
Y N
Check for mechanical bindings, broken, missing or loose parts.
Return to the previous RAP.

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 Procedure
SQF-SW1 Interlock circuit SQF-SW3 RAP
Uninstall Booklet Folder and Trimmer, run Booklet Maker in standalone mode
This RAP is for troubleshooting a not working Interlock Circuit related to SW1 in SQF.
Does the Booklet Maker start up properly when powered on
Initial Actions
Y N
• Ensure that all connectors to MD6DC PCB “D” are properly connected.
Go to Booklet Maker SW1 Interlock circuit (SW16) RAP
• Ensure that all connectors to LED PCB “B” (PL 10.2) are properly connected.
Power off, disconnect the Power Connection Cable between the BM, SQF and Trimmer.
• Ensure that all connectors connecting SW1 are properly connected. Measure resistance between pin 1 to pin 1, pin 2 to pin 2 and so on for both Power Con.
Cables
• Ensure the Power Connection Cable between the BM, SQF and TR
are properly connected and not damaged. Is there connectivity for all 12 pins
Y N
Replace/repair the Power Connection Cable(s) (PL 10.9).
Below measurements shall be performed inside Square Folder
Power off the machine, remove the mains power cord, Connected power cable and the
“cheat” plug to J31. Open all covers, measure resistance between J.30-3 and SW1-1
There is connectivity
Y N
Repair/replace harness
Keep the machine powered off and the mains power cord disconnected keep covers opened,
measure resistance between J.31-3 and SW1-2
There is connectivity
Y N
Repair/replace harness
Keep the machine powered off and the mains power cord disconnected
Keep covers opened, measure resistance between SW1-1 and SW1-2
There is connectivity
N Y
Replace SW1
Keep the machine powered off and the mains power cord disconnected close covers,
measure resistance between SW1-1 and SW1-2 (PL 11.0)
There is connectivity
N Y
Go to SW1 Software signal (SW2) RAP
Replace SQF-SW1 (PL 10.0)

continued on next page

See block schematic diagram on next page

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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SQF-SW1 Software signal SQF-SW2 RAP Procedure
This RAP is for troubleshooting SW2 Software signal in Square Folder In Square Folder
this fault results in software can not register that the top cover is closed/opened.
• Power off, remove the mains power cord. Disconnect D.P15, D.P13, D.P16 and B.P2
Fault code indicates that the Interlock switch SQF-SW2 (PL 10.0) in Square Folder is faulty.
• Close the top cover. Measure resistance between D.P13-15 and B.P2-4.
Relay REL-1 in BM will be activated and turn on the power supply 30V when There is connectivity
all covers (BM, SQF, TR) are closed.
Y N
Initial Actions Repair/replace harness
• Enter Service (GP1) mode and check the SQF voltmeter. Keep the machine powered off.
• Power ON and Power OFF the System (Ensure that the Top cover interlock, Keep the mains power cord, D.P15, D.P13, D.P16 and B.P2 disconnected, close the top cover.
and the External Interlock Device interlock is interlocked). Measure resistance between B.P-2 and B.P2-3.

• Ensure that all connectors to MD6DC PCB “D” are properly connected. There is 10kohm±10%

• Ensure that all connectors to LED PCB “B” (PL 10.2) are properly connected. Y N

• Ensure that all connectors connecting SW1 (PL 10.0) are properly connected. Repair/replace harness

• Ensure the Power Connection Cable between the BM, SQF and TR Keep the machine powered off.
are properly connected and not damaged. Keep the mains power cord, D.P15, D.P13, D.P16 and B.P2 disconnected, close the top cover.
Measure resistance between B.P-4 and SW1.3.
There is connectivity
Y N
Repair/replace harness
Keep the machine powered off.
Keep the mains power cord D.P15, D.P13, D.P16 and B.P2 disconnected, close the top cover.
Measure resistance between D.P15-2 and SW1.4.
There is connectivity
Y N
Repair/replace harness
Keep the machine powered off and
the mains power cord, D.P15, D.P13, D.P16 and B.P2 disconnected,
open the top cover, measure resistance between SW1.3 and SW1.4.
There is connectivity
Y N
Keep the machine powered off.
Keep the mains power cord, D.P15, D.P13, D.P16 and B.P2 disconnected.
Close the top cover, measure resistance between SW1.3 and SW1.4.
There is connectivity
Y N

Continued on next page

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 Replace SW1 (PL 11.0).
Keep the machine powered off
Keep the mains power cord, D.P15, D.P13, D.P16 and B.P2 disconnected,
Open the top cover, disconnect white wire from SW1.3.
Measure resistance between white wire and chassis.
There is a short circuit
Y N
Replace components in following order.
1. LED PCB “B” (PL 11.2).
2. MD6DC PCB “D” (PL 11.2).

Repair/replace harness

Replace SW1 (PL 11.0).

Continued on next page

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RS232 Program Loading Chassis 9-P D-sub RAP Square Folder does not square form a 4 sheet booklet RAP
This RAP is for troubleshooting the RS232 Program Loading Chassis 9-P D-sub
Initial Actions
Initial Actions Ensure that the Square Folder is set to Mode 1.
• Ensure that connectors P1 and P10 at PCB “D” (PL 11.2) to J47 are properly connected.
Procedure
• Check that the crimp sockets in D-sub are not damage.
• The Square Folder performs spine folding action on
Procedure booklets with approximately 6 sheets/booklet, up to 50 sheet/booklet.
• In [Auto] mode, the Booklet maker detects how may sheets there are in the booklet,
• Disconnect plug P1 and P10 from MD6DC PCB “D” (PL 11.2).
and automatically set the Square Folder to the correct mode.
• Check continuity for the white wire D.P1-1 and (J.47-7 and J.47-8)
• Check continuity for the white wire D.P1-2 and J.47-4 NOTE
• Check continuity for the white wire D.P10-1 and J.47-2
When the Square Folder is set to [Auto] and the booklet has less than approximately six sheets/booklet,
• Check continuity for the white wire D.P10-2 and J.47-3 the Square Folder will bypass the square forming action and transport the booklet to the belt stacker.
• Check continuity for the white wire D.P10-3 and J.47-5 To be able to square form a booklet with approximately 5 sheet/booklet or less,
the Square Folder must be set to [Mode 1].
• Check for Short circuit between wires (J.47-7 and J.47-8 are supposed to be shorted)
• Check for short circuit between all wires and chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
Replace MD6DC PCB “D” (PL 11.2).

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Square Folder, LED Lamp PCB “L”Faulty
This RAP is for troubleshooting the LED Lamp PCB “L”.

Initial Actions
• Enter Service Mode
• Check the LED Lamp (PL 10.0)
• Ensure that the connector is properly connected to the LED Lamp.
• Ensure that connector in the top cover J35/P35 is connected.
• Ensure connector J34/P34, D.P15 and D.P4 at PCB “D” (PL 10.2) is correctly connected.

Procedure
• Disconnect plug D.P15 from MD6DC PCB “A” (PL 10.2).
• Measure VDC between D.P4-4 and D.P4-5 (12 VDC and GND)
The voltage is 12 VDC ± 10%.
Y N
Replace MD6DC PCB “D”
• Power off, disconnect plug from LED Lamp PCB “L” (PL 10.0) and D.P4 from PCB “D”.
• Check continuity for the white wire at Plug L.P1 at LED Lamp PCB “L” to D.P15-1
• Check continuity for the red wire at plug L.P1 at LED Lamp PCB “L” to D.P4-4
• Check for short circuit between red/white wires and red/white wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug D.P15 and D.P4 to MD6DC PCB “D”.
• Enter Service Mode and activate LED Lamp.
• Measure VDC at the LED Lamp L.P1 connector between the red and white
The voltage is 12 VDC ± 10%.
Y N
• Replace/Repair Wire Harness.
• Replace LED Lamp PCB “L” (PL 10.0)
• Replace MD6DC PCB “D”
Replace LED Lamp PCB “L” (PL 10.0).

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No 12VDC RAP
This RAP is for troubleshooting a loss of 12VDC.

Initial Actions
Go to No 12VDC RAP in Trimmer section.
• Ensure that all connectors to MD6DC PCB “A” are properly connected.
Below measurements shall be performed inside Square Folder
• Ensure that all connectors to LED PCB “B” (PL 11.4) are properly connected.
Power off.
• Ensure that all connectors connecting SW1 (PL 11.0) are properly connected. Reconnect Power connection cable between Square Folder and Booklet Maker.
• Ensure the Power Connection Cable between the Booklet Maker, Square Folder and Disconnect D.P5 power on, measure VDC between connected D.P4-4 and D.P4-5
Trimmer are properly connected and not damaged.
The voltage is 12VDC±10%
Procedure
Y N
Disconnect the Power Connection Cable between the BM, SQF and TR, power on Booklet Maker in
Power off.
stand alone mode, remember to move the CAN temination to Booklet maker.
Disconnect D.P4-4 and D.P4-5 wait 120 seconds, power on the machine,
Does the UI in start up measure VDC between D.P4-4 and D.P4-5.
Y N The voltage is 12VDC±10%
Go to UI Blank RAP Y N
Power off, measure resistance between pin 1 to pin 1, Repair/replace harness between D.P4 to J30
pin 2 to pin 2 and so on for the Power Connection Cables
Disconnect L.P1, check for short circuit between red wire L.P1-1 to chassis.
Is there connectivity for all 12 pins for both cables
There is short circuit
Y N
Y N
Replace/repair the Power Connection Cable(s) (PL 11.9).
Replace MD6DC PCB “D”
Disconnect G.P2, check continuity between red wire from G.P2-2 to J12-10 and
Repair/replace
between black wire from G.P2-4 to J12-9.
Repair/replace harness between D.P5 to J31
There is continuity for both wires
Y N
Repair/replace harness
Reconnect the Power connection cable to the Trimmer and G.P2,
leave Square Folder disconnected.
Power on, inside Trimmer measure VDC between A.P4-4 to A.P4-5 (12V and GND).
The voltage is 12VDC±10%
Y N

Continued on next page

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No 12VDC RAP, continued

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Counter RAP, SQF
This RAP is for troubleshooting the electromechanical counter.

Initial Actions
• Enter Service Mode. Check the counter.
• Ensure that the connector is properly connected to the Counter.
• Ensure that connector D.P2 at PCB “D” is correctly connected.

Procedure
• Disconnect plug D.P2 from MD6DC PCB “D”.
• Measure VDC between J.2-7 and D.P11-2 (GND)
The voltage is 30 VDC ± 10%.
Y N
Replace MD6DC PCB “D”.
• Disconnect plug from counter.
• Check continuity for the orange wire at plug Counter to D.P2-7
• Check continuity for the violet wire at plug Counter to D.P2-14
• Check for short circuit between orange/violet wires and
between orange/violet wires to chassi/GND.
There is continuity for all wires and no short circuit
Y N
Repair/replace harness
• Connect plug D.P2 to MD6DC PCB “D”.
• Measure VDC at the counter connector between the orange and D.P10-2 (GND)
The voltage is 30 VDC ± 10%.
Y N
• Repair/replace harness.
• Replace MD6DC PCB “D”
• Replace Counter (PL 10.8).
• Replace MD6DC PCB “D” .

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Trimmer (TR)
Procedure
TR-001 Transport knife Motor TR-M1 pulse timeout TR-Q4 Enter Service Mode (GP1) and select Transport motor (TR-M1) in (GP4) check motors.
Fault code indicates that the Transport motor TR-M1 does not receive any displacement pulses. Does the encoder disc run properly.

Initial Actions Y N
• Go to Trimmer Transport RAP.
• Ensure that plug A.P14 on MD6DC PCB “A” in the Trimmer is connected.
• Ensure that plug A.P3 on MD6DC PCB “A in the Trimmer is connected. • Replace motor TR-M1.
• Ensure that the Transport belt sensor TR-Q4 (PL 11.4) is installed correctly.
• Ensure encoder is not loose and mounted correctly on shaft and • Disconnect plug A.P14 from MD6DC PCB “A”.
does interfere with sensor TR-Q4.
• Measure between J.14-1 and J.14-13 (5V and GND)
• Measure between J.14-14 and J.14-13 (Signal and GND)
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “A” .
• Disconnect plug from sensor TR-Q4.
• Check continuity for the red wire at plug Q4 to A.P14-1
• Check continuity for the white wire at plug Q4 to A.P14-14
• Check continuity for the black wire at plug Q4 to A.P14-13
• Check wire for short circuit between red/white/black wires
• Check for short circuit between red/white/black and chassis/GND
There is continuity for all wires and no short circuit
Y N
Repair/replace harness.
• Connect plug A.P14 to MD6DC PCB “A”.
• Measure between the red wire Q4 and the black wire Q4 (5V and GND).
• Measure between the white wire Q4 and the black wire Q4 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Repair/replace harness.
• Replace sensor TR-Q4.
• Replace MD6DC PCB “A”.

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TR-002 Transport Knife Motor TR-M1 timeout TR-Q5
Fault code TR-002 indicates that either the Transport / Knife motor (M1) or
the Trim Knife motor (M2) had a cycle timeout.

Initial Actions
• Disconnect the motor plug M1 to Transport / Knife motor (M1).
Ensure that the TR-Q5 (PL 11.4) is installed correctly.
• Enter Service Mode (GP1) and
Procedure start Transport motor (M1) in (GP4) check motors.

• Enter Service Mode (GP1) • Measure VDC between the orange wire M1 and the violet wire M1.

• Select Trimmer knife home position sensor (Q5) in (GP4) check sensors. The voltage is 22 VDC ± 10%.

The Trimmer knife home position sensor (Q5) indicates : Y N

1 when the sensor is blocked, and 0 when the sensor is unblocked. • Disconnect plug A.P3 from MD6DC PCB “A”.
Y N • Measure VDC between J.3-2 and J.3-3
• Disconnect plug A.P13 from MD6DCPCB “A”. The voltage is 22 VDC ±10%.
• Measure between J.13-13 and.13-25 (5V and GND). Y N
The voltage is 5 VDC ± 10%. Replace MD6DC PCB “A”.
Y N
Replace MD6DC PCB “A”. Repair/replace harness.

• Disconnect plug from sensor Q5.

• Disconnect the motor plug M2 to Trim Knife motor TR-M2.
• Check continuity for the white wire Q5 to A.P13-24.
• Enter Service Mode (GP1) and
• Check for short circuit between white wire to chassi/GND. start Trim Knife motor (M2) in (GP4) check motors.
Measure VDC between the orange wire M2 and the violet wire M2.
There is continuity and no short circuit.
The voltage is is 28 VDC ± 10%.
Y N
Y N
Repair/replace harness.
• Disconnect plug A.P3 from MD6DC PCB “A”.
• Connect plug A.P13 to MD6DC PCB “A”.
• Measure VDC between J.3-6 and J.3-7
• Measure between the red wire Q5 andthe black wire Q5 (5V and GND).
The voltage is 28 VDC ± 10%.
The voltage is 5 VDC ± 10%.
Y N
Y N
Replace MD6DC PCB “A”.
Repair/replace harness.
Repair/replace harness.
• Replace sensor TR-Q5 (PL 11.4).
• Ensure that nothing interferes with the mechanical movement.
• Replace MD6DC PCB “A”.
• Lubricate where needed.
• Enter Service Mode
• Select Transport motor (M1) and Trim Knife motor (M2) and check motors.
• Ensure that nothing interferes with the mechanical movement.
Both motors energizes.
• Lubricate where needed.
Y N Continued on next page

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TR-002 Transport Knife Motor TR-M1 timeout TR-Q5, continued

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TR-003 Transport Knife Motor TR-M1 short circuit TR-004 Transport Knife Motor TR-M1 open circuit
Fault code indicates that the Transport motor TR-M1 has a short circuit. Fault code indicates that the Transport motor TR-M1 has an open circuit.

Procedure Procedure
• Disconnect the motor plug M1. • Disconnect the motor plug M1.
• Enter Service Mode (GP1) and run M1 (GP4). • Enter Service (GP1) mode and start Transport motor (M1) in (GP4) check motors.
• Measure VDC between the orange wire M1 and the violet wire M1.
Fault code TR-004 (Open circuit) is displayed.
Y N The voltage is 22 VDC ± 10%.
• Disconnect plug A.P3 from MD6DC PCB “A”. Y N
• Check wires for a short circuit across A.P3-3 to A.P3-2. • Disconnect plug A.P3 from MD6DC PCB “A”.
• Check for short circuit between wires to chassis. • Measure VDC between J.3-2 and J.3-3
Is there a short circuit. The voltage is 22 VDC ± 10%.
Y N Y N
Replace MD6DC PCB “A”. Replace MD6DC PCB “A”.
Repair/replace harness. Repair/replace harness.
Replace motor TR-M1. Replace motor TR-M1.

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TR-005 Trim Knife Motor TR-M2 short circuit TR-006 Trim Knife Motor TR-M2 open circuit
Fault code indicates that the Trim knife motor TR-M2 has a short circuit. Fault code indicates that the Trim knife motor TR-M2 has an open circuit.

Procedure Procedure
• Disconnect the motor plug M2. • Disconnect the motor plug M2.
• Enter Service Mode (GP1) and run M2 (GP4). • Enter Service mode (GP1) and start Trim knife motor (M2) in (GP4) check motors.
Fault code TR-006 (Open circuit) is displayed. • Measure VDC between the orange wire M2 and the violet wire M2.
Y N
The voltage is 28 VDC ± 10%.
• Disconnect plug A.P3 from MD6DC PCB “A”.
Y N
• Check for short circuit acrossA.P3-6 and A.P3-7.
• Disconnect plug A.P3 from MD6DC PCB “A”.
• Check for short circuit between wires to chassis.
• Measure VDC between J.3-6 and J.3-7
Is there a short circuit
The voltage is 28 VDC ± 10%.
Y N
Y N
Replace MD6DC PCB “A”.
Replace MD6DC PCB “A”.
Replace/Repair Wire Harness.
Replace/Repair Wire Harness.
Replace motor TR-M2 .
Replace motor TR-M2 .

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TR-007 Trim Knife Motor TR-M2 Cycle timeout Q5
Trim Knife motor TR-M2 had a Cycle timeout.
(With thin books only M2 is active. Thick books both M1 + M2 are active.)
Possible causes: Mechanical binding

Initial Actions
• Ensure that sensor TR-Q5 is installed correctly.

Procedures
• Enter Service Mode (GP1)
• Select Trimmer knife home position sensor (Q5) in check sensors.
The Trimmer knife home position sensor (Q5) indicates :
1 when the sensor is blocked, and 0 when the sensor is unblocked.
Y N
• Disconnect plug A.P13 from MD6DC PCB “A”.
• Measure between J.13-13 and J.13-25 (5V and GND)
• Measure between J.13-24 and J.13-25 (Signal and GND)
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “A”.
• Disconnect plug from sensor Q5.
• Check continuity for the red wire at plug Q5 to A.P13-13
• Check continuity for the white wire at plug Q5 to A.P13-24
• Check continuity for the black wire at plug Q5 to A.P13-25
• Check for short circuit between red/white/black wires.
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug A.P13 to MD6DC PCB “A”.
• Measure between the red wire Q5 and the black wire Q5 (5V and GND).
• Measure between the white wire Q5 and the black wire Q5 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Continued on next page

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TR-007 Trim Knife Motor TR-M2 Cycle timeout Q5, continued

Replace/Repair Wire Harness.
• Replace sensor Q5.
• Replace MD6DC PCB “A”.
Enter Service Mode and select Trim Knife motor TR-M2 in check motor.
Motor energizes.
Y N
• Disconnect M2 at Trim Knife motor (M2).
• Enter Service Mode (GP 1) and start Trim Knife motor (M2) in (GP4) check motors.
• Measure VDC between M2 pin 1 and 2.
The voltage is 28 VDC ± 10%.
Y N
• Disconnect plug A.P3 from MD6DC PCB “A”.
• Measure VDC between J.3-6 and J.3-7.
The voltage is 28 VDC ± 10%.
Y N
Replace MD6DC PCB “A”.
Replace/Repair Wire Harness.
• Ensure that nothing interferes with the mechanical movement.
• Ensure chain is tensioned correctly.
• Lubricate where needed.

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TR-008 Stop Gate Motor TR-M3 cycle timeout TR-Q7
Fault code indicates that the Stop gate motor TR-M3 had a Cycle timeout.

Initial Actions Replace/Repair Wire Harness.

• Replace sensor TR-Q7.
• Check Stop Gate for mechnical bindig
• Replace MD6DC PCB “A”.
• Ensure that plug A.P13 and A.P16 on MD6DC PCB “A”
• Go to Trimmer Transport RAP.
in the Trimmer are connected.
• Replace motor TR-M3.
• Ensure that jack/plug J20/P20 in the Trimmer is connected.
• Enter Service Mode (GP1) and check Stop gate motor (M3) in (GP4) check motors.
• Ensure that Paper stop gate home position sensor TR-Q7 is installed correctly.

Procedure
• Enter Service Mode (GP1)
Select Paper stop gate home position sensor (Q7) in (GP4) 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
Disconnect plug A.P13 and P16 from PCB “A”.
Measure between J.16-6 and J.13-9 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “A”.
• Disconnect plug Q7
• Check continuity for the the red wire at plug Q7 to A.P16-6
• Check continuity for the white wire at plug Q7 to A.P13-8
• Check continuity for the black wire at plug Q7 to A.P13-9
• Check for short circuit between red/white/black wires.
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug A.P13 and A.P16 to MD6DC PCB “A”.
• Measure between the red wire Q7 and the black wire Q7 (5V and GND).
• Measure between the white wire Q7 and the black wire Q7 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N

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TR-009 Stop Gate Motor TR-M3 short circuit TR-010 Stop Gate Motor TR-M3 open circuit
Fault code indicates that the Stop Gate Motor TR-M3 has a short circuit. Fault code indicates that the Stop gate motorTR-M3 has an open circuit.

Procedure Procedure
• Disconnect the motor plug M3. • Disconnect the motor plug M3.

• Enter Service Mode (GP1) and run M3 (GP4). • Enter Service mode (GP1) and start Stop gate motor (M3) in (GP4) check motors.
• Measure VDC between the orange wire M3 and the violet wire M3
Fault code TR-010 (Open circuit) is displayed The voltage is 28 VDC ± 10%.
Y N Y N
• Disconnect plug A.P2 from MD6DC PCB “A”. • Disconnect plug A.P2 from MD6DC PCB “A”.
• Check wires for Short circuit across A.P2-11 (violet) and A.P2-4 (orange). • Measure VDC between J.2-4 and J.2-11
• Check short circuit between wires to chassis. The voltage is 28 VDC ± 10%.
Is there a short circuit Y N
Y N Replace MD6DC PCB “A”.
Replace MD6DC PCB “A”. Replace/Repair Wire Harness
Replace/Repair Wire Harness. Replace motor TR-M3.
Replace motor TR-M3.

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TR-011 Length Adjustment Motor TR-M4 pulse timeout Procedure
Fault code indicates that the Length Adjustment Motor TR-M4 had a pulse timeout. Enter Service Mode (GP1) and select sensor Q12A and Q12B in check sensors.
Initial Actions Q12A, Q12B is toggling between 0 and 1 when rotating the M4 motor shaft.

• Ensure that plugA.P2 on MD6DC PCB “A” in the Trimmer is connected. Y N

• Enter Service Mode (GP1) • Disconnect P14 at MD6DC PCB “A”

• Run Length adjustment motor (M4) in (GP1) check motors. • Measure between J.14-2 and J14-3 (5V and GND)
• Measure between J14-7 and J14-3 (Signal and GND)
• Measure between J144 and J14-3 (Signal and GND)
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “A”.
• Disconnect Q12 sensor plug at motor M4
• Check continuity for the red wire at plug Q12 to A.P14-2
• Check continuity for the white wire at plug Q12 to A.P14-7
• Check continuity for the grey wire at plug Q12 to A.P14-4
• Check continuity for the black wire at plug Q12 to A.P14-3
• Check wire for short circuit between red/white/black/grey wires
• Check for short circuit between red/white/black/grey and chassis/GND

There is continuity for all wires and no short circuit

Y N
Replace/Repair Wire Harness.
• Connect plug A.P14 to MD6DC PCB “A”.
• Measure between the red wire Q12 and the black wire Q4 (5V and GND).
• Measure between the white wire Q12 and the black wire Q4 (Signal and GND)
• Measure between the grey wire Q12 and the black wire Q4 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace/Repair Wire Harness.
• Replace motor TR-M4 (PL 11.9).
• Replace MD6DC PCB “A”. .
Go to TR-012 Length Adjustment Motor (TR-M4) cycle timeout Q12 RAP

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TR-012 Length Adjustment Motor TR-M4 cycle timeout Procedure
Fault code indicates that the Length Adjustment Motor TR-M4 had a cycle • Enter Service Mode (GP1)
timeout. • Select Length Adjustment home position sensor (Q11) in (GP4) check sensors.
(M4 motor received pulses but did not reach home position)
The Length Adjustment home position sensor indicates :
Possible failure: 1 when the sensor is activated, and 0 when the sensor is deactivated.
• Mechanical bind / failure Y N
• Defect Lenght Adjustment Home Position Sensor TR-Q11 • Disconnect plug A.P13 and A.P16 from PCB “A”.
• Defect M4 motor • Measure between J.16-4 and J.13-3 (5V and GND).
Initial Actions The voltage is 5 VDC ± 10%.
Y N
• Ensure that PJ20 in the Trimmer is connected. Replace MD6DC PCB “A”.
• Enter Service Mode (GP1) and • Disconnect plug Q11
run Length adjustment motor (M4) in (GP4) check motors.
• Check continuity for the red wire at plug Q11 to A.P16-4
• Ensure that the Length adjustment home position sensor (TR-Q11)
is installed correctly (ADJ 10.21). • Check continuity for the white wire at plug Q11 to A.P13-2
• Check continuity for the black wire at plug Q11 to A.P13-3
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug A.P13 and A.P16 to MD6DC PCB “A”.
• Measure between the red wire Q11 and the black wire Q11 (5V and GND).
• Measure between the white wire Q11 and the black wire Q11 (Signal and GND).
The voltage is 5 VDC ± 10%.
Y N
Replace/Repair Wire Harness.
• Replace sensor TR-Q11 (PL 11.9).
• Replace MD6DC PCB “A”.
Enter Service mode and select length adjustment motor (M4) in check motors.
The motor energizes.
Y N
Replace motor TR-M4 (PL 11.9)
• Check allen screws on TR-M4 drive gears (PL 11.9)
• Lubricate where needed.

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TR-013 Length Adjustment Motor TR-M4 short circuit TR-014 Length Adjustment Motor TR-M4 open circuit
Fault code indicates that the Length adjustment motor TR-M4 has an open circuit.
Fault code indicates that the Length adjustment motor TR-M4 has a short circuit.

Procedure Procedure
• Disconnect the motor plug M4.
Disconnect the motor plug M4. Enter Service Mode (GP1) and run M4 (GP4).
• Enter Service mode and start Length adjustment motor (M4) in check motors.
Fault code TR-014 (Open circuit) is displayed? • Measure VDC between the orange wire M4 and the violet wire M4
Y N The voltage is 30 VDC ± 10%.
• Disconnect plug A.P2 from MD6DC PCB “A”. Y N
• Check wires for short circuit across leads the orange wire M4 to A.P2-9 (violet). Disconnect plug A.P2 from MD6DC PCB “A”.
Measure VDC between J.2-2 and J2-9
• Check wires for short circuit across leads the the violet wire M4 to A.P2-2 (orange).
• Check for short circuit between wires to chassis.
The voltage is 30 VDC ± 10%.
Y N
Is there a short circuit
Replace MD6DC PCB “A”.
Y N
Replace/Repair Wire Harness.
Replace MD6DC PCB “A”.
Replace motor TR-M4 (PL 11.9).
Replace/Repair Wire Harness.
Replace motor TR-M4 (PL 11.9).

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TR-015 Blower Motors Motor TR-M5/TR-M6 open circuit
Fault code indicates that the blowers (M5/M6) have an open circuit.

Procedure
Replace MD6DC PCB “A”. (PL 11.4)
• Disconnect the blowers.
Replace PWM To DC PCB “C” (PL 11.4).
• Enter Service mode (GP1) and start blowers (M5/M6) in (GP4) check motors.
• Check continuity for the orange wire at plug C.P2-1 to M5/M6
• Measure between the orange wire M5/M6 and the violet wire M5/M6 (24V and GND).
• Check continuity for the violet wire at plug C.P2-2 to M5/M6
The voltage is 24 VDC ± 10%.
• Check for short circuit between orange/violet wires
Y N and orange/violet wires to chassis/GND
• Disconnect plug A.P2 from MD6DC PCB “A”. There is continuity for all wires and no short circuit
• Disconnect plug C.P1 from PWM TO DC PCB “C”. Y N
• Check continuity for the orange wire at plug C.P.1-1 to A.P2-5 Replace/Repair Wire Harness.
• Check continuity for the violet wire at plug C.P1-2 to A.P2-12
• Check for short circuit between orange/violet wires Connect plug C.P2 and A.P2, start blowers M5/M6 in check motors.
and orange/violet wires to chassis/GND
Measure VDC between the orange wire M5/M6 and the violet wire M5/M6
There is continuity for all wires and no short circuit
The voltage is 24 VDC ± 10%.
Y N
Y N
• Replace/Repair Wire Harness.
• Replace PWM To DC PCB “C” (PL 11.4).
• Replace Diode
• Replace MD6DC PCB “A”. (PL 11.4)
• Connect plug A.P2 to MD6DC PCB “A” and C.P1 to PWM To DC PCB “C”.
• Replace/Repair Wire Harness.
• Disconnect C.P2, start blowers M5/M6 in check motors.
• Measure VDC between C.J2-1 and C.J2-2
Replace blowers TR-M5/TR-M6 (PL 11.2).
The voltage is 24 VDC ± 10%.
Replace blowers TR-M5/TR-M6 (PL 11.2).
Y N
• Connect plug A.P2 to MD6DC PCB “A”
• Disconnect C.P1 to PWM To DC PCB “C” and C.P2,
• Start blowers M5/M6 in check motors.
• Measure VDC between C.P1-1 and C.P1-2
The voltage is 24 VDC ± 10%.
Y N

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TR-016 Lift Motor TR-M8 cycle timeout
Fault code indicates that the Lift Motor TR-M8 had a Cycle timeout.
(The motor is not reaching home position.)
Replace/Repair Wire Harness.
Possible failure:
• Mechnical binding
• Connect plug D.P2 ADDON 8 INPUT PCB “D” leave plug Q15 disconnected.
• Defect Lift Motor home position sensor TR-Q15
• Measure between the red wire Q15 and the black wire Q15 (5V and GND).
• Defect TR-M8 Motor
• Measure between the white wire Q15 and the black wire Q15 (Signal and GND).
The voltage is 5 VDC ± 10%.
Initial Actions
Ensure that jack/plug A.P2, A.P8, D.P1, D.P3 and D.P2 is connected. Y N

• Enter Service Mode (GP1) and run Lift motor TR-M8 in (GP4) check motors. Replace/Repair Wire Harness.

• Ensure that the Lift Motor home position Sensor TR-Q15 is installed correctly • Replace sensor TR-Q15 (PL 11.6).
(REP 10.30 TR-M8 Lifter Motor & TR-Q15 Lift Motor Home Pos. Sensor). • Replace ADDON 8 INPUT PCB “D” (PL 11.4).
• Replace MD6DC PCB “A”.
Procedure
Enter Service mode and select Lift motor TR-M8 in check motors.
• Enter Service Mode (GP1)
The motor energizes.
• Select Lift Motor Home Position Sensor (Q15) in (GP4) check sensors.
Y N
The Lift Motor Sensor indicates :
Replace motor TR-M8 (PL 11.6)
1 when the sensor is activated, and 0 when the sensor is deactivated.
Check allen screw on the motor shaft.
Y N
• Disconnect plug D.P2 from PCB “D” and plug Q15.
• Measure between J.2-4 and J.2-6 (5V and GND).
The voltage is 5 VDC ± 10%.
Y N
• Replace ADDON 8 INPUT PCB “D” (PL 11.4).
• Replace/Repair wires between MD6DC PCB “A”
• Replace/Repair ADDON 8 INPUT PCB “D”
• Replace MD6DC PCB “A”
• Check continuity for the red wire at plug Q15 to D.P2-4
• Check continuity for the white wire at plug Q15 to D.P2-5
• Check continuity for the black wire at plug Q15 to D.P2-6
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N

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TR-017 Lift Motor TR-M8 short circuit TR-018 Lift Motor TR-M8 open circuit
Fault code indicates that the Lift Motor TR-M8 has a short circuit. Fault code indicates that the Lift Motor TR-M8 has an open circuit.

Procedure Procedure
• Disconnect the motor plug M8. • Disconnect the motor plug M8.
• Enter Service Mode (GP1) and run M8 (GP4). • Enter Service mode (GP1) and start (M8) in (GP4) check motors.
Fault code TR-017 (Open circuit) is displayed • Measure VDC between the orange wire M8 pin1 and the violet wire M8 pin2.
Y N
The voltage is 28 VDC ± 10%.
• Disconnect plug A.P2 from MD6DC PCB “A” and M8 motor plug.
Y N
• Check wires for Short circuit from orange wire M8 to A.P2-8 (violet)
• Disconnect plug A.P2 from MD6DC PCB “A”.
• Check wires for Short circuit from the violet wire at M8 to A.P2-1 (orange).
• Measure VDC between J.2-1 and J.2-8 (PWM 30V and GND).
• Check short circuit between wires to chassis.
The voltage is 28 VDC ± 10%.
Is there a short circuit
Y N
Y N
Replace MD6DC PCB “A”.
Replace MD6DC PCB “A”.
Replace/Repair Wire Harness.
Replace/Repair Wire Harness.
Replace motor TR-M8 (PL 11.6).
Replace motor TR-M8 (PL 11.6).

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TR-019 Infeed Sensor TR-Q13 faulty
Fault code indicates that the Infeed sensor TR-Q13 is faulty.

Initial Actions
• Ensure that Q13 is installed and connected correctly.
• Ensure that jack/plug J31/P31, A.P16, A.P13 is connected.

Procedure
Enter Service Mode (GP1) and select Infeed sensor (TR-Q2) in (GP4) check sensors.
The Control Sensor Infeed indicates: 1 activated, and 0 deactivated.
Y N
• Disconnect plugs A.P13 and A.P16 from MD6DC PCB “A”.
• Measure between J.16-5 and J.13-22 (5V and GND)
• Measure between J.13-21 and J.13-22 (Signal and GND)
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “A”. (PL 11.4)
• Disconnect plug from sensor Q2.
• Check continuity for the red wire at plug Q2 to A.P16-5
• Check continuity for the white wire at plug Q2 to A.P13-21
• Check continuity for the black wire at plug Q2 to A.P13-22
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
Is there continuity and no short circuit between cables
Y N
Replace/Repair Wire Harness.
Replace sensor TR-Q2 (PL 11.4).
Replace sensor TR-Q2.

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TR-020 Control Sensor Infeed TR-Q2 faulty
Fault code indicates that the Control infeed sensor (TR-Q2) is faulty.

Initial Actions
• Ensure that the Infeed shaft is in it lower position (PL 11.4).
• Ensure TR-Q2 (PL 11.4) is installed, connected correctly and is clean.
• Ensure A.P13 and A.P16 are properly connected.

Procedure
• Enter Service Mode (GP1)
• Select Infeed sensor (Q13) in (GP4) check sensors.
The Infeed Sensor indicates: 1 activated, and 0 deactivated.
Y N
• Disconnect plugs A.P13 and A.P16 from MD6DC PCB “A”.
• Measure between J.16-2 and J.13-19 (5V and GND)
• Measure between J.13-18 and J.13-19 (Signal and GND)
The voltage is 5 VDC ± 10%.
Y N
Replace MD6DC PCB “A”. (PL 11.4)

• Disconnect plug from sensor TR-Q13.

• Check continuity for the red wire at plug Q13 to A.P16-2
• Check continuity for the white wire at plug Q13 to A.P13-18
• Check continuity for the black wire at plug Q13 to A.P13-19
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
Replace sensor TR-Q13 (PL 11.5).
Replace sensor TR-Q13

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TR-021 Control Sensor Exit TR-Q3 faulty
Fault code indicates that the Control Sensor Exit Sensor TR-Q3 is faulty.

Initial Action
• Ensure the Exit mechanism is in the lower position (PL 11.7)
• Ensure TR-Q3 (PL 11.4) is installed and connected correctly and is clean.
• Ensure connector A.P8, D.P1, D.P2 and D.P3 are connected correctly.

Procedure
• Enter Service Mode (GP1)
• Select Control sensor exit (TR-Q3) in (GP4) check sensors.
The Control Sensor Exit indicates: 1 activated, and 0 deactivated.
Y N
• Disconnect plugs D.P2.
• Measure between D.P2-7 and D.P2-9 (5V and GND)
• Measure between D.P2-8 and D.P2-9 (Signal and GND)
The voltage is 5 VDC ± 10%.
Y N
• Replace ADDON 8 INPUT PCB “D” (PL 11.4).
• Replace/Repair wires between MD6DC PCB “A” and ADDON 8 INPUT PCB “D”
• Replace MD6DC PCB “A”.
• Disconnect plug from sensor Q3.
• Check continuity for the red wire at plug Q3 to D.P2-7
• Check continuity for the white wire at plug Q3 to D.P2-8
• Check continuity for the black wire at plug Q3 to D.P2-9
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
Replace sensor TR-Q3
Replace sensor TR-Q3

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TR-022 Exit Sensor TR-Q6 faulty TR-023 Trim Bin Full Sensor TR-Q8 faulty
Fault code indicates that the Exit sensor Trimmer TR-Q6 is faulty. The fault code indicates that the Trim bin full sensor TR-Q8 is faulty.

Initial Actions Initial Actions

• Ensure that the Exit sensor Trimmer TR-Q6 is installed correctly (REP 10.19). Ensure that the Trim bin full sensor TR-Q8 is installed correctly (REP 10.8).

• Ensure that A.P16 and J/P21 are properly installed Procedure

Procedure • Disconnect plugs A.P14 and A.P13 from MD6DC PCB “A”.

• Disconnect plugs A.P13 and A.P16 from MD6DC PCB “A”. • Measure between J.14-9 and J.13-12 (5V and GND)

• Measure between J.16-3 and J.13-6 (5V and GND) • Measure between J.13-11 and J.13-12 (Signal and GND)

• Measure between J.13-5 and J.13-6 (Signal and GND) The voltage is 5 VDC ± 10%.

The voltage is 5 VDC ± 10%. Y N

Y N Replace MD6DC PCB “A”

Replace MD6DC PCB “A”. • Disconnect plug from sensor Q8.

• Disconnect plug from sensor Q6. • Check continuity for the red wire at plug Q8 to A.P14-9

• Check continuity for the red wire at plug Q6 to A.P16-3 • Check continuity for the white wire at plug Q8 to A.P13-11

• Check continuity for the white wire at plug Q6 to A.P13-5 • Check continuity for the black wire at plug Q8 to A.P13-12

• Check continuity for the black wire at plug Q6 to A.P13-6 • Check for short circuit between red/white/black wires

• Check for short circuit between red/white/black wires • Check for short circuit between red/white/black wires to chassis/GND

• Check for short circuit between red/white/black wires to chassis/GND There is continuity for all wires and no short circuit

There is continuity for all wires and no short circuit Y N

Y N Replace/Repair Wire Harness.

Replace/Repair Wire Harness. Replace sensor TR-Q8 (PL 11.1).

Replace sensor TR-Q6 (PL 11.11).

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TR-024 Paper Path Sensor TR-Q14 Faulty TR-025 Lift Motor Sensor TR-Q15 Faulty
Fault code indicates that the Paper Path Sensor TR-Q14 is faulty. Fault code indicates that the Lift Motor Home position sensor TR-Q15 is faulty.

Initial Actions Initial Actions

• Ensure that Paper Path Sensor TR-Q14 (PL 11.11) is installed correctly (REP 10.19). • Ensure that sensor TR-Q15 (PL 11.6) is installed correctly
(REP 10.30 TR-M8 Lifter Motor & TR-Q15 Lift Motor Home Pos. Sensor).
• Ensure connector A.P8, D.P1, D.P2 and D.P3 are connected correctly.
• Ensure connector A.P8, D.P1, D.P2 and D.P3 are connected correctly.
Procedure
Procedure
• Disconnect plugs D.P2 from ADDON 8 INPUT PCB “D” (PL 11.4).
• Disconnect plugs D.P2 from ADDON 8 INPUT PCB “D” (PL 11.4).
• Measure between J.2-1 and J.2-3 (5V and GND)
• Measure between J.2-4 and J.2-6 (5V and GND)
• Measure between J.2-2 and J.2-3 (Signal and GND)
• Measure between J.2-5 and J.2-6 (Signal and GND)
The voltage is 5 VDC ± 10%.
The voltage is 5 VDC ± 10%.
Y N
Y N
• Replace ADDON 8 INPUT PCB “D” (PL 11.4).
• Replace ADDON 8 INPUT PCB “D” (PL 11.4).
• Replace/Repair wires between MD6DC PCB “A” and ADDON 8 INPUT PCB “D”
• Replace/Repair wires between MD6DC PCB “A” and ADDON 8 INPUT PCB “D”
• Replace MD6DC PCB “A”.
• Replace MD6DC PCB “A”.
• Disconnect plug from sensor Q14.
• Disconnect plug from sensor Q15.
• Check continuity for the red wire at plug Q14 to D.P2-1
• Check continuity for the red wire at plug Q15 to D.P2-4
• Check continuity for the white wire at plug Q14 to D.P2-2
• Check continuity for the white wire at plug Q15 to D.P2-5
• Check continuity for the black wire at plug Q14 to D.P2-3
• Check continuity for the black wire at plug Q15 to D.P2-6
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
There is continuity for all wires and no short circuit
Y N
Y N
Repair wire Harness.
Repair wire Harness.
Replace sensor TR-Q14 (PL 11.11).
Replace sensor TR-Q15 (PL 11.6).

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TR-150 30V Input low
This RAP is for troubleshooting a low 30VDC.
Replace / repair the Power Connection Cables (PL 10.7)
Initial Actions Below measurements shall all be performed inside the Trimmer
• Ensure connectors related to Q1 are properly connected.
• Ensure that all connectors to MD6DC PCB “A” are properly connected. • Reconnect Power Connection Cable between the BM, SQF and TR.

• Ensure that all connectors to LED PCB “B” are properly connected. • Disconnect A.P11 and A.P12, power on the machine

• Ensure that all connectors connecting SW1 are properly connected. • Measure VDC between A.P11-1 and A.P11-2.
There might be only a short period when the voltage is present so pay attention.
• Ensure the Power Connection Cable between the Booklet Maker and Trimmer Close all top covers.
are properly connected and not damaged.
The voltage is 29.0-31.0VDC
Procedure N Y
• Power off. • Power off, reconnect A.P11 and A.P12
• Disconnect the Power Connection Cable between the BM, SQF and TR, • Disconnect A.P2 and A.P3 wait 120 seconds then power on the machine
connect the Short link connector to Booklet Maker J12.
• Measure VDC between A.P11-1 and A.P11-2.
• Disconnect com. cables and move CAN termination to Booklet Maker, There might be only a short period when the voltage is present so pay attention.
wait 120 seconds then power on the machine. Close all top covers.
The system setup in UI may need to be changed.
The voltage is 29.0-31.0VDC
• Measure VDC between J.12-1 and J.12-2.
There might be only a short period when the voltage is present so pay attention. N Y
• Close all top covers. Locate short circuit related to A.P2 and A.P3 and repair/replace.
The voltage is 29 -31 VDC Success
Y N Y N
Go to No 30VDC from SCP PCB “D” in Booklet Maker service manual Replace MD6DC PCB “A”
• Power off. Exit
• Leave the Power Connection Cables between the Booklet Maker,Square Folder and Replace MD6DC PCB “A”
Trimmer disconnected
• Measure resistance between pin 1 to pin 1, pin 2 to pin 2 and so on for both cables. • Power off, disconnect A.P11, A.P12 and the two Power Connection Cables.
Is there connectivity for all 12 pins • Check continuity for the red wire between A.P11-1 to J25-1
Y N • Check continuity for the red wire between A.P12-1 to J25-7
• Check continuity for the black wire between A.P12-2 to J25-8
• Check continuity for the black wire between A.P11-2 to J25-2
• Check for short circuit between red/black wires and between red wires to chassis/GND

There is Continuity on all wires and no short circuit between

red/black wires and red wires to chassis.
Y N
Continued on next page

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TR-150, continued

Replace/repair harness
Below measurements shall be performed inside Square Folder

• Power off, reconnect everything from earlier steps, disconnect D.P11 and D.P12.
• Check continuity for the red wire between D.P11-1 to J13-1
• Check continuity for the red wire between D.P12-1 to J30-1
• Check continuity for the black wire between D.P12-2 to J30-2
• Check continuity for the black wire between D.P11-2 to J31-2
• Check continuity for the red wire between J31-7 to J30-7
• Check continuity for the black wire between J31-8 to J30-8
• Check for short circuit between red/black wires and between red wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/repair harness
• Power off,
• Re-connect D.P12 and D.P11, disconnect D.P2 and D.P3 wait 120 seconds
then power on the machine
• Measure VDC between D.P12-1 and D.P12-2.
There might be only a short period when the voltage is present so pay attention.
Close all top covers.
The voltage is 29.0-31.0VDC
N Y
Locate short circuit related to D.P2 and D.P3 and repair/replace.
Success
Y N
Replace MD6DC PCB “D” (PL 11.2)
Exit
Replace MD6DC PCB “D” (PL 11.2)
Success
Y N
Go to No 30VDC from SCP PCB “D” in Booklet Maker service manual
Exit Continued on next page

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TR-150, continued

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TR-151 30V Input high
This RAP is for troubleshooting a high 30VDC.

Initial Actions
• Ensure that all connectors to MD6DC PCB “A” in Trimmer and
MD6DC PCB “D” in Square Folder are properly connected.
• Ensure the Power Connection Cable between the BM, SQF and TR are
properly connected and not damaged.

Procedure
Go to BM-152 30VDC High at Lower MD6DC PCB “C” in Booklet Maker service manual.
Success
Y N
• Replace MD6DC “A” in Trimmer
• Replace MD6DC “D” in Square Folder
Exit

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TR-152 TR-SW1 Software signal TR-SW10 RAP
• This RAP is for troubleshooting SW1 Software signal,
this fault results in that software can not register if the top cover is closed or opened.

• Fault code indicates that the Interlock switch TR-SW1 in is faulty.

• Interlock switches TR-SW9, SQF-SW3 and BM-SW16 are serial connected.

• The Relay-1 in BM will be activated. Turn on the power supply 30V when
all covers in BM, SQF, TR are closed.

Initial Actions
• Enter the Service (GP1) mode and check the Trimmer voltmeter.
• Power ON and Power OFF the System (Ensure that the Top cover interlock,
and the External Interlock Device interlock is interlocked).
• Ensure that all connectors to MD6DC PCB “A” are properly connected.
• Ensure that all connectors to LED PCB “B” (PL 11.4) are properly connected.
• Ensure that all connectors connecting TR-SW1 (PL 11.2) are properly connected.
• Ensure the Power Connection Cable between the BM, SQF and TR
are properly connected and not damaged.

Procedure
• Power off the machine. Remove the mains power cord.
• Disconnect A.P13, A.P16 and B.P2
• Close the top cover, check continuity between A.P13-15 and B.P2-4.
There is connectivity
Y N
Repair/replace harness
• Keep the machine powered off
• Keep the mains power cord, A.P13, A.P16 and B.P2 disconnected,
• Close the top cover, measure resistance between B.P-2 and B.P2-3.
There is 10kohm±10%
Y N

Continued on next page

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TR-152 TR-SW1 Software signal TR-SW10 RAP, continued

Repair/replace harness
• Keep the machine powered off
• Keep the mains power cord, A.P13, A.P16 and B.P2 disconnected Replace components in following order.

• Close the top cover, measure resistance between B.P-4 and SW1-3. 1. LED PCB “B” (PL 11.4).

There is connectivity 2. MD6DC PCB “A”

Y N Repair/replace harness

Repair/replace harness Replace TR-SW1 (PL 11.2)

• Keep the machine powered off

• Keep the mains power cord, A.P13, A.P16 and B.P2 disconnected
• Close the top cover, measure resistance between A.P13-16 and SW1-4.
There is connectivity
Y N
Repair/replace harness
• Keep the machine powered off
• Keep the mains power cord, A.P13, A.P16 and B.P2 disconnected.
• Open the top cover, measure resistance between SW1-3 and SW1-4.
There is connectivity
Y N
• Keep the machine powered off
• Keep the mains power cord, A.P13, A.P16 and B.P2 disconnected
• Close the top cover, measure resistance between SW1-3 and SW1-4.
There is connectivity
Y N
Replace TR-SW1 (PL 11.2)
• Keep the machine powered off
• Keep the mains power cord, A.P13, A.P16 and B.P2 disconnected
• Open the top cover, disconnect white wire from SW1-3,
measure resistance between white wire and chassis.
There is a short circuit
Y N

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TR-153 Interlock Sensor Faulty TR-Q1
Fault code indicates that the Interlock sensor TR-Q1 is faulty or activated too long.
This sensor is not possible to “cheat”. See Trimmer Interlock system.

Initial Actions
• Ensure TR-Q1 (PL 11.2) is installed and connected correctly and is clean. (REP10.5).
• Ensure connector A.P8, D.P1, D.P2 and D.P3 are connected properly

Procedure
• Disconnect plug D.P2 from ADDON 8 INPUT PCB “D” (PL 11.4).
• Measure between J2-13 and J2-15 (5V and GND)
• Measure between J2-14 and J2-15 (Signal and GND)
The voltage is 5 VDC ± 10%.
Y N
• Replace ADDON 8 INPUT PCB “D” (PL 11.4).
• Replace/Repair wires between MD6DC PCB “A” and ADDON 8 INPUT PCB “D”
• Replace MD6DC PCB “A”.
• Disconnect plug from sensor Q1.
• Check continuity for the red wire at plug Q1 to D.P2-13
• Check continuity for the white wire at plug Q1 to D.P2-14
• Check continuity for the black wire at plug Q1 to D.P2-15
• Check for short circuit between red/white/black wires
• Check for short circuit between red/white/black wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
Replace sensor TR-Q1 (PL 11.2).

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TR-201 Infeed Sensor TR-Q13 not activated in time TR-202 Infeed Sensor TR-Q13 activated too long
Fault code indicates that during run Infeed sensor was not blocked within timeout. Fault code indicates that during run Infeed sensor was blocked exceeding timeout.

Initial Actions Initial Actions

• Ensure that the Infeed sensor TR-Q13 (PL 11.5) is installed correctly and is clean. • Ensure that the Infeed sensor TR-Q13 (PL 11.5) is installed correctly and is clean.

Procedure Procedure
• Ensure that nothing interferes with the paper path. • Ensure that nothing interferes with the paper path.
• Ensure that the Trimmer is correctly installed (see Installation). • Ensure that the Trimmer is correctly installed (see Installation).
• Go to Trimmer Transport RAP. • Go to Trimmer Transport RAP.
• Go to Folding Unit RAP. • Go to Trim Knife RAP.
• Go to Folding Unit RAP.

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TR-203 Paper Path Sensor TR-Q14 not activated in time TR-204 Paper Path Sensor TR-Q14 activated too long
During run Paper Path Sensor Trimmer TR-Q14 was not blocked within timeout. Fault code indicates that at “initialization” or during run,
the Paper Path sensor in Trimmer, TR-Q14, was blocked exceeding timeout.
Initial Actions
• Ensure that sensor TR-Q14 (PL 11.11) is installed correctly and is clean. Initial Actions
Procedure • Ensure that sensor TR-Q14 (PL 11.11) is installed correctly and is clean.

• Ensure that nothing interferes with the paper path. Procedure

• Go to Trimmer Transport RAP. • Ensure that nothing interferes with the paper path.
• Go to Trimmer Blower RAP. • Go to Trimmer Transport RAP.
• Go to Trim Knife RAP. • Go to Trimmer Blower RAP.
• Go to Trim Knife RAP.

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TR-205 Exit Sensor TR-Q6 not activated in time TR-206 Exit Sensor TR-Q6 activated too long
Fault code indicates that during run the Exit sensor Trimmer TR-Q6, Fault code indicates that at “initialization” or during run the Exit sensor Trimmer TR-Q6
was not blocked within timeout. was blocked exceeding timeout.

Initial Actions
Initial Actions
• Ensure that the sensor TR-Q6 (PL 11.11) is installed correctly and is clean.
• Ensure that sensor TR-Q6 (PL 11.11) is installed correctly and is clean.
Procedure
• Ensure that nothing interferes with the paper path. Procedure
• Go to Trimmer Transport RAP. • Ensure that nothing interferes with the paper path.
• Go to Trimmer Blower RAP. • Go to Trimmer Transport RAP.
• Go to Trim Knife RAP. • Go to Trimmer Blower RAP.
• Go to Trim Knife RAP.

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TR-501 Waste Bin Full TR-505 Close Trimmer Infeed and Exit Belts
This code will be displayed when the Waste Bin is full. This code will be displayed if the Infeed and the Exit Trimmer Belts are locked in their Upper
position.
Procedure
Initial Actions
• Empty Waste Bin and press Done on the UI.
• Open Top Cover
• Check that no Trim Strips are covering Trim Bin Full Sensor (Q8)
(REP 10.7 Trim Bin Full Sensor). • Check that both Trimmer Belt Assemblies are in their lower position
(REP 10.22, REP 10.23).

TR-502 Stacker Full Procedure

• Perform ADJ 10.23 and 10.24.
This Fault code indicates that the Belt Stacker is full.
• Go to TR-020 and TR-021
Procedure
• Empty Belt Stacker and press Done on the UI.
Note: This function can also be turned off under the Tools menu on the UI. RS232 Program Loading Chassis 9-P D-sub
This RAP is for troubleshooting the RS232 Program Loading Chassi 9-P D-sub

TR-503 Close Trimmer Infeed Belts Initial Actions

This code will be displayed if the Infeed Trimmer Belts are locked in their Upper position. • Ensure that connectors P1 and P10 at MD6DC PCB “A” are properly connected to J47.

Initial Actions • Check that the crimp sockets in D-sub are not damage.

• Open Top Cover Procedure

• Check that both Trimmer Belt Assemblies are in their lower position • Disconnect plug P1 and P10 from MD6DC PCB “A”.
(REP 10.22, REP 10.23).
• Check continuity for the white wire A.P1-1 and (J.47-7 and J.47-8)
Procedure • Check continuity for the white wire A.P1-2 and J.47-4
• Perform ADJ 10.23 and 10.24. • Check continuity for the white wire A.P10-1 and J.47-2
• Go to TR-020 and TR-021 • Check continuity for the white wire A.P10-2 and J.47-3
• Check continuity for the white wire A.P10-3 and J.47-5
TR-504 Close Trimmer Exit Belts • Check for Short circuit between wires (J.47-7 and J.47-8 are supposed to be shorted)
This code will be displayed if the Infeed Exit Trimmer Belts • Check for short circuit between all wires and chassis/GND
are locked in their Upper position.
Is there continuity and no short circuit between wires
Initial Actions Y N
• Open Top Cover Replace/Repair Wire Harness.
• Check that both Trimmer Belt Assemblies are in their lower position Replace MD6DC PCB “A”.
(REP 10.23, REP 10.24).

Procedure
• Perform ADJ 10.23 and 10.24.
• Go to TR-021 and TR-022

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Trim Knife RAP Trimmer Transport RAP
This RAP is for troubleshooting the Trimmer Knife. This RAP is for troubleshooting the Trimmer Transport.
You should have been re-directed to this RAP from another Status indicator RAP. You should have been re-directed to this RAP from another Status indicator RAP.

Procedure Procedure
Check Motor TR-M2 (PL 11.2) according to GP4. Check Sensor TR-Q13 (PL 11.5) according to GP4.
The Trimmer Knife is working correctly The sensor Q13 is working correctly
Y N Y N
Check for mechanical bindings, broken, missing or loose parts. Go to TR-019.
Return to the previous RAP. Check Sensor TR-Q6 (PL 11.11) according to GP4.
The sensor Q6 is working correctly
Y N
Trimmer Blower RAP Go to TR-022.
This RAP is for troubleshooting the Trimmer Blower.
Check Motor TR-M1 (PL 11.3) according to GP4.
You should have been re-directed to this RAP from another Status indicator RAP.
Are the Upper and Lower Transport belts working correctly?
Initial Actions Y N
• Check Blow Type (GP13). • Check for mechanical bindings, broken, missing or loose parts.

Procedure • Check adjustment of the Transport belt Sensor TR-Q4 (ADJ 10.13).

Check Motors TR-M5 and TR-M6 (PL 11.2) according to GP4. Check Motor TR-M3 (PL 11.4) according to GP4.

The blowers are working correctly The Stop Gate is working correctly

Y N Y N

• Check for mechanical bindings, broken, missing or loose parts. Check for mechanical bindings, broken, missing or loose parts.

• Go to TR-015 Check infeed and exit sensors TR-Q2 and TR-Q3 (PL 11.4) according to GP4.
Sensors are working correctly
Return to the previous RAP. Y N
Check for mechanical bindings, broken, missing or loose parts.
Check Lift motor M8 and TR-Q15 (PL 11.6) according to GP4.
The sensor and motor are working correctly
Y N
Check for mechanical bindings, broken, missing or loose parts.
Return to the previous RAP.

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No 12VDC RAP
This RAP is for troubleshooting a loss of 12VDC.

Initial Actions
• In system consisting only BM: Inside Square Folder
Ensure that interlock jumper (PL 7.0) is connected to J12 on rear panel of BM.
• Power off.
• In system consisting of BM and SQF only:
Ensure that interlock jumper (PL 7.0) is connected to J31 on rear panel of BM • Check continuity between J30-10 to J31-10

• Ensure that all connectors to LED PCB “B” are properly connected. • Check continuity between between J30-9 to J31-9.

• Ensure that all connectors connecting to interlock switches: • Check short circuit between J31-10 to chassis/GND
BM-SW1, SQF-TR1 and TR-SW1 are properly connected.
• Check short circuit between J30-10 to chassis/GND.
• Ensure that the Power Connection Cable between the Booklet Maker, Square Folder and
There is continuity for all wires and no short circuit
Trimmer are properly connected and not damaged.
Y N
Procedure
Go to No 12VDC RAP in Square Folder section.
• Disconnect the Power Connection Cable between the BM, SQF and TR
Repair/replace harness
• Power on Booklet Maker in standalone mode,
remember to move the CAN temination to Booklet maker. Below measurements shall be performed inside Trimmer

Does the UI in start up • Power off

Y N • Disconnect A.P4 and the power connection cable between TR and BM

Go to UI Blank RAP • Check continuity between A.P4-4 to J25-10 and

between A.P4-5 to J25-9.
• Power off
• Check for short circuit between J25-10 and chassis/GND and
• Measure resistance between pin 1 to pin 1, pin 2 to pin 2 and so on between J25-9 and J25-10.
for the Power Connection Cables
There is continuity for all wires and no short circuit
Is there connectivity for all 12 pins for both cables
Y N
Y N
Repair/replace harness between
Replace/repair the Power Connection Cable(s) (PL 11.9).
• Disconnect A.P5
• Disconnect G.P2
• Check for short circuit between A.P5-4 to chassis/GND.
• Check continuity between red wire from G.P2-2 to J12-10
and between black wire from G.P2-4 to J12-9. There is no short circuit

There is continuity for both wires Y N

Y N Repair/replace harness between

Repair/replace harness Replace MD6DC PCB “A”.

• Reconnect the Power connection cable to the Trimmer and G.P2,

leave Square Folder disconnected.
• Power on, inside Trimmer measure VDC between A.P4-4 to A.P4-5 (12V and GND).
The voltage is 12VDC±10%
Continued on next page
N Y

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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Counter RAP, Trimmer
This RAP is for troubleshooting the chassis counter .

Initial Actions
• Enter Service Mode
• Check the COUNTER
• Ensure that the connector is properly connected to the counter.
• Ensure that connector A.P2 at PCB “A” is correctly connected.

Procedure
• Disconnect plug A.P2 from MD6DC PCB “A”.
• Measure VDC between J.2-7 and A.P11-2
The voltage is 30 VDC ± 10%.
Y N
Replace MD6DC PCB “A”.
• Disconnect plug from counter.
• Check continuity for the orange wire at plug Counter to A.P2-7
• Check continuity for the violet wire at plug Counter to A.P2-14
• Check for short circuit between orange/violet wires and orange/violet wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug A.P2 to MD6DC PCB “A”.
• Measure VDC at the counter connector between the orange and A.P11-2 (GND).
The voltage is 30 VDC ± 10%.
Y N
• Replace/Repair Wire Harness.
• Replace MD6DC PCB “A”.
• Replace Counter.
• Replace MD6DC PCB “A”.

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TR-SW1 Interlock circuit (TR-SW9,TR-SW10) RAP
This RAP is for troubleshooting a not working Interlock Circuit related to SW1.
Repair/replace harness
Initial Actions • Keep the machine powered off and the mains power cord disconnected
• Ensure that all connectors to MD6DC PCB “A” are properly connected. • Keep covers opened,
• Ensure that all connectors to LED PCB “B” (PL 11.4) are properly connected. • Measure resistance between SW1-1 and SW1-2
• Ensure that all connectors connecting TR-SW1 (PL 11.2) are properly connected. There is continuity
• Ensure the Power Connection Cable between the N Y
Procedure Replace SW1

Uninstall Booklet Folder and Trimmer, run Booklet Maker in standalone mode • Keep the machine powered off and the mains power cord disconnected

Does the Booklet Maker start up properly when powered on • Close covers.

Y N • Measure resistance between SW1-1 and SW1-2

Go to Booklet Maker SW1 Interlock circuit (SW16) RAP There is continuity

• Power off, disconnect the Power Connection Cable between the BM, SQF and Trimmer. N Y

• Measure resistance between pin 1 to pin 1, pin 2 to pin 2 and so on Go to SW1 Software signal (SW10) RAP.
for the Power Con. Cable Replace SW1 (PL 11.2)
Is there continuity for all 12 pins
Y N
Replace/repair the Power Connection Cable.

Below measurements shall all be performed inside the Trimmer

• Power off the machine
• Remove the mains power cord, open all covers
• Measure resistance between J25-3 and SW1-2
There is continuity
Y N
Repair/replace harness
• Keep the machine powered off and the mains power cord disconnected
• Keep covers opened
• Measure resistance between J25-4 and SW1-1
There is continuity
Y N

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Trimmer, LED Lamp Faulty RAP
This RAP is for troubleshooting the LED Lamp PCB “L” (PL 11.2).

Initial Actions
• Enter Service Mode
• Check the LED Lamp
• Ensure that the connector is properly connected to the LED Lamp.
• Ensure that connector in the top cover J35/P35 is connected.
• Ensure connector A.P15 and A.P5 at PCB “A” is correctly connected.

Procedure
• Disconnect plug A.P15 and A.P5 from MD6DC PCB “A”.
• Measure VDC between A.P4-4 and A.P4-5 (12 VDC and GND)
The voltage is 12 VDC ± 10%.
Y N
Replace MD6DC PCB “A”
• Power off, disconnect plug from LED Lamp PCB “L” (PL 11.2) and A.P4 from PCB “A”.
• Check continuity for the white wire at Plug L.P1 at LED Lamp PCB “L” to A.P15-1
• Check continuity for the red wire at plug L.P1 at LED Lamp PCB “L” to A.P4-4
• Check for short circuit between red/white wires and red/white wires to chassis/GND
There is continuity for all wires and no short circuit
Y N
Replace/Repair Wire Harness.
• Connect plug A.P15 and A.P4 to MD6DC PCB “A”.
• Enter Service Mode and activate LED Lamp.
• Measure VDC at the LED Lamp L.P1 connector between the red and white
The voltage is 12 VDC ± 10%.
Y N
• Replace/Repair Wire Harness.
• Replace LED Lamp PCB “L” (PL 11.2)
• Replace MD6DC PCB “A”
Replace LED Lamp PCB “L” (PL 11.2).

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AF602 FAULT CODE DESCRIPTIONS 1009 Q301 USDS Error Bín A
Goto RAP 003 Ultrasonic DSD
Entry RAP 1010 Q302 USDS Error Bín B
Goto RAP 003 Ultrasonic DSD
This RAP determines the correct starting point to analyse all issues within the system.
Always start with this RAP before you proceed to an actual RAP. 1011 Q102 USDSD Error Bin A
Goto RAP 002 Ultrasonic DSD
Initial Actions
1012 Q202 USDSD Error Bin B
Run system to verify reported fault. Goto RAP 002 Ultrasonic DSD
Enter service mode
Run diagnostics for the AF602. 1013 No XCAN Communication
Goto RAP 005 No XCAN Communication
Procedure 1014 Stepper Motor M101 PCB (K) No Communication
WARNING! Goto RAP 037 Stepper Motor Driver M101 PCB ”K”
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before 1015 Stepper Motor M201 PCB (O) No Communication
disconnecting, removing or replacing any electrical components or measuring Goto RAP 038 Stepper Motor Driver M201 PCB ”O”
resistance inside the machine. 1016 Stepper Motor M301 PCB (G) No Communication
Goto RAP 039 Stepper Motor Driver M301 PCB ”G”
A fault code is displayed on the UI 1017 Bin A CPU PCB (H) No Communication
Y N Goto RAP 026 CPU PCB ”A”
Run the job that caused the problem 1018 Bin B CPU PCB (L) No Communication
Perform the RAP for the fault code displayed. Goto RAP 028 CPU PCB ”L”
A fault code is displayed on the UI 1019 Stepper Motor M101 PCB (K) 48 Voltage Very Low
Y N Goto RAP 020 24V/48V very low entry RAP
Run several or all jobs that customer have and check reliability 1020 Stepper Motor M201 PCB (O) 48 Voltage Very Low
Perform the RAP for the fault code displayed. Goto RAP 020 24V/48V very low entry RAP
1021 Stepper Motor M301 PCB (G) 48 Voltage Very Low
Goto RAP 020 24V/48V very low entry RAP
Fault Codes 1022 Stepper Motor M101 PCB (K) 48 Voltage Low
Goto RAP 020 24V/48V very low entry RAP
1023 Stepper Motor M201 PCB (O) 48 Voltage Low
1001 Fan101 Bin A Pulse Timeout Goto RAP 020 24V/48V very low entry RAP
Goto RAP 011 Fan x pulse time out 1024 Stepper Motor M301 PCB (G) 48 Voltage Low
1002 Fan102 Bin A Pulse Timeout Goto RAP 020 24V/48V very low entry RAP
Goto RAP 011 Fan x pulse time out 1025 Bin A CPU PCB (H) 24 Voltage Very Low
1003 Fan103 Bin A Pulse Timeout Goto RAP 022 BIN A 24V very low
Goto RAP 011 Fan x pulse time out 1026 Bin B CPU PCB (L) 24 Voltage Very Low
1004 Fan104 Bin A Pulse Timeout Goto RAP 022 BIN B 24V very low
Goto RAP 011 Fan x pulse time out 1027 Bin A CPU PCB (H) 24 Voltage Low
1005 Fan201 Bin B Pulse Timeout Goto RAP 018 12/24/48V low or high
Goto RAP 011 Fan x pulse time out 1028 Bin B CPU PCB (L) 24 Voltage Low
1006 Fan202 Bin B Pulse Timeout Goto RAP 018 12/24/48V low or high
Goto RAP 011 Fan x pulse time out 1029 Stepper Motor M101 PCB (K) 48 Voltage Very High
1007 Fan203 Bin B Pulse Timeout Goto RAP 018 12/24/48V low or high
Goto RAP 011 Fan x pulse time out 1030 Stepper Motor M201 PCB (O) 48 Voltage Very High
1008 Fan204 Bin B Pulse Timeout Goto RAP 018 12/24/48V low or high
Goto RAP 011 Fan x pulse time out

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1031 Stepper Motor M301 PCB (G) 48 Voltage Very High 1051 Q104 Other Postion Sensor M101 Not Deactivated in Time
Goto RAP 018 12/24/48V low or high Goto RAP 009 M101/M201 Bin elevator upper home position sensor not activated
1032 Stepper Motor M101 PCB (K) 48 Voltage High in time/activated too long
Goto RAP 018 12/24/48V low or high 1052 Q204 Other Postion Sensor M201 Not Activated in Time
1033 Stepper Motor M201 PCB (O) 48 Voltage High Goto RAP 009 M101/M201 Bin elevator upper home position sensor not activated
Goto RAP 018 12/24/48V low or high in time/activated too long
1034 Stepper Motor M301 PCB (G) 48 Voltage High 1053 Q204 Other Postion Sensor M201 Not Deactivated in Time
Goto RAP 018 12/24/48V low or high Goto RAP 009 M101/M201 Bin elevator upper home position sensor not activated
in time/activated too long
1035 Bin A CPU PCB (H) 24 Voltage Very High
Goto RAP 018 12/24/48V low or high 1054 Interlock Mismatch, No Interlock with Power
Goto RAP 032 Interlock mismatch
1036 Bin B CPU PCB (L) 24 Voltage Very High
Goto RAP 018 12/24/48V low or high 1055 Bin A Didn’t Open
Goto RAP 015 Bin A/B opening
1037 Bin A CPU PCB (H) 24 Voltage High
Goto RAP 018 12/24/48V low or high 1056 Bin B Didn’t Open
Goto RAP 015 Bin A/B opening
1038 Bin B CPU PCB (L) 24 Voltage High
Goto RAP 018 12/24/48V low or high 1057 Software Versions Machine Mismatch
Check Software version in AF602, (BM500 5.1.7)
1039 Stepper Motor M101 PCB (K) 12 Voltage Low
Goto RAP 018 12/24/48V low or high 1058 Software Versions System Mismatch CST500
Check Software version in AF602, (BM500 5.1.7)
1040 Stepper Motor M201 PCB (O) 12 Voltage Low
Goto RAP 018 12/24/48V low or high 1059 Software Versions System Mismatch BM500
Check Software version in AF602, (BM500 5.1.7)
1041 Stepper Motor M301 PCB (G) 12 Voltage Low
Goto RAP 018 12/24/48V low or high 1060 Software Versions System Mismatch FTR500
Check Software version in AF602, (BM500 5.1.7)
1042 Bin A CPU PCB (H) 12 Voltage Low
Goto RAP 018 12/24/48V low or high 1061 Software Versions System Mismatch SQF500
Check Software version in AF602, (BM500 5.1.7)
1043 Bin B CPU PCB (L) 12 Voltage Low
Goto RAP 018 12/24/48V low or high
1044 App CPU (A) 12 Voltage Low Fault Codes Only Presented at Performed Diagnostics
Goto RAP 018 12/24/48V low or high
1045 App CPU EEPROM Error 1062 Q103 Home and Q104 Other Position Sensor M101 Conflict
Goto RAP 007 EEPROM Goto RAP 008 and 009
1046 Q103 Home Postion Sensor M101 Not Activated in Time 1063 Q203 Home and Q204 Other Position Sensor M201 Conflict
Goto RAP 008 M101/M201 home position sensor not activated in time/activated
Goto RAP 008 and 009
too long
1047 Q103 Home Postion Sensor M101 Not Deactivated in Time 1064 Q105 Bin Empty Sensor Activated, Bin A Loaded
Check if paper is present in Bin. if not goto RAP 107/207
Goto RAP 008 M101/M201 home position sensor not activated in time/activated
too long 1065 Q205 Bin Empty Sensor Activated, Bin B Loaded
Check if paper is present in Bin. if not goto RAP 107/207
1048 Q203 Home Postion Sensor M201 Not Activated in Time
Goto RAP 008 M101/M201 home position sensor not activated in time/activated 1066 Q101 Optical DSD Sensor Bin A Open Circuit
too long Goto RAP 001
1049 Q203 Home Postion Sensor M201 Not Deactivated in Time 1067 Q201 Optical DSD Sensor Bin B Open Circuit
Goto RAP 008 M101/M201 home position sensor not activated in time/activated Goto RAP 001
too long 1068 Q101 Optical DSD Sensor Bin A Paper Present
1050 Q104 Other Postion Sensor M101 Not Activated in Time Check if paper is present at sensor. If not goto RAP 001
Goto RAP 009 M101/M201 Bin elevator upper home position sensor not activated 1069 Q201 Optical DSD Sensor Bin B Paper Present
in time/activated too long Check if paper is present at sensor. If not goto RAP 001

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1070 Q303 Exit Sensor, Output Paper Present
Check if paper is present at sensor. If not goto RAP 300
1073 Q102 US DSD Sensor, Paper Detect Bin A Paper Present
Check if paper is present at sensor. If not goto RAP 002
1074 Q202 US DSD Sensor, Paper Detect Bin B Paper Present
Check if paper is present at sensor. If not goto RAP 002
1075 Bin A Open
Goto RAP 025
1076 Bin B Open
Goto RAP 025
1077 Stepper Motor M101 PCB (K) Current Malfunction
Goto RAP 037
1078 Stepper Motor M201 PCB (O) Current Malfunction
Goto RAP 038
1079 Stepper Motor M301 PCB (G) Current Malfunction
Goto RAP 039

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AF602 RAPs
RAP 100/200 Misfeed Bin A/B
Misfeed is a paper flow error detection. Misfeed checks if a sheet is moved correctly from
paper pile to optical DSD sensor. Time is measured from the start of the drive roller (used
to feed and separate a sheet from the paper pile) until the optical DSD sensor can see the
leading paper edge. A Misfeed condition is generated if this measured time is too long.
Initial Actions
• Ensure that all connectors to the optical DSD sensor are properly connected
• Ensure that DSD sensor Q101/201 is clean
• Check that there are no obstructions in the paper path
• Ensure that DSD sensor Q101/201 is calibrated (BM500 Operators Manual, AF602
Sensor Calibration Section)

Procedure

WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
• Enter the Service Mode (GP 1)
• Check optical DSD sensor Q101/201 (GP 4)
DSD Sensor (Q101/201) works
Y N
Perform RAP 001 Optical DSD sensor
Check drive clutch and roller according to RAP 012.
Drive clutch and roller works
Y N
Perform RAP 012 Drive clutch and roller
Check M1 Drive Motor (REP 14.28)
M1 Drive motor works
Y N
Perform RAP 013 M301 Drive Motor
Check M2/M3 Elevator Motor according to (REP 14.13)
M2/M3 Elevator motor works
Y N
Perform RAP 014 M101/M201 Elevator Motor
If misfeed Perform RAP 107/207 Empty sensor. Else Exit

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RAP 101/201 Jam, Too Long, Bin A/B RAP 105/205 DSD Functionality Uncertain, Bin A/B
Jam is a paper flow error detection. Jam checks if a sheet is moved past the optical DSD DSD functionality uncertain is a warning that can be generated at calibration. DSD func-
sensor correctly. Time is measured from when the optical DSD sensor sees the leading tionality uncertain checks if the sheet thickness is within reading range for the optical DSD
paper edge until the optical DSD sensor sees the trailing paper edge. A Jam condition is sensor.
generated if this measured time is too long. Actions: See RAP 104/204
Actions: See 100/200 RAP

RAP 102/202 Too Long, Bin A/B RAP 106/206 Too Thick US DSD, Bin A/B
Too thick US DSD is a paper thickness error detection. Too thick US DSD checks if a sheet
Too Long is a paper length error detection. Too long checks if a sheet is too long when it
is too thick when it passes the ultrasonic DSD sensor Q102/202. When the ultrasonic DSD
passes the optical DSD sensor Q101/201. Time is measured from when the optical DSD
sensor sees the leading paper edge, thickness is measured. A Too Thick condition is gener-
sensor sees the leading paper edge until the optical DSD sensor sees the trailing paper
ated if the measured thickness on a sheet is too thick.
edge. A Too Long condition is generated if the measured time is too long, but not long
enough to generate a Jam. Initial Actions
Actions: See RAP 100/200 • Enter service mode (GP 1)
• Check sensor according to GP 4
• Ensure that sensor is clean
RAP 103/203 Too Short, Bin A/B • Ensure that all connectors at the sensor are properly connected
Too Short is a paper length error detection. Too Short checks if a sheet is too short when it • Ensure that all connectors at PCB CPU (H/L) are properly connected.
passes the optical DSD sensor Q101/201. Time is measured from the situation when the
optical DSD sensor sees the leading paper edge until the optical DSD sensor sees the trail- NOTE!
ing paper edge. A Too Short condition is generated if the measured time is too short. For measuring references see BSD (next page)

Actions: See RAP 100/200

Procedure
RAP 104/204 Too Thick, Bin A/B WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
Too Thick is a paper thickness error detection. Too Thick checks if a sheet is too thick when
disconnecting, removing or replacing any electrical components or measuring
it passes the optical DSD sensor Q101/201. When the optical DSD sensor sees the leading
resistance inside the machine.
paper edge, thickness is measured. A Too Thick condition is generated if the measured
thickness on a sheet is too thick compared to the calibration sheet. Swap the faulty USDS sensor with the one in the other bin.
Initial Actions Does the sensor work at new location
• Ensure that all connectors to the optical DSD sensor are properly connected Y N
• Ensure that DSD sensor is clean Perform RAP 002 Ultrasonic DSD (Double Sheet Detection)
• Check that there are no obstructions in the paper path Exit.
• Ensure that DSD sensor is calibrated (BM500 Operators Manual, AF602 Sensor Calibra-
tion Section)

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
Enter the Service Mode (GP 1)
Check optical DSD sensor Q101/201 according to GP 4
DSD Sensor Q101/201 works OK
Y N
Perform RAP 001 Optical DSD sensor BSD on next page
Exit

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RAP 107/207 Bin Empty, Bin A/B
Bin Empty is a paper present detection. Bin Empty checks if sheets are present in the
activated bin during process. A Bin Empty condition is generated if sensor Q105/205 cannot
see any paper.
Initial Actions
• Enter service mode
• Check sensor according to GP 4
• Ensure that sensor is clean
• Ensure that all connectors at the sensor are properly connected
• Ensure that all connectors at PCB CPU App 32 (L / H) are properly connected.
NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Swap the faulty sensor with the sensor in the other bin. After swapping the sensors check
the Empty sensor functionality.
Sensor works at the new location
Y N
Replace the sensor
At the faulty location, disconnect sensor wire both from PCB and sensor. Check all wires
(red, white, black) for short circuit and continuity.
There is continuity and no short circuit
Y N
Repair/replace harness
Swap PCB (that the faulty Empty sensor is connected to) with the PCB in the other bin.
After swapping the PCB, set the address DIP switches to the settings shown in the circuit
diagram.
Empty sensor works at new PCB location
Y N
Replace the PCB
Exit

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RAP 108/208 Too Thin, Bin A/B
Too Thin is a paper thickness error detection. Too Thin checks if a sheet is too thin when it
passes the optical DSD sensor Q101/201. When the optical DSD sensor sees the leading
paper edge, thickness is measured. A Too Thin condition is generated if the measured
thickness on a sheet is too thin compared to the calibration sheet.
Initial Actions
• Ensure that all connectors to the optical DSD sensor are properly connected
• Ensure that DSD sensor is clean
• Check that there are no obstructions in the paper path
• Ensure that DSD sensor is calibrated (BM500 Operators Manual, AF602 Sensor Calibra-
tion Section)

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
Enter the Service Mode (GP 1)
Check optical DSD sensor Q101/201 according to GP 4
DSD Sensor Q101/201 works OK
Y N
Perform RAP 001 Optical DSD sensor
Exit

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RAP 300 Exit Miss
Exit Miss is a paper flow error detection. Exit Miss checks if a sheet gets stuck between op-
tical DSD sensor Q101/201 and Exit sensor Q303. Time is measured from when the optical
DSD sensor sees the trailing paper edge until the Exit sensor sees the trailing paper edge.
An Exit Miss condition is generated if this measured time is too long.
Initial Actions
• Enter service mode according to GP 1
• Check sensors according to GP 4
• Ensure that Exit sensor is clean
• Ensure that the Exit sensor is properly connected
• Ensure that all connectors at PCB CPU “A” are properly connected.

NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Swap the faulty sensor with one Empty sensor. After swapping, check the sensor function-
ality.
Does the sensor work at new location
Y N
Replace the sensor
At the faulty location, disconnect sensor wire both from PCB and sensor. Check all wires
(red, white, black) for short circuit and continuity.
There is continuity and no short circuit
Y N
Repair/replace harness
Replace PCB “A”

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RAP 301 Exit Error RAP 302 No Feed Sequence
Exit Error is a paper flow error detection. Exit Error checks if a sheet has moved past the No Feed Sequence is a startup error detection. No Feed Sequence checks if a feeding
Exit sensor Q303 correctly. Time is measured from when the Exit sensor sees the leading sequence has been programmed. No Feed Sequence is generated if the machine is started
paper edge until the Exit sensor sees the trailing paper edge. An Exit Error is generated if without a programmed feeding sequence.
this measured time is too long.
Initial Actions This is caused by an operator error. Nothing else can cause this.
• Ensure that the Exit sensor is properly connected
• Ensure that the Exit sensor is clean
• Check that there are no obstructions in the paper path

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Enter service mode

Check exit sensor according to GP 4
Sensor works OK
Y N
Perform RAP 300 Exit miss
Check M301 Drive Motor according to GP 4
Drive Motor (M1) works OK
Y N
Perform RAP 039 Stepper Motor Driver M301 PCB ”G”
Check that transportation drive and idler rollers are in good working order
Drive and idler rollers are OK
Y N
Fix problem
Ensure that AF602 is correctly installed. Check first for paper path misalignment and inter-
face cables
Installation is OK
Y N
Re-install AF602
Exit

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RAP 401 No Answer on PAC (Propose, Accept, Confirm)
When the Feeder wants to start feeding it asks for status from the downstream device (BM
or RCT). If no response is received within a specified time, fault 401 is displayed.

Initial Actions
• Make sure that the communication cable is properly connected
• See Service Manual BM500-3 Section 4 BM-158 or
Service Manual CST500 Section 4 CST-150

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RAP 001 Optical DSD Sensor

Initial Actions
• Enter service mode according to GP 1
• Check sensor according to GP 4
• Ensure that optical DSD LED and DSD PhT is clean
• Ensure that all connectors at the DSD LED and sensor are properly connected
• Ensure that all connectors at PCB ‘H’ and ‘L’ are properly connected.
• Ensure that DSD sensor is calibrated (BM500 Operators Manual, AF602 Sensor Calibra-
tion Section)

NOTE!
For measuring references see BSD
A DSD sensor includes one DSD LED (transmitter) and one DSD PhT (receiver)

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Swap the faulty optical DSD PhT with one in the other bin.
Sensor works at new location
Y N
Replace DSD PhT
Swap the faulty optical DSD LED with one in the other bin
LED works at new location
Y N
Replace DSD LED
At the faulty location, disconnect DSD PhT and DSD LED wires from PCB, DSD LED and
DSD PhT. Check all wires (white, black) to DSD PhT and (red, black) to DSD LED for short
circuits and continuity. Also check for short circuits between wires and chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Swap PCB that faulty optical DSD sensor is connected to with the one in the other bin.
After swapping the PCB, set the address DIP switches to the settings shown in the circuit
diagram. Check sensor functionality.
The optical DSD sensor at new PCB location works
Y N
Replace the original CPU PCB (The one that causes the failure)
Exit

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RAP 002 Ultrasonic DSD (Double Sheet Detection) Still no functionality at the original location (BIN)
This RAP is for troubleshooting the US (Ultrasonic) DSD sensor. Y N
The primary objective is to determine if the failure is related to the PCB, sensor or harness. Replace the original US DSD sensor transmitter/receiver package (The one that
causes the failure).
Initial Actions
Power off, swap the CPU PCB (set DIP switches correctly between the two BINs. After the
• Make sure that plugs/jacks J/P112, J/P211, J/P311, J/P212, P310/J310, J/P107, J/P207
transmitter, receiver and CPU have been moved to the other bin: power on, recalibrate the
and P312/J312 are properly connected.
sensor and check functionality.
• Make sure that all connectors connecting to the US (Ultrasonic) DSD sensor (both trans-
mitter and receiver) are properly connected. Still no functionality at the original location (BIN)
• Ensure that all connectors to “H”, “I”, “L” and “M” PCBs are properly connected. Y N
• Recalibrate the sensor and check functionality (BM500 Operators Manual, AF602 Sensor Replace the original CPU PCB (The one that causes the failure).
Calibration Section) Exit
Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power off the machine, disconnect CPU PCB connector [P1], 24V Distribution PCB con-
nector [P2] and Sensor connectors at US DSD sensor transmitter and receiver. Measure
continuity between all wires from PCB connectors to Sensor connectors.
There is continuity
Y N
Repair/replace harness
Check short circuits between all wires at CPU connectors and between all wires at CPU
connectors to chassis.
There is no short circuit
Y N
Repair/replace harness
Reconnect all connectors, power on and close the door (activate door switch).
LED D1 at the 24V Distribution PCB I or M activates
Y N
Go to RAP 022 / RAP 023 BIN A / B 24V very low
Power off, swap the US DSD sensor receiver between the two BINs, power on, recalibrate
the sensor and check functionality.
Still no functionality at the original location (BIN)
Y N
Replace the original US DSD sensor transmitter/receiver package (The one that
causes the failure)
Power off, swap the US DSD sensor transmitter between the two BINs. After both transmit-
ter and receiver have changed BIN location; power on, recalibrate the sensor and check
functionality.

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RAP 003 Ultrasonic DS (Distance Sensor) Q301 / Q302
This RAP is for troubleshooting the US (Ultrasonic) DS sensor.
The primary objective is to determine if the failure is related to the PCB, sensor or harness.
Initial Actions
• Make sure that plugs/jacks A/P2, A/P3, A/P4, A/P5, A/P6 and A/P10 are properly con-
nected.
• Make sure that the connector connecting to the USDS sensor is properly connected.
• Ensure that all connectors to PCB ‘A’ are properly connected.
• Enter service mode according to GP 1 and check functionality of sensor (GP 4)

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
Swap the faulty USDS sensor with the sensor in the other bin. After swapping the sensors,
check USDS sensor functionality.

Does sensor work at new location?

Y N
Replace sensor
At the faulty location, disconnect sensor wire booth from PCB and sensor ([J/P303] or [J/
P304]). Check all wires (red, white, black, grey) for short circuits and continuity. Also check
for short circuits between all wires to chassis.
There is continuity and no short circuit?
Y N
Repair Harness
Reconnect all connectors and Power on, measure VDC on sensor between pin 1 (red) and
pin 4 (black)
The voltage is 5VDC±10%
Y N
Replace PCB “A”
Exit

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RAP 004 No ICAN Communication Entry
This RAP is for troubleshooting a failed ICAN circuit.
The RAP checks wires and PCBs for short/open circuits and if the ICAN termination is OK.
Initial Actions
• Make sure that plugs/jacks J/P309, J/P312, J/P111 and J/P211 are properly connected
(reference Master Wiring Diagram)
• Make sure that all DIP switch settings on CPU PCBs and Stepper Motor Driver PCBs are
correct (see GP’s)
• Ensure that all connectors to “A”, “B”, “G”, “H”, “K”, “L”, “O”, PCBs are properly connected

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

There are multiple codes related to ICAN communication failure

Y N
Perform the PCB “x” RAP for the PCB “x” mentioned in the failure code
PCB RAP “x” solved the problem
Y N
Perform RAP 006 ICAN Circuit
ICAN Circuit RAP solved the problem
Y N
Replace the PCB “x”
Exit
Exit
Check D5 Blue LED on PCBs “A”, “H” and “L” and D2 Blue LED on PCBs “G”, “K” and “O”.
If diode is not activated there is no 12V to the PCB.
All diodes are activated
Y N
Perform the PCB “x” RAP for the PCB “x” with the deactivated LED.
PCB RAP “x” solved the problem
Y N
Perform RAP 006 ICAN Circuit
ICAN Circuit RAP solved the problem
Y N
Replace the PCB “x”
Exit
Exit
Perform RAP 006 ICAN Circuit
BSD on next page

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 005 No XCAN Communication
This RAP is for troubleshooting XCAN communication failure, no communication with
machines in the system.
Target is to give directions to possible source of failure
Initial Actions
• Ensure that plugs/jacks J/P309, J/P312, J/P111, J/P311, J/P23, J/P24 and J/P211 are
properly connected
• Ensure that all DIP switch settings on PCBs “A”, “G”, “H”, “L”, “K” and “O” are correct (see
GP’s)
• Ensure that all connectors to SW1, PSU (12V) and “A”, “B”, “G”, “H”, “K”, “L”, “O” PCBs
are properly connected

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
WARNING!
Use caution when making the voltage measurements and always disconnect the
Power Cord when it is necessary to work inside the Power Module. AC Power is pre-
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet.

Power on the machine. Measure between [B, P1-6] to [B, P1-1]

The voltage is 12VDC±10%
Y N
Power off and disconnect the Power Cord, check status of fuse F1 located in the
power inlet.
F1 is blown
N Y
Go to RAP 031 F1 Blown Fuse
Go to RAP 034 PSU (12V)
Go to RAP 026 CPU PCB “A”

BSDs on next to next pages

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 006 ICAN Circuit Locate the short circuit by performing the following steps:
Harness check:
This RAP is for troubleshooting a failed ICAN circuit related to multiple PCBs.
1. Disconnect all [P6] and [P10] connectors on PCBs “A”, “H” and “L”.
Target is to checks wires and PCBs for short/open circuit and check if the ICAN termination
2. Disconnect all [P5] and [P6] connectors on PCBs “G”, “K” and “O”.
is OK.
3. Check short circuits between all Red and Black wires, between all White and
Initial Actions Brown wires, all Yellow and Green wires and all wires to chassis included in the
• Make sure that plugs/jacks J/P309, J/P312, J/P111 and J/P211 are properly connected. ICAN circuit, check BSD.
• Make sure that all dip switch settings on CPU PCBs and Stepper Motor Driver PCBs are PCBs check:
correct (see GP’s) 1. Check short circuit between [J6-4] to [J6-6] and [J10-4] to [J10-6] on PCBs “A”,
• Ensure all connectors to “A”, “B”, “G”, “H”, “K”, “L”, “O” PCBs are properly connected. “H” and “L”.
2. Check continuity between [J5-4] to [J5-6] and [J6-4] to [J6-6] on PCBs “G”, “K”
and “O”
Go to RAP 026 CPUPCB A
Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power off the machine, check continuity between wire from [P309-5] to [G, P6-4] and wire
from [P309-7] to [G, P6-4] (ICAN Start to ICAN End continuity check).
There is continuity
Y N
Locate the open circuit by performing following steps:
Harness check:
1. Disconnect all [P6] and [P10] connectors on PCBs “A”, “H” and “L”.
2. Disconnect all [P5] and [P6] connectors on PCBs “G”, “K” and “O”.
3. Check continuity for all wires included in the ICAN circuit, check BSD.
PCBs check:
1. Check continuity between [J6-4] to [J10-4] and [J6-6] to [J10-6] on PCBs “A”,
“H” and “L”.
2. Check continuity between [J5-4] to [J6-4] and [J5-6] to [J6-6] on PCBs “G”, “K”
and “O”.
Repair/replace harness or replace PCB depending on the source of open circuit.
Measure resistance between [P309-5] to [P309-7].
The resistance is 50-70 ohm
Y N
The resistance lower than 50 ohm (short circuit)
Y N
Disconnect [P5] and [P6] on PCB “G” and “K”.
Check dip switch settings for PCB “G” and “K”. (Service tables BM500)
Dip switch settings are OK
Y N
Set correctly and exit
Locate the open circuit by performing following steps:
Check open circuit between [J5-4] to [J5-6] on PCBs “G” and “K”. Re-
place the failed PCB

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RAP 007 EEPROM RAP 009 M101/M201 Bin Elevator Upper Home Position Sensor Not
This RAP determines if there is corrupted software or if the PCB needs to be replaced. Activated in Time/Activated Too Long
The fault codes that lead to this RAP may be generated if the top and bottom home position
Initial Actions sensors are activated at the same time. Each bin has sensors for its home positions; one
No initial action required for the bottom position and one for the top position.

Procedure Initial Actions

• Ensure that all connectors at the other position sensor are properly connected.
WARNING! • Check that there are no obstructions in the elevator path
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before • The feed rollers/feed shaft may be stuck out of position. The feed rollers need to fall
disconnecting, removing or replacing any electrical components or measuring down into default position when the tray is lowered. If the feed rollers are stuck out of
resistance inside the machine. position, see REP 14.26 to address the issue

Perform NVM reset according to Service Manual System 500-3

Re-load S/W according to Service Manual System 500-3
Procedure
Replace PCB controller according to REP 14.37 WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
RAP 008 M101/M201 Lower Home Position Sensor Not Activated In
Time/Activated Too Long
Enter service mode according to GP 1
Check upper position sensor according to GP 4
Initial Actions Sensor works OK
• Ensure that all connectors at the home position sensor are properly connected Y N
• Verify that there are no obstructions in the elevator path Go to RAP 010 Bin Elevator Upper and Lower Home Position Sensor
Go to RAP 014 M101/M201 Elevator Motor

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components.

Enter service mode according to GP 1

Check Home Position Sensor according to GP 4
Sensor works OK
Y N
Go to RAP 010 Bin Elevator Upper and Lower Home Position Sensor
Go to RAP 014 M101/M201 Elevator Motor

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RAP 010 Bin Elevator Upper and Lower Home Position Sensor

Initial Actions
• Enter service mode (GP 1)
• Check sensor according to GP 4
• Ensure that sensor is clean
• Ensure that all connectors at the sensor are properly connected
• Ensure that all connectors at PCB ‘O’ and ‘K’ are properly connected

NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Swap the faulty sensor with the sensor in the other bin. After swapping the sensors check
the sensor functionality. Does sensor work at new location
Sensor works OK.
Y N
Replace sensor
At the faulty location, disconnect sensor wire both from PCB and sensor. Check all wires
(red, white, black) for short circuit and continuity
There is continuity and no short circuit
Y N
Repair/replace harness
Swap PCB, that the faulty sensor is connected to, with the PCB in the other bin. After swap-
ping the PCB, set the address dip switches to settings in the circuit diagram. Check sensor
functionality
Does home/outer sensor at new PCB location work
Y N
Replace PCB
Exit

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RAP 011 Fan X Pulse Time Out
Refer to this RAP if any fan in the machine FAN101-FAN104 (upper bin) or FAN201-
FAN204 (lower bin) does not give a pulse.
Initial Actions
• Enter service mode according to GP 1
• Check fan according to GP 4
• Ensure that plug / jack at the side guide are properly connected
• Ensure that all connectors at PCB are properly connected

NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord
before disconnecting, removing or replacing any electrical components or
measuring resistance inside the machine.

Swap the faulty fan with one of the three other fans in the bin. After swapping the fan,
check fan functionality.
Fan works at new location
Y N
Replace Fan
At the faulty location, disconnect fan wire both from fan and PCB. Check all wires
between fan and PCB for short circuit and continuity
There is continuity and no short circuit
Y N
Repair/replace harness
Measure 24 volts at Fan location
There are 24 volts at Fan location
Y N
Replace the PCB
Perform RAP 020 24/48 voltage very low entry RAP

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RAP 012 Drive Clutch and Roller
Rotate shaft in arrow direction and check that
shaft [A] rotates and shaft [B] do not rotate.
Initial Actions A
• Enter service mode (GP 1)
• Ensure that all connectors at the clutch are properly connected
• Ensure that all connectors at PCB ‘K’ and ‘O’ are properly connected.

NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before B
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Rotate drive roller manually and check that all drive clutch transmission components are
moving as indicated in figure.
Transmission works
Y N
Fix problem
Swap the stepper motor PCB that the faulty clutch is connected to with the one in the other
bin. After swapping the PCB, set the address dip switches to settings in the circuit diagram.
Check clutch functionality.
Does the clutch at new PCB location work
Y N
Replace PCB
At the faulty location, disconnect the clutch wire from PCB and clutch. Check all wires
(orange, violet) for short circuit and continuity.
There is continuity and no short circuit
Y N
Replace harness
Swap the faulty clutch with the one in the other bin. Check clutch functionality.
Does clutch at new location work
Y N
Replace clutch
Go to RAP 020 24/48 voltage very low entry RAP

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RAP 013 M301 Drive Motor RAP 014 M101/M201 Elevator Motor

Initial Actions Initial Actions

• Enter service mode according to GP 1 • Enter service mode according to GP 1
• Check motor functionality according to GP 4 • Check motor functionality according to GP 4
• Ensure that all connectors are properly connected to stepper motor PCB • Ensure that all connectors are properly connected to the stepper motor PCB
NOTE! NOTE!
For measuring references see BSD For measuring references see BSD on next page
Procedure
Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before WARNING!
disconnecting, removing or replacing any electrical components or measuring Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
resistance inside the machine. disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
Disconnect motor harness from PCB and rotate drive motor M1 manually and check that all
M1 drive motor transmission components are moving. Does transmission work OK Check Bin Interlock according to GP 5
Transmission works Bin Interlock works
Y N Y N
Fix problem Go to RAP 033 Motor Relay
Swap the stepper motor PCB that the faulty motor is connected to with one of the two bin Disconnect motor harness from PCB and rotate elevator belts manually. Check that all M2/
stepper motor PCB’s. After swapping the PCB, set the address DIP switches to the settings M3 elevator motor transmission components are moving properly.
shown in the circuit diagram. Check motor functionality. Transmission works
Does the motor at new PCB location work Y N
Y N Fix problem
Replace PCB Swap the stepper motor PCB that the faulty motor is connected to with the one in the other
At the faulty location, disconnect motor wire from PCB. Check for short circuits between all bin. After swapping the PCB, set the address DIP switches to settings in the circuit diagram.
wires and chassis. Check motor functionality.
There are no short circuits Motor works at new location
Y N Y N
Repair/replace harness Replace PCB
Swap the faulty stepper motor with one of the two bin stepper motors. Check motor func- At the faulty location, disconnect motor wire from PCB. Check for short circuits between all
tionality. wires and chassis.
Does motor at new location work There are no short circuits
Y N Y N
Replace motor Repair/replace Harness
Go to RAP 020 24/48 voltage very low entry RAP Swap the faulty stepper motor with one of the two bin stepper motors. Check motor func-
tionality.
Motor works at new location
Y N
Replace motor
Goto RAP 020 24/48 voltage very low entry RAP

BSD on next page

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 015 Bin A/B Opening
Utilize this RAP when the open bin function does not work for the upper or lower bin
Initial Actions
• Check if bin has actually opened
• Enter service mode (GP 1)
• Check solenoid functionality (GP 4)
• Check bin switch functionality (GP 5)
• Ensure that all connectors at the solenoid are properly connected
• Ensure that all connectors at PCB ‘I’, ‘H’, ‘M’ and ‘L’ are properly connected

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Manually check that the Damper is strong enough to push the bin out
The damper is strong enough
Y N
Replace damper
Manually check that all solenoid A/B transmission components are easy to move. Also
check that bin moves in and out easily.

Does transmission work OK

Y N
Fix the problem
Swap the faulty solenoid with the one in the other bin. After swapping the solenoids check
the solenoid functionality.
Does solenoid work at new location
Y N
Replace solenoid
Swap PCB that faulty solenoid is connected to with the PCB in the other bin. After swapping
the PCB, set the address DIP switches to settings in the circuit diagram. Check solenoid
functionality.
Does solenoid at new PCB location work
Y N
Replace PCB
Go to RAP 022 / RAP 023 Bin A / B 24V very low

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 RAP 016 Lamp RAP

Initial Actions
Check lamp functionality
Ensure that lamp is clean
Ensure that all connectors at the lamp are properly connected
Ensure that all connectors at PCB ‘H’ and PCB ‘L’ are properly connected.

NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Swap the faulty lamp with the lamp in the other bin. After swapping the lamps, check lamp
functionality.
Lamp works at new location
Y N
Replace lamp (REP 14.21)
At the faulty location, disconnect lamp wires both from PCB and lamp. Check all wires (red,
white, black) to lamp for short circuits and continuity.
There is continuity and no short circuit
Y N
Repair/replace harness
Swap PCB that the faulty lamp is connected to with the one in the other bin. After swap-
ping the PCB, set the address DIP switches to settings in the circuit diagram. Check lamp
functionality.
Does lamp at new PCB location work
Y N
Replace PCB
Exit

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RAP 017 Counter

Initial Actions
Ensure that all connectors at the counter are properly connected.
Ensure that all connectors at PCB ‘A’ are properly connected.

NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Disconnect Counter and PCB connectors. Check all wires (red, white, black) for short cir-
cuits and continuity. Also check for short circuits between all wires and chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Replace Counter
Replace PCB

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RAP 018 12/24/48V Low or High
This RAP is for troubleshooting a low or high 12V, 24V or 48V
Initial Actions
None

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before 12V
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Adjust to the correct level according to the table below, if there is 48V low, start by checking
and adjusting the 24V level at PSU (24V) before continuing with the PSU (24/48V) adjust- V+ TRIM
ment. V-
12V 12V
NOTE!
Turn the TRIM knob clockwise to increase and counter clockwise to decrease the output
voltage. Note that 1/4 turn is approximately 3,0 VDC.

Ideal level Code alert levels 24/48V

Adjust to
PSU LOW HIGH Measure between
[VDC] [VDC]
[VDC] [VDC]
(12V) 12V <11,5V >12,5V 11.8-12.3 V V- to V+ at PSU(12V)
(24V) 24V 20.0-22.9V 25.1-27.8V 23.8-24.3 V V- to V+ at PSU(24V)
V- at PSU(24V) to V+
(24/48V) 48V 43.6-46.9 V 49.1-66.0 V 47.8-48.3 V
at PSU(24/48V) V- V+
24/48V 24/48V
V+
V-
24V
24V
24V

TRIM

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RAP 019 24/48V Secondary Circuit There is continuity and no short circuit
This RAP is for troubleshooting a very low 24V and/or 48V. Y N
The primary objective is to check the harness between PSUs<>Short Circuit Protection Repair/replace harness
(SCP) PCBs and the functionality of the SCP PCBs.
Leave connectors from previous step disconnected.
Initial Actions Check continuity between [D, P2-5] to [D, P2-12].
• Make sure that plugs/jacks J/P301, P310/J310 and P312/J312 are properly connected There is continuity
(see Master Wiring Diagram) Y N
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL301,
Repair/replace harness
REL302, PSU (24V) and PSU (24/48V) are properly connected
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “I”, “K”, “L”, “M” and “O”, Reconnect [P2] at PCBs “C” and “D.” Leave [P2] at “E”, “F” and [P9] at Stepper Motor Driver
PCBs are properly connected PCBs “G”, “K” and “O” disconnected. Disconnect [P1] at SCP PCBs “E” and “F”. Power on
the machine and close the door.
Relay at SCP PCB “C” and “D” activates (connectors shorted away from coil) a pe-
riod of time after power on/door closed.
Procedure
Y N
WARNING! Replace PCB “C” and/or “D” depending on which relay that failed.
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before Reconnect [P1] at PCBs “E” and “F,” leave the rest disconnected. Power on the machine
disconnecting, removing or replacing any electrical components or measuring and close the door. Measure voltage (VDC) between [E, J2-1] and [E, J2-3]
resistance inside the machine.
The voltage is 24VDC±10% for at least a short period of time (measure during a peri-
NOTE! od of at least 10 seconds after Power ON). “N” means no reaction at all on the output.
For safety reasons - in case of a “very low/high 24V and/or 48V,” there is a limited time
when voltages are applied to PSU (24V) and PSU (24/48V). This affects the voltage meas- Y N
urements. Please see “24/48 Vdc Interlock/PSU procedure” for further information. Replace PCB “E”
Power off the machine, keep [P2] at “E” and “F” disconnected. Power on the machine and
This RAP assumes that “24V and/or 48V very low entry RAP” has been performed. close the door. Measure voltage (VDC) between [F, J2-1] and [F, J2-3].
Power off the machine, disconnect [P1] at SCP PCBs “D”, “E” and “F”. The voltage is 24VDC±10% for at least a short period of time (measure during a peri-
Measure continuity between wires from PSU (24V) to [P1] for all three PCBs and check for od of at least 10 seconds after Power ON). “N” means no reaction at all on the output.
short circuits between black and red wires. Also, check for short circuits from red wires to Y N
chassis. Replace PCB “F”
There is continuity and no short circuit Exit
Y N
Repair/replace harness
Disconnect [C, P1]. Measure continuity between wires from PSU (24/48V) to [C, P1], check
for short circuits between Orange and Red wires. Also, check for short circuits from Red and
Orange wires to chassis
There is continuity and no short circuit
Y N
Repair/replace harness
Reconnect all connectors, disconnect [P2] at SCP PCBs “C”, “D”, “E” and “F”. Measure
continuity between wires from [C, P2-7] to [D, P2-1]
There is continuity
Y N
Repair/replace harness
Leave connectors from previous step disconnected and disconnect [P9] at Stepper Motor
Driver PCBs “G”, “K” and “O”, check for short circuits between all wires on [C, P2] to chassis
and continuity between position [C, P2-5] to [C, P2-12]. Also check for short circuit between
BSD on next page
all Orange wires at [C, P2] to all Black wires at [D, P2].

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RAP 020 24V/48V Very Low Entry RAP RAP 021 24V/48V Very Low
This RAP gives directions to correct RAP in the case of multiple or single codes This RAP is for troubleshooting a very low 24V and/or 48V.
The primary objective is to to determine if the source of failure is related to the primary or
Initial Actions secondary circuit of the PSUs or if one of the PSUs is broken.
• Make sure that plugs/jacks J/P310, J/P312, J/P112 and J/P212 are properly connected
(reference Master Wiring Diagram)
Initial Actions
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL301, • Make sure that plugs/jacks J/P310, J/P312, J/P112 and J/P212 are properly connected
REL302, PSU (24V) and PSU (24/48V) are properly connected (reference Master Wiring Diagram)
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “I”, “K”, “L”, “M”, and “O” • Make sure that all connectors connecting to the Door Switch(S301/S302), REL301,
PCBs are properly connected REL302, PSU (24V) and PSU (24/48V) are properly connected
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “I”, “K”, “L”, “M”, and “O”
Procedure PCBs are properly connected

WARNING! Procedure
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before WARNING!
disconnecting, removing or replacing any electrical components or measuring Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
resistance inside the machine. disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
NOTE!
Check service codes For safety reasons - in case of a “very low/high 24V and/or 48V,” there is a limited time
Code is a single code very low 24V at BIN “x” (A or B) when voltages are applied to PSU (24V) and PSU (24/48V). This affects the voltage meas-
Y N urements. Please see “24/48 Vdc Interlock/PSU procedure” for further information.
Code is a single very low 48V at PCB “x”
Y N WARNING!
Go to RAP 021 24V/48V very low Use caution when making the voltage measurements and always disconnect the
Power Cord when it is necessary to work inside the Power Module. AC Power is pre-
24V/48V very low RAP solved the problem
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet.
Y N
Power on the machine and close the door. Measure voltage (VAC) between L and N on the
Perform RAPs in following order: PSU (24V) input
1. RAP 042 Stepper Motor M301 PCB 48V very low
The voltage is 90-264VAC
2. RAP 041 Stepper Motor M201 PCB 48V very low
3. RAP 040 Stepper Motor M101 PCB 48V very low Y N
4. RAP 022 BIN A 24V very low Go to RAP 035 REL301
5. RAP 023 BIN B 24V very low Power off the machine, wait 5 seconds, Power on the machine and close the door. Measure
If no success, replace PCBs in same order. (BINs: replace voltage (VAC) between L and N on the PSU (24/48V) input
both CPU and 24V Distribution PCBs) The voltage is between 90-264VAC
Exit Y N
Perform RAP 040, 041, or 042 Stepper Mot. (M101, M201 or M301) PCB 48V Go to RAP 036 REL302
very low
Power off the machine, wait 5 seconds, disconnect V+ and V- from both PSU (24V) and
Perform RAP 022 or 023 BIN A or B 24V very low PSU (24/48V). Disconnect diodes, power on the machine and close the door. Measure volt-
BIN x 24V very low RAP solved the problem age (VDC) between V+ and V- on the PSU (24V) output
Y N The voltage is 24VDC±10% for at least a short period of time (measure during a
Go to RAP 021 24V/48V very low RAP period of at least 10 seconds after Power ON). “N” means no reaction at all on the
24V/48V very low RAP solved the problem output
Y N Y N
Replace CPU and 24V Distribution PCBs Replace PSU (24V) (REP 3.7.2)
Exit Power off the machine. Keep V+ and V- disconnected, wait 5 seconds, Power on the ma-
chine and close the door. Measure voltage (VDC) between V+ and V- on the PSU (24/48V)
Exit BSD on previous page
output

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The voltage is 24VDC±10% for at least a short period of time (measure during a There is continuity
period of at least 10 seconds after Power ON). “N” means no reaction at all on the Y N
output Repair/replace harness
Y N Reconnect all connectors except [E, P1], check for short circuit between [I, P1] Red and
Power off the machine, measure resistance for the two diodes when disconnected Black wires
from PSU There is no short circuit
One or both diodes are shorted (resistance<1000 Ohms) Y N
Y N Disconnect [E, P2], check for short circuit between [I, P1] Red and Black wires
Replace PSU (24/48V) There is no short circuit
Replace diode/diodes N Y
Go to RAP 019 24/48V secondary circuit Replace PCB “E”
Disconnect all FAN connectors and Q102 connector, check for short circuit
between FAN connectors on the FAN side Black wires to Red wires and between
Q102 chassis connector pin 3 to pin 6
There is no short circuit
N Y
RAP 022 BIN A 24V Very Low Disconnect SOL101 and SOL102 connectors. Measure resistance
This RAP is for troubleshooting a very low 24V related to BIN A between connectors on the solenoid for both SOL101 and SOL102.
Initial Actions The resistance is lower than 10 ohms
• Make sure that plugs/jacks J/P310 and J/P112 are properly connected. N Y
• Ensure that all connectors to “E”, “H”, “I” PCBs are properly connected (REPx). Replaced the failed solenoid SOL101 or SOL102
Disconnect all connectors to PCB “I”, check for short circuit between
following positions:
Procedure [I, P1] all Red to all Black wires, all Red and Orange wires to chassis.
WARNING! [I, P2] all White to all Green wires, all Red to Black wires, all White and
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before Red wires to chassis.
disconnecting, removing or replacing any electrical components or measuring [I, P3] White to Black wires, White wire to chassis
resistance inside the machine. There is no short circuit
Y N
Power off the machine, disconnect [E, P1] and [E, P2], measure continuity between PCB Repair/replace harness
connectors [E, J2-1] and [E, J1-1]. (Checking blown fuse at PCB “E”). Disconnect [K, P8] and check for short circuits on PCB connector [K, J8]
There is continuity between pin 7 and pin 8
Y N There is no short circuit
Replace PCB “E” Y N
The fuse at PCB “E” blows up again at Power on Replace PCB “K”
Y N Replace PCB “I”
Exit Replace the failed FAN/Q102
Proceed to the next step in this RAP Power off, reconnect [E, P1], swap CPU PCB “H” with CPU PCB “L”, make sure to set DIP
Leave [E, P1] and [E, P2] disconnected and disconnect [I, P1], [I, P3] and [H, P1]. Measure switches correct (Service tables BM500) and that all connectors at both PCBs are properly
continuity for all wires between [E, P2] and [I, P1], check continuity for all wires between installed before power on the machine. Power on
[I, P3] and [H, P1]. Still “BIN A 24V very low”
Y N
Replace the original CPU PCB “H”

BSD on next page

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Power off, swap PCB “M” with PCB “I”, make sure all connectors at both PCBs properly
installed before power on the machine. Power on
Still “BIN A 24V very low”
Y N
Replace the original 24V Distribution PCB “I”
Go to RAP 020 24V/48V very low entry RAP

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RAP 023 BIN B 24V Very Low N Y
This RAP is for troubleshooting a very low 24V related to BIN B Replaced the failed solenoid SOL201 or SOL202
Disconnect all connectors to PCB ”M”, check for short circuit between fol-
Initial Actions lowing positions:
• Make sure that plugs/jacks J/P312 and J/P212 are properly connected. [M, P1] all Red to all Black wires, all Red and Orange wires to chassis.
• Ensure that all connectors to “F”, “L” and ”M” PCBs are properly connected [M, P2] all White to all Green wires, all Red to Black wires, all White and
Red wires to chassis.
[M, P3] White to Black wires, White wire to chassis.
Procedure
WARNING! There is no short circuit
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before Y N
disconnecting, removing or replacing any electrical components or measuring Repair/replace harness
resistance inside the machine.
Disconnect [O, P8] check for short circuits on PCB connec-
tor [O, J8] between pin 7 and pin 8
Power off the machine, disconnect [F, P1] and [F, P2], measure continuity between PCB con- There is no short circuit
nectors [F, J2-1] and [F, J1-1]. (Checking blown fuse at PCB “F”).
Y N
There is continuity
Replace PCB “O”
Y N
Replace PCB “M”
Replace PCB “F”
Replace the failed FAN/Q202
The fuse at PCB “F” blows up again at Power on
Power off, reconnect [F,P1], swap CPU PCB “L” with CPU PCB “H”, make sure to set DIP
Y N switches correct (Service tables BM500) and that all connectors at both PCBs are properly
Exit installed before power on the machine. Power on
Proceed to the next step in this RAP Still “BIN B 24V very low”
Leave [F, P1] and [F, P2] disconnected and disconnect [M, P1], [M, P3] and [L, P1]. Measure Y N
continuity for all wires between [F, P2] and [M, P1], check continuity for all wires between [M, Replace the original CPU PCB “L”
P3] and [L, P1].
Power off, swap PCB “M” with PCB “I”, make sure all connectors at both PCBs properly in-
There is continuity stalled before power on the machine. Power on
Y N Still “BIN B 24V very low”
Repair/replace harness Y N
Reconnect all connectors except [F, P1], check for short circuit between [M, P1] Red and Black Replace the original 24V Distribution PCB “M”
wires.
Go to 24V/48V very low entry RAP
There is no short circuit
Y N
Disconnect [F, P2], check for short circuit between [I, P1] Red and Black wires
There is no short circuit
N Y
Replace PCB “F”
Disconnect all FAN connectors and Q202 connector, check for short circuit between
FAN connectors on the FAN side Black wires to Red wires and between Q202 chas-
sis connector pin 3 to pin 6
There is no short circuit
N Y
Disconnect SOL201 and SOL202 connectors. Measure resistance be-
tween connectors on the solenoid for both SOL201 and SOL202
The resistance is lower than 10 ohms BSD on previous page

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RAP 024 Antistatic Bars There is continuity
This RAP is for troubleshooting the Antistatic Bars. No fault code exists for this RAP. If Y N
papers are statically charged after printing, refer to this RAP. Repair/replace harness
The primary objective is to determine why the Antistatic Bars are not functioning properly. Power on, close the door and activate REL303 in component control
Initial Actions REL303 activates
• Make sure that plugs/jacks J/P27, J/P34 and J/P301 are properly connected Y N
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL301, Measure VDC between [REL303, A1] and [REL303, A2].
REL302, REL303, TR1, PSU (24V) and PSU (24/48V) are properly connected The voltage is 12VDC±10%
• Ensure that all connectors to “A”, “B” and “G” PCBs are properly connected
Y N
• Check that the voltage selector on TR1 is in correct position
• Ensure that the built in fuse for TR1 has not tripped Replace PCB “G“
• REL303 is activated upon startup (Door Switch must be activated). Listen closely to Replace REL303
BAR1 and BAR2. If there is a 50Hz sound when REL303 is activated, BAR1 and BAR2 Listen to BAR1
are working. If there is only sound at one of the BARs, replace the one that does not emit There is a 50Hz sound
any sound
Y N
Procedure Listen to BAR2
There is a 50Hz sound
WARNING! Y N
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring Replace transformer TR1
resistance inside the machine. Replace BAR1
WARNING! Listen to BAR2
Use caution when making the voltage measurements and always disconnect the There is a 50Hz sound
Power Cord when it is necessary to work inside the Power Module. AC Power is pre- Y N
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet Replace BAR2
Exit
Power on the machine close the door.
Does REL301 and/or REL302 activate
Y N
Go to REL301 and/or REL302
Power off the machine, disconnect the Power Cord. Measure continuity between [SW1,1] to
[REL303, 31] and [SW1,4] to [REL301, 11]
There is continuity
Y N
Repair/replace harness
Keep machine Powered off and the Power Cord disconnected. Measure continuity between
[G, P8-6] to [REL303, A2] and between [REL302, A1] to [REL303, A1].
There is continuity
Y N
Repair/replace harness
Keep machine Powered off and the Power Cord disconnected. Measure continuity between
connector [TR1-1] to [REL303, 14] and between [TR1-2] to [REL303, 34].

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 025 BIN Switch Software Signal
This RAP is for troubleshooting a BIN Switch software signal circuit.
The primary objective is to determine if the BIN Switch or CPU PCB has failed.
This procedure may be applied on either bin.
Initial Actions
• Make sure that plugs/jacks J/P301, J/P310, J/P312, J/P112, J/P106, J/P206 and J/P212
are properly connected (reference Master Wiring Diagram)
• Make sure that all connectors connecting to the BIN Switch are properly connected
• Ensure that all connectors to CPU PCB H/L are properly connected

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components.

Power off the machine, disconnect the Power Cord. Leave Door Switch deactivated, meas-
ure resistance from BIN Switch pos. 3 to 4.
There is open circuit, resistance > 1 Mohm
Y N
Replace BIN Switch
Activate Door Switch, measure resistance from Door Switch pos. 3 to 4.
There is continuity
Y N
Replace the BIN Switch
Disconnect CPU PCB H/L connector [P4] and deactivate BIN Switch. Measure continuity
from BIN Switch pos. 3 to [P4-20] and BIN Switch pos. 4 to [P4-21]. Check for short circuits
between Black and White wire, and between Black/White wires and chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Replace CPU PCB H/L

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RAP 026 CPU PCB ”A”
Measure VDC between GND and 3,3VDC (see image on following page).
This RAP is for troubleshooting a failed CPU PCB “A” The voltage is 3,3VDC±5%
The primary objective is to check if the PCB communicates correctly and logic voltages are Y N
OK.
Replace PCB “A”
Initial Actions Previous performed RAP was No XCAN Communication RAP
• Ensure that plugs/jacks J/P309, J/P312, J/P111, J/P311, J/P23, J/P24 and J/P211 are Y N
properly connected (reference Master Wiring Diagram) Go to RAP 004 No ICAN Communication entry RAP
• Ensure that all dip switch settings on PCBs “A”, “G”, “H”, “L”, “K” and “O” are correct (see
Power off the whole system and AF602, disconnect [A, P7], [A, P8], [J/P23] and [J/P24].
GP’s)
Check continuity for all wires from [A, P7] to [J23] and all wires from [A, P8] to [P24].
• Ensure that all connectors to PSU (12V) and “A”, “B”, “G”, “H”, “K”, “L”, “O” PCBs are
properly connected. There is continuity
Y N
Procedure Repair/replace harness
WARNING! Keep the whole system and AF602 powered off and [A, P7], [A, P8], [J/P23] and [J/P24]
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before disconnected. Check for short circuits between all wires connected to [J23] and [P24] and
disconnecting, removing or replacing any electrical components or measuring all wires from [J23] and [P24] to chassis. Pin 3 for both [J23] and [P24] are connected to
resistance inside the machine. chassis
There is no short circuit except for pin 3
Power on the machine. If D5 Blue LED on PCB “A” is deactivated, go directly to N (it means Y N
no 12VDC). If D5 is activated, measure VDC between [A, P6-1] and [A, P6-10]. Repair/replace harness
The voltage is 12VDC±10% Check the XCAN communications cables (one or two) for continuity and short circuits. The
Y N positions that need to be checked are pins 1,2,3,5 and 7
Power off, disconnect [A, P2], power on. There is continuity and no short circuit
D5 Blue LED at PCB “A” is activated Y N
N Y Repair /replace harness
Go to RAP 017 Counter Disconnect XCAN terminations (two) connected to the system and check resistance be-
Power off, disconnect [A, P6] and [B, P2], check continuity between all wires from tween pin 2 and 7.
[A, P6] to [B, P2], check short circuits between all wires connected to [A, P6], and The resistance is between 110-130 ohms
between all wires from [A, P6] to chassis. Y N
There is continuity and no short circuit Repair /replace termination(s)
Y N Go to and perform XCAN communication RAPs in service manuals for the machines con-
Repair/replace harness nected to AF602
Leave [A, P6] and [B, P2] disconnected, power on. If D6 Blue LED on PCB “B” is Success
deactivated go directly to N, it means no 12VDC. If D6 activated, measure VDC at Y N
PCB connector [B, J2] between [B, J2-23] to [B, J2-22]. Replace PCB “A”
The voltage is 12VDC±10% Exit
Y N
Replace PCB “B”
Replace PCB “A”
Measure VDC between GND and VCC (see image on following page).
The voltage is 5VDC±10%
Y N
Replace PCB “A”

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 LED D1, CPU
controlled LED
LED D10,
VCC (+5VDC) GND measur-
Sensors. ing point, all four
Deactivated=no plated holes are
voltage present. connected to
Activated= volt- GND
age present, not
necessary the +3,3VDC
correct voltage measuring point
level.
VCC (+5VDC)
measuring point

LED D5

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RAP 027 CPU PCB ”H” Power off, disconnect [H, P6] and [B, P2], and check continuity between all wires
This RAP is for troubleshooting a failed CPU PCB H. from [H, P6] to [B, P2]. Check for short circuits between all wires connected to [H,
The target is to check if the PCB communicates correctly and logic voltages are OK P6], and between all wires from [H, P6] to chassis.
Initial Actions There is continuity and no short circuit
• Ensure that plugs/jacks J/P309, J/P312, J/P111, J/P311 and J/P211 are properly con- Y N
nected. Repair/replace harness
• Ensure that all dip switch settings on PCBs “A”, “G”, “H”, “L”, “K” and “O” are correct. (see
GP’s) Leave [H, P6] and [B, P2] disconnected, power on. If D3 Blue LED on PCB “B” is
• Ensure that all connectors to “A”, “B”, “G”, “H”, “K”, “L”, “O” PCBs are properly connected. deactivated go directly to N, it means no 12VDC. If D3 activated, measure VDC at
PCB connector [B, J2] between [B, J2-10] to [B, J2-9].
The voltage is 12VDC±10%
Procedure
Y N
WARNING! Replace PCB “B”
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
Replace PCB “H”
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine. Measure VDC between GND and VCC (see image on next page).
The voltage is 5VDC±10%
Power on the machine. If D5 Blue LED on PCB “H” is deactivated, go directly to N (it means Y N
no 12VDC). If D5 is activated, measure VDC between [H, P6-1] to [H, P6-10]. Replace PCB “H”
The voltage is 12VDC±10% Measure VDC between GND and 3,3VDC (see image on next page).
Y N The voltage is 3,3VDC±5%
Power off, disconnect [H, P10], power on. Y N
D5 Blue LED at PCB “H” is activated Replace PCB “H”
N Y Exit
Power off, disconnect [H, P10] and [B,P2]. Check for short circuits be-
tween all wires connected to [H,P10] and between all wires from [H,P10]
to chassis.
There is no short circuit
Y N
Repair/replace harness
Go to RAP 037. Stepper Motor Driver M101 PCB “K” RAP
Power off, disconnect [H, P1], power on.
D5 Blue LED at PCB “H” is activated
N Y
Go to RAP 002 Ultrasonic DSD (pay attention to short circuit measure-
ments).
Power off, disconnect [H, P3], keep [H, P1] disconnected, power on.
D5 Blue LED at PCB “H” is activated
N Y
Go to RAP 016 LAMP (pay attention to short circuit measurements).

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 LED D1, CPU
controlled LED
LED D10,
VCC (+5VDC) GND measur-
Sensors. ing point, all four
Deactivated=no plated holes are
voltage present. connected to
Activated= volt- GND
age present, not
necessary the +3,3VDC
correct voltage measuring point
level.
VCC (+5VDC)
measuring point

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RAP 028 CPU PCB ”L” Power off, disconnect [L, P6] and [B, P2], check continuity between all wires from
[L, P6] to [B, P2], check for short circuits between all wires connected to [L, P6],
This RAP is for troubleshooting a failed CPU PCB L.
and between all wires from [L, P6] to chassis.
Target is to check if the PCB communicates correctly and logic voltages are OK
There is continuity and no short circuit
Initial Actions
Y N
• Ensure that plugs/jacks J/P309, J/P312, J/P111, J/P311 and J/P211 are properly con-
Repair/replace harness
nected.
• Ensure that all dip switch settings on PCBs “A”, “G”, “H”, “L”, “K” and “O” are correct. (see Leave [L, P6] and [B, P2] disconnected, power on. If D3 Blue LED on PCB “B”
GP’s). is deactivated, go directly to N (it means no 12VDC). If D3 is activated, measure
• Ensure that all connectors to “A”, “B”, “G”, “H”, “K”, “L”, “O” PCBs are properly connected. VDC at PCB connector [B, J2] between [B, J2-10] and [B, J2-9].
The voltage is 12VDC±10%
Y N
Procedure Replace PCB “B”
WARNING! Replace PCB “L”
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before Measure VDC between GND and VCC (see image on following page).
disconnecting, removing or replacing any electrical components or measuring The voltage is 5VDC±10%
resistance inside the machine.
Y N
Replace PCB “L”
Power on the machine. If D5 Blue LED on PCB “L” is deactivated, go directly to N (it means
no 12VDC). If D5 activated, measure VDC between [L, P6-1] to [L, P6-10]. Measure VDC between GND and 3,3VDC (see image on following page).
The voltage is 12VDC±10% The voltage is 3,3VDC±5%
Y N Y N
Power off, disconnect [L, P10], power on. Replace PCB “L”
D5 Blue LED at PCB “L” is activated Exit
N Y
Power off, disconnect [L, P10] and [B,P2]. Check for short circuits be-
tween all wires connected to [L,P10] and between all wires from [L,P10]
to chassis.
There is no short circuit
Y N
Repair/replace harness
Go to RAP 038. Stepper Motor Driver M201 PCB “O” RAP
Power off, disconnect [L, P1], power on.
D5 Blue LED at PCB “L” is activated

N Y
Go to RAP 002 Ultrasonic DSD (pay attention to short circuit measure-
ments).
Power off, disconnect [L, P3], keep [L, P1] disconnected, power on.
D5 Blue LED at PCB “L” is activated
N Y
Go to RAP 016 LAMP (pay attention to short circuit measurements).

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 LED D1, CPU
controlled LED
LED D10,
VCC (+5VDC) GND measur-
Sensors. ing point, all four
Deactivated=no plated holes are
voltage present. connected to
Activated= volt- GND
age present, not
necessary the +3,3VDC
correct voltage measuring point
level.
VCC (+5VDC)
measuring point

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RAP 029 Door Switch Interlock Circuit There are no short circuits
This RAP is for troubleshooting when the Door Switch Interlock circuit does not activate Y N
REL301 and/or REL302. The primary objective is to determine which part of the Door Repair/replace harness
Switch Interlock circuit fails. Leave connectors disconnected, Measure resistance between harness connectors
Initial Actions [REL301, A1] to [REL301, A2] ,[REL302, A1] to [REL302, A2] and [REL303, A1] to [REL303,
A2]
• Ensure that plugs/jacks J/P301, J/P310, J/P312, J/P112 and J/P212 are properly con-
nected (reference Master Wiring Diagram) Resistance > 200 ohms
• Make sure that all connectors connecting to the Door Switch (S301/S302), REL301, Y N
REL302, REL303 and PSU (24V) and PSU (24/48V) are properly connected Repair/replace the Harness
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N”, “O” Leave connectors disconnected, Measure resistance between relay connectors A1 to A2 at
PCBs are properly connected REL301, A1 to A2 at REL302 and A1 to A2 at REL303.
Resistance 30-60 ohms
Procedure Y N
Replace the failed Relay
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before Reconnect all connectors, Power on, measure VDC between [B, P2-18,20] and [B, P1-7].
disconnecting, removing or replacing any electrical components or measuring The voltage is 12VDC±10%
resistance inside the machine. Y N
Note! If there is no Antistatic BAR Kit installed, skip all measuring related to REL303. Replace PCB “B”
Power off the machine, disconnect the Power Cord and all four wires connected to Door Replace PCB “A”
Switch. Leave Door Switch deactivated, measure resistance from Door Switch pos. 1 to 2
(not harness connectors).
There is an open circuit, resistance > 1 Mohm
Y N
Replace Door Switch
Activate Door Switch, measure resistance from Door Switch pos. 1 to 2 (not harness con-
nectors)
There is continuity
Y N
Replace Door Switch
Disconnect [A, P4], [A, P5], [B, P2] and all Relay connectors marked A1 and A2 (six total).
Deactivate Door Switch, measure continuity between the following positions:
1. [A, P5-3,4] to [REL302, A2] and [A, P5-1,2] to [REL301, A2]
2. [B, P2-18,20] to Door Switch pos.1
3. Door Switch pos. 2 to [REL302, A1] and [REL301, A1]
There is continuity
Y N
Repair/replace harness
Leave connectors disconnected, Check for short circuits between the following positions:
1. [A, P4-23,24], [A, P5-1,2,3,4] and [B, P2] to chassis.
2. All Relay wires (six total) marked A1 and A2 to chassis

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RAP 030 Door Switch Software Signal Power off the machine and disconnect the Power Cord. Leave Door Switch deactivated and
measure resistance from Door Switch pos. 3 to 4.
This RAP is for troubleshooting Door Switch software signal circuit.
Target is to find the out if the Door Switch or PCB “A” has failed. There are open circuits, resistance > 1 Mohm
Y N
Initial Actions Replace Door Switch (REP 14.40)
• Make sure that plugs/jacks J/P301, J/P310, J/P312, J/P112 and J/P212 are properly con- Activate Door Switch, measure resistance from Door Switch pos. 3 to 4.
nected (reference Master Wiring Diagram) There is continuity
• Make sure that all connectors connecting to the Door Switch(S301/S302) are properly Y N
connected Replace the Door Switch (REP 14.40)
• Ensure that all connectors to “A” PCB are properly connected
Disconnect [A, P4], deactivate Door Switch and measure continuity from Door Switch pos.
3 to [A, P4-23] and Door Switch pos. 4 to [A, P4-24]. Check for short circuits from Black to
White wire and from Black and White wires to chassis.
Procedure There is continuity and no short circuit
WARNING! Y N
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before Repair/replace harness
disconnecting, removing or replacing any electrical components or measuring
Replace PCB “A”
resistance inside the machine.

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RAP 031 F1 Blown Fuse Locate and Repair/replace harness between SW1 and REL301/REL302/J27/PSU
(12V)
This RAP is for troubleshooting when fuse F1 frequently blows up.
The primary objective is to find the source that makes fuse F1 to blow up Leave all connectors in previous steps disconnected. Disconnect L and N from PSU (24V),
check for short circuits from L to N, and L/N to chassis at the PSU (24V).
Initial Actions
There are no short circuits
• Ensure that there is proper voltage at the wall outlet
Y N
• Check all connectors related to Power Entry, SW1, REL301, REL302, REL303/TR1 (op-
tion) and input side of PSU (24V), PSU (24/48V) Replace PSU (24V) (REP 14.34)
Leave all connectors in previous steps disconnected. Check for short circuits between
wire from [REL301,14] to wire from [REL301,34] and between wires from [REL301,14] and
Procedure [REL301,34] to chassis.
WARNING! There are no short circuits
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before Y N
disconnecting, removing or replacing any electrical components or measuring Repair/replace harness
resistance inside the machine. Leave all connectors in previous steps disconnected, disconnect L and N from PSU
WARNING! (24/48V). Check for short circuits from L to N, and L/N to chassis at the PSU (24/48V).
Use caution when making the voltage measurements and always disconnect the There are no short circuits
Power Cord when it is necessary to work inside the Power Module. AC Power is pre- Y N
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet. Replace PSU (24/48V) (REP 14.35)
Leave all connectors in previous steps disconnected. Check for short circuits between
For the duration of this RAP: power off the machine, disconnect the Power Cord (very wire from [REL302,14] to wire from [REL302,34] and between wires from [REL302,14] and
important!) and leave Door Switch deactivated. Disconnect [POW,3] and [POW,4] from the [REL302,34] to chassis.
Power Entry, check short circuits from positions 3 to 4 and chassis to position 3 and 4 at the There are no short circuits
Power Entry
Y N
There are no short circuits
Repair/replace harness
Y N
There is an Antistatic KIT installed
Replace Power Entry
Y N
Leave all connectors in previous step disconnected. Check for short circuits between wires
Exit
from [SW1,2] to [SW1,5] and between wires from [SW1,2] and [SW1,5] to chassis.
Leave all connectors in previous steps disconnected. Check for short circuits between wire
There are no short circuits
from [P27,1] to wire from [P27,2] and between wires from [P27,1] and [P27,2] to chassis
Y N
There are no short circuits
Repair/replace harness
Y N
Leave all connectors in previous steps disconnected, and disconnect [J/P27]. Check for
Repair/replace harness
short circuits between wires from [SW1,1] to [SW1,4] and between wires from [SW1,1] and
[SW1, 4] to chassis. Leave all connectors in previous steps disconnected and disconnect TR,1 connector. Check
for short circuits between wire from [REL303,14] to wire from [REL303,34] and between
There are no short circuits
wires from [REL303,14] and [REL303,34] to chassis
Y N
There are no short circuits
Leave all connectors in previous steps disconnected. Disconnect L and N from
Y N
PSU (12V) input. Check for short circuits from L to N, and L/N to chassis at the
PSU (12V) input. Repair/replace harness
There are no short circuits Replace TR1
Y N
Replace PSU (12V) (REP 14.33)

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 032 Interlock Mismatch Procedure
This RAP is for troubleshooting a failed Interlock circuit; i.e. voltage is present when the WARNING!
Interlock circuit should be open. Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
The primary objective is to determine the source of failure: relay, harness, PCB or the disconnecting, removing or replacing any electrical components or measuring
interlock switch itself resistance inside the machine.
Initial Actions WARNING!
• Make sure that plugs/jacks J/P310, J/P312, J/P112 and J/P212 are properly connected Use caution when making the voltage measurements and always disconnect the
(reference Master Wiring Diagram) Power Cord when it is necessary to work inside the Power Module. AC Power is pre-
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL301, sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet.
REL302, PSU (24V) and PSU (24/48V) are properly connected
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N”, “O”
PCBs are properly connected Power on the machine and leave the Door switch deactivated (door open). Measure voltage
• Check Interlock functionality (GP 5). If Interlock Switch does not function properly, re- (VAC) between L and N on the PSU (24V) input.
place Interlock Switch (REP 14.40) The voltage is 90-264VAC.
Y N
Power on the machine and leave the Door Switch deactivated (door open). Meas-
ure voltage (VAC) between L and N on the PSU (24/48V) input.
The voltage is 90-264VAC.
Y N
Replace the PCB mentioned in the failure code (REP 14.37-14.38)
Replace REL302 (REP 14.36)
Power on the machine and leave the Door Switch deactivated (door open). Measure volt-
age (VAC) between L and N on the PSU (24/48V) input.
The voltage is 90-264VAC.
Y N
Replace REL301 (REP 14.36)
Perform RAP 030 Door Switch software signal
Success
Y N
Perform RAP 029 Door Switch Interlock circuit
Succes
Y N
Replace Door switch
Exit
Exit

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 033 Motor Relay Y N
This RAP is for troubleshooting why the Motor Relay does not work. Replace RELAY (REP 14.36)
The primary objective is to determine the cause of failure: PCB, Relay, BIN Switch or har- Keep machine powered off, leave BIN Switch deactivated and leave connectors discon-
ness nected. Measure resistance between BIN Switch pos. 1 to 2 (not harness connectors).
Initial Actions There is an open circuit (Resistance > 1 Mohm)
• Make sure that plugs/jacks J/P301, J/P310, J/P312, J/P112 and J/P212 are properly Y N
connected. Replace BIN Switch (REP 3.7.7)
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL301, Activate BIN Switch, measure resistance between BIN Switch pos. 1 to 2 (not harness con-
REL302, PSU (24V) and PSU (24/48V) are properly connected. nectors)
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N”, “O” There is continuity
PCBs are properly connected.
Y N
Replace BIN Switch (REP 3.7.7)
Procedure
Disconnect Stepper Motor Driver PCB connector [P7] and Motor connector. Check continu-
WARNING! ity between all wires from [P7] to RELAY, [P7] to Motor Connector and RELAY to Motor
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before connector.
disconnecting, removing or replacing any electrical components or measuring There is continuity
resistance inside the machine. Y N
Repair/replace harness
Power off the machine, disconnect the Power Cord. Disconnect [P6] at the Stepper Motor Check short circuit between all wires at [P7] and Motor connector (harness connector),
Driver PCB. Measure continuity between following positions: between all wires at [P7] to chassis and all wires at Motor connector (harness connector) to
1. PCB Connector [P6-1] to BIN Switch pos. 1. chassis.
2. PCB Connector [P6-10] to RELAY pos. A2.
3. BIN Switch pos. 2 to RELAY pos. A1. There is no short circuit
There is continuity Y N
Y N Repair/replace harness
Repair/replace harness Reconnect all connectors, activate BIN Switch and power on. Measure VDC between
RELAY A1 to A2.
Keep [P6] disconnected, disconnect BIN Switch pos. 1, 2 and RELAY pos. A1, A2. Check
short circuit between following positions: The voltage is 12VDC±10%
1. [P6-1] to [P6-10]. Y N
2. [P6-1, 10], RELAY harness connectors A1, A2, BIN Switch pos. 1 and 2 to chassis Replace Stepper Motor Driver PCB (REP 3.7.5)
RELAY activates
There is no short circuit Y N
Y N Replace RELAY (REP 14.36)
Repair/replace harness Exit
Leave connectors disconnected, Measure resistance between RELAY harness connectors
A1 to A2.
Resistance > 200 ohms
Y N
Repair/replace the Harness
Leave connectors disconnected, Measure resistance between RELAY connectors (not har-
ness connectors) A1 to A2.
Resistance is 30-60 ohms

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 034 PSU (12V) Repair/replace harness
This RAP is for troubleshooting the 12V circuit. Replace the Power entry
The primary objective is to determine if the failure is related to the primary circuit, PCB “B” Power off, disconnect wires from V- and V+ at PSU, power on.
or PSU (12V). Measure VDC between V- to V+ at PSU (12V).
The voltage is 12VDC±10%
Initial Actions Y N
• Ensure that plugs/jacks J/P309, J/P312, J/P111, J/P311, J/P23, J/P24, and J/P211 are Replace PSU (12V)
properly connected Power off, keep wires from V- and V+ at PSU (12V) disconnected and disconnect [B, P1].
• Ensure that all DIP switch settings on PCBs “A”, “G”, “H”, “L”, “K”, and “O” are correct Check continuity between all wires from V- and V+ to [B, P1], check short circuits between
(GP 5.4). Black to Red wires and between Black and Red wires to chassis.
• Ensure that all connectors to SW1, PSU (12V) and “A”, “B”, “G”, “H”, “K”, “L”, and “O” There is continuity and no short circuit
PCBs are properly connected
Y N
Procedure Repair/replace harness
Replace PCB “B”
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
WARNING!
Use caution when making the voltage measurements and always disconnect the
Power Cord when it is necessary to work inside the Power Module. AC Power is pre-
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet.

Power on the machine. Measure VAC between L to N on PSU (12V)

The voltage is between 90-264VAC
Y N
Power off and disconnect the Power Cord, check status of F1 located in the
power inlet.
F1 is blown
N Y
Go to RAP 031 F1 Blown Fuse
Keep the machine off and Power Cord disconnected. Measure continuity between
L Black1 wire to SW1,4 and between N Black2 wire to SW1,1.
There is continuity
Y N
Repair/replace harness
Keep Power Cord disconnected set SW1 to on. Measure continuity between
SW1,4 to SW1,5 and SW1,1 to SW1,2.
There is continuity
Y N
Replace SW1
Keep the machine off and Power Cord disconnected. Measure continuity between
SW1,5 Black1 wire to POW,1 and SW1,2 Black2 wire to POW,4.
There is continuity
Y N BSD on next page

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 035 REL301 Power off the machine and disconnect the Power Cord. Measure continuity between wires
from REL301 and PSU (24V) input.
This RAP is for troubleshooting the REL301 primary circuit.
The primary objective is to determine why there is not 90-240VAC at the PSU (24V) input. There is continuity
Y N
Initial Actions
Repair/replace harness
• Make sure that plugs/jacks J/P301, J/P310, J/P312, J/P112 and J/P212 are properly con-
nected (reference Master Wiring Diagram) Keep machine Powered off and the Power Cord disconnected. Measure continuity all the
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL301, way between wires from REL301 and SW1.
REL302, PSU (24V) and PSU (24/48V) are properly connected There is continuity
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N”, and Y N
“O” PCBs are properly connected Repair/replace harness
Connect the Power Cord and Power on the machine keep the door open, pay close atten-
Procedure tion to REL301. Close the door.
The REL301 activates for at least a short period of time.
WARNING! Y N
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring Power off the machine, wait 5 seconds, Power on the machine and close the
resistance inside the machine. door. Measure VDC between [REL301, A1] and [REL301, A2].
NOTE! The voltage is 12VDC±10% for at least a short period of time.
For safety reasons in case of a “very low/high 24V and/or 48V” there is a limited time when Y N
voltage are applied to PSU (24V) and PSU (24/48V), this affects the voltage measure- Go to RAP 029 Door Switch Interlock circuit
ments, please see “24/48VDC Interlock/PSU procedure” for further information. Replace REL301
WARNING! Power off the machine and wait 5 seconds. Power on the machine and close the door.
Use caution when making the voltage measurements and always disconnect the Measure voltage (VAC) between L and N on the PSU (24V) input.
Power Cord when it is necessary to work inside the Power Module. AC Power is pre- The voltage is 90-264VAC for at least a short period of time.
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet. Y N
Replace REL301 (REP 14.36)
Exit

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RAP 036 REL302 Power off the machine and disconnect the Power Cord. Measure continuity between wires
from REL302 and PSU (24/48V) input.
This RAP is for troubleshooting the REL302 primary circuit.
The primary goal is to determine why there is not 90-240VAC at the PSU (24/48V) input. There is continuity
Y N
Initial Actions
Repair/replace harness
• Make sure that plugs/jacks J/P301, J/P310, J/P312, J/P112 and J/P212 are properly con-
nected (reference Master Wiring Diagram) Keep machine powered off and the Power Cord disconnected. Measure continuity all the
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL302, way between wires from REL302 and SW1.
REL302, PSU (24V) and PSU (24/48V) are properly connected There is continuity
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N”, and Y N
“O” PCBs are properly connected Repair/replace harness
Connect the Power Cord and Power on the machine. Keep the door open; pay close atten-
Procedure tion to REL302. Close the door.
The REL302 activates for at least a short period of time.
WARNING! Y N
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring Power off the machine, wait 5 seconds. Power on the machine and close the
resistance inside the machine. door. Measure VDC between [REL302, A1] and [REL302, A2].
NOTE! The voltage is 12VDC±10% for at least a short period of time.
For safety reasons - in case of a “very low/high 24V and/or 48V,” there is a limited time Y N
when voltages are applied to PSU (24V) and PSU (24/48V). This affects the voltage meas- Go to RAP 029 Door Switch Interlock circuit
urements - please see “24/48VDC Interlock/PSU procedure” for further information. Replace REL302 (REP 14.36)
WARNING! Power off the machine, wait 5 seconds, Power on the machine and close the door. Measure
Use caution when making the voltage measurements and always disconnect the voltage (VAC) between L and N on the PSU (24/48V) input.
Power Cord when it is necessary to work inside the Power Module. AC Power is pre- The voltage is 90-264VAC for at least a short period of time.
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet. Y N
Replace REL302 (REP 14.36)
Exit

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RAP 037 Stepper Motor Driver M101 PCB ”K” Go to RAP 008 M101/M201 home position sensor not activated in time/activated
too long (pay attention to short circuit measurements).
This RAP is for troubleshooting a failed Stepper Motor Driver M101 PCB. Measure VDC between GND and 3,3VDC (see image on following page).
The primary objective is to check whether the PCB communicates correctly and logic volt-
ages are OK. The voltage is 3,3VDC±5%
Y N
Initial Actions Replace PCB “K” (REP 14.37)
• Ensure that plugs/jacks J/P309, J/P312, J/P111, J/P311 and J/P211 are properly con- Go to RAP 004 No ICAN Communication entry
nected.
• Ensure that all dip switch settings on PCBs “A”, “G”, “H”, “L”, “K” and “O” are correct (see
GP’s)
• Ensure that all connectors to “A”, “B”, “G”, “H”, “K”, “L”, “O” PCBs are properly connected

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power on the machine. If D2 Blue LED on PCB “K” is deactivated, go directly to N (it means
no 12VDC). If D2 is activated, measure VDC between [K, P5-1] to [K, P5-10]
The voltage is 12VDC±10%
Y N
Power off, disconnect [H, P10]. Power on.
D5 Blue LED at PCB “H” is activated
Y N
Go to RAP 027 CPU PCB “H”
Power off, disconnect [K, P5] and keep [H, P10] disconnected. Check continuity
between all wires from [H, P10] to [K, P5]. Check short circuits between all wires
connected to [K, P5], and between all wires from [K, P5] to chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Reconnect [H, P10] and [K, P5], disconnect [K, P6], power on.
D2 Blue LED at PCB “K” is activated
Y N
Replace PCB “K” (REP 14.37)
Go to RAP 033 Motor Relay
Measure VDC between GND and VCC (see image).
The voltage is 5VDC±10%
Y N
Power off, disconnect [K, P3], measure VDC between GND and VCC.
The voltage is 5VDC±10%
Y N
Replace PCB “K” (REP 14.37)
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M21H stepper motor PCB LEDs and measuring points

LED D31, VCC (+5VDC).

Deactivated=no voltage present. Activated= LED D1, CPU controlled LED GND measuring point
voltage present, not necessary the correct
voltage level.

LED D2, 12V logic Power in.

Deactivated=no voltage present. Acti-
vated= voltage present, not necessary
the correct voltage level.

VCC (+5VDC) measuring point

+3,3VDC measuring point

LED D30, motor Power in.

Deactivated=no voltage
present. Activated= voltage
present, not necessary the
correct voltage level.

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RAP 038 Stepper Motor Driver M201 PCB ”O” Power off, disconnect [O, P5] and keep [L, P10] disconnected. Check continuity
between all wires from [L, P10] to [O, P5]. Check for short circuits between all
This RAP is for troubleshooting a failed Stepper Motor Driver M201 PCB
wires connected to [O, P5], and between all wires from [O, P5] to chassis.
The primary objective is to check whether PCB communicates correctly and logic voltages
are OK. There is continuity and no short circuit
Y N
Initial Actions
Repair/replace harness
• Ensure that plugs/jacks J/P309, J/P312, J/P111, J/P311 and J/P211 are properly con-
nected. Reconnect [L, P10] and [O, P5], disconnect [O, P6], power on.
• Ensure that all DIP switch settings on PCBs “A”, “G”, “H”, “L”, “K” and “O” are correct D2 Blue LED at PCB “K” is activated
(see GP’s) Y N
• Ensure that all connectors to “A”, “B”, “G”, “H”, “K”, “L”, “O” PCBs are properly connected Replace PCB “O” (REP 14.37)
Go to RAP 033 Motor Relay
Procedure Measure VDC between GND and VCC (see image on previous page).
The voltage is 5VDC±10%
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before Y N
disconnecting, removing or replacing any electrical components or measuring Power off, disconnect [O, P3], measure VDC between GND and VCC.
resistance inside the machine. The voltage is 5VDC±10%
Y N
Power on the machine. If D2 Blue LED on PCB “O” is deactivated, go directly to N (it means Replace PCB “O” (REP 14.37)
no 12VDC). If D2 activated, measure VDC between [O, P5-1] to [O, P5-10]. Go to RAP 008 M101/M201 home position sensor not activated in time/activated
The voltage is 12VDC±10% too long (pay attention to short circuit measurements).
Y N Measure VDC between GND and 3,3VDC (see imagex).
Power off, disconnect [L, P10]. Power on. The voltage is 3,3VDC±5%
D5 Blue LED at PCB “L” is activated Y N
Y N Replace PCB “O” (REP 14.37)
Go to RAP 028 CPU PCB “L” Go to RAP 004 No ICAN Communication entry RAP

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RAP 039 Stepper Motor Driver M301 PCB ”G” There is continuity and no short circuit
This RAP is for troubleshooting a failed Stepper Motor Driver M301 PCB Y N
Target is to check if the PCB communicates correctly and logic voltages are OK. Repair/replace harness
Initial Actions Leave [G, P5] and [B, P2] disconnected, power on. If D4 Blue LED on PCB “B”
is deactivated, go directly to N (it means no 12VDC). If D4 is activated, measure
• Ensure that plugs/jacks J/P309, J/P312, J/P111, J/P311 and J/P211 are properly con-
VDC at PCB connector [B, J2] between [B, J2-14] and [B, J2-13].
nected
• Ensure that all dip switch settings on PCBs “A”, “G”, “H”, “L”, “K” and “O” are correct The voltage is 12VDC±10%
(see GP’s) Y N
• Ensure that all connectors to “A”, “B”, “G”, “H”, “K”, “L”, “O” PCBs are properly connected. Replace PCB “B”
Replace PCB “G”
Measure VDC between GND and VCC (see image on page 4-328)
Procedure
The voltage is 5VDC±10%
WARNING! Y N
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before Replace PCB “G”
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine. Measure VDC between GND and 3,3VDC (see image on page 4-328)
The voltage is 3,3VDC±5%
Y N
Power on the machine. If D2 Blue LED on PCB “G” is deactivated, go directly to N (it means
Replace PCB “G”
no 12VDC). If D2 is activated, measure VDC between [G, P5-1] to [G, P5-10]
Go to RAP 004 No ICAN Communication entry RAP
The voltage is 12VDC±10%
Y N
Power off, disconnect [G, P5] and [B, P2], check continuity between all wires from
[G, P5] to [B, P2], check short circuits between all wires connected to [G, P5], and
between all wires from [H, P5] to chassis.

Image, measuring points on page 4-324

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RAP 040 Stepper Motor M101 PCB 48V Very Low RAP 041 Stepper Motor M201 PCB 48V Very Low
This RAP is for troubleshooting a very low 48V related to Stepper Motor M101 PCB “K”. This RAP is for troubleshooting a very low 48V related to Stepper Motor M201 PCB “O”.
The primary objective is to determine if the failure is related to the PCB or the harness. The primary objective is to determine if the failure is related to the PCB or the harness.
Initial Actions Initial Actions
• Make sure that plugs/jacks P310/J310 and P312/J312 are properly connected • Make sure that plugs/jacks P310/J310 and P312/J312 are properly connected
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL301, • Make sure that all connectors connecting to the Door Switch(S301/S302), REL301,
REL302, PSU (24V) and PSU (24/48V) are properly connected REL302, PSU (24V) and PSU (24/48V) are properly connected
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N”, “O” • Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N”, and
PCBs are properly connected “O” PCBs are properly connected

Procedure Procedure
WARNING! WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine. resistance inside the machine.

Power off the machine, disconnect [C, P2], [D, P2] and [K, P9]. Measure continuity between Power off the machine, disconnect [C, P2], [D, P2] and [O, P9]. Measure continuity between
[K, P9] Orange and Black wires to [C, P2] and [D, P2]. Check for short circuits between [O, P9] Orange and Black wires to [C, P2] and [D, P2]. Check for short circuits between
Black and Orange wires, also check for short circuits from Orange wire to chassis. Black and Orange wires, also check for short circuits from Orange wire to chassis.
There is continuity and no short circuit There is continuity and no short circuit
Y N Y N
Repair/replace harness Repair/replace harness
Disconnect all connectors connected to PCB “K”. Disconnect all connectors connected to PCB “O”.
Check short circuit between [J9-1] to [J9-2] (PCB connector). Check short circuit between [J9-1] to [J9-2] (PCB connector).
There is no short circuit There is no short circuit
Y N Y N
Replace PCB “K” Replace PCB “O”
Keep connectors disconnected and disconnect M101 Motor Connector. Check short circuit Keep connectors disconnected and disconnect M201 Motor Connector. Check for short cir-
between all wires at [P7] and Motor connector (harness connector), between all wires at cuits between all wires at [P7] and Motor connector (harness connector), between all wires
[P7] to chassis and all wires at Motor connector (harness connector) to chassis. at [P7] to chassis and all wires at Motor connector (harness connector) to chassis.
There is no short circuit There is no short circuit
Y N Y N
Repair/replace harness Repair/replace harness
Swap the Stepper Motor M101 PCB “K” with Stepper Motor M201 PCB “O”, make sure that Swap the Stepper Motor M201 PCB “O” with Stepper Motor M101 PCB “K”, make sure
DIP-switches are correctly set (see GP’s) and all connectors are properly installed at both SW1 is correctly set and all connectors are properly installed at both PCBs before power on
PCBs before powering on the machine. Power on the machine. the machine. Power on the machine.
Still “Stepper Motor M101 PCB 48V very low” Still “Stepper Motor M201 PCB 48V very low”
Y N Y N
Replace the original Stepper Motor M101 PCB “K” Replace the original Stepper Motor M201 PCB “O”
Exit Exit

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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 RAP 042 Stepper Motor M301 PCB 48V Very Low
This RAP is for troubleshooting a very low 48V related to Stepper Motor M301 PCB “G”.
The primary objective is to determine if the failure is related to the PCB or the harness.
Initial Actions
• Make sure that plugs/jacks P310/J310 and P312/J312 are properly connected
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL301,
REL302, PSU (24V) and PSU (24/48V) are properly connected
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N”, and
“O” PCBs are properly connected

Procedure
WARNING!
Turn off the AF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power off the machine, disconnect [C, P2], [D, P2] and [G, P9]. Measure continuity between
[G, P9] Orange and Black wires to [C, P2] and [D, P2]. Check for short circuits between
Black and Orange wires, also check for short circuits from Orange wire to chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Disconnect all connectors connected to PCB “G”.
Check for short circuits between [J9-1] to [J9-2] (PCB connector).
There is no short circuit
Y N
Replace PCB “G”
Keep connectors disconnected and disconnect M301 Motor Connector. Check for short cir-
cuits between all wires at [P7] and Motor connector (harness connector), between all wires
at [P7] to chassis and all wires at Motor connector (harness connector) to chassis.
There is no short circuit
Y N
Repair/replace harness
Swap the Stepper Motor M301 PCB “G” with Stepper Motor M101 PCB “K”, make sure
SW1 is correctly set and all connectors are properly installed at both PCBs before power on
the machine. Power on the machine.
Still “Stepper Motor M301 PCB 48V very low”
Y N
Replace the original Stepper Motor M301 PCB “G”
Exit

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VF602 FAULT CODE DESCRIPTIONS 300 Exit Miss
Goto RAP 300
Entry RAP 301 Exit Error
Goto RAP 301
This RAP determines the correct starting point to analyse all issues within the system.
Always start with this RAP before you proceed to an actual RAP. 302 No Feed Sequence
Goto RAP 302
Initial Actions
Run system to verify reported fault. 1001 Fan101 Bin A Pulse Timeout
Enter service mode Goto RAP 011 Fan x pulse time out
Run diagnostics for the VF602. 1002 Fan102 Bin A Pulse Timeout
Goto RAP 011 Fan x pulse time out
Procedure
1003 Fan103 Bin A Pulse Timeout
WARNING! Goto RAP 011 Fan x pulse time out
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before 1004 Fan104 Bin A Pulse Timeout
disconnecting, removing or replacing any electrical components or measuring Goto RAP 011 Fan x pulse time out
resistance inside the machine.
1005 Fan201 Bin B Pulse Timeout
Goto RAP 011 Fan x pulse time out
A fault code is displayed on the UI
1006 Fan202 Bin B Pulse Timeout
Y N Goto RAP 011 Fan x pulse time out
Run the job that caused the problem 1007 Fan203 Bin B Pulse Timeout
Perform the RAP for the fault code displayed. Goto RAP 011 Fan x pulse time out
A fault code is displayed on the UI 1008 Fan204 Bin B Pulse Timeout
Y N Goto RAP 011 Fan x pulse time out
Run several or all jobs that customer have and check reliability 1009 Q301 USDS Error Bín A
Perform the RAP for the fault code displayed. Goto RAP 003 Ultrasonic DSD
1010 Q302 USDS Error Bín B
Goto RAP 003 Ultrasonic DSD
Fault Codes 1011 Q102 USDSD Error Bin A
Goto RAP 002 Ultrasonic DSD
1012 Q202 USDSD Error Bin B
100/200 Misfeed Goto RAP 002 Ultrasonic DSD
Goto RAP 100/200
1013 No XCAN Communication
101/201 Jam, Too Long, Bin A/B Goto RAP 005 No XCAN Communication
Goto RAP 101/201
1014 Stepper Motor M101 PCB (K) No Communication
102/202 Too Long Bin A/B Goto RAP 037 Stepper Motor Driver M101 PCB ”K”
Goto RAP 102/201
1015 Stepper Motor M201 PCB (O) No Communication
103/203 Too short Bin A/B Goto RAP 038 Stepper Motor Driver M201 PCB ”O”
Goto RAP 103/203
1016 Stepper Motor M301 PCB (G) No Communication
104/204 Too thick Bin A/B Goto RAP 039 Stepper Motor Driver M301 PCB ”G”
Goto RAP 104/204
1017 Bin A CPU PCB (H) No Communication
105/205 DSD Functionality Uncertain, Bin A/B Goto RAP 026 CPU PCB ”A”
Goto RAP 105/205
1018 Bin B CPU PCB (L) No Communication
106/206 Too Thick US DSD, Bin A/B Goto RAP 028 CPU PCB ”L”
Goto RAP 106/206
1019 Stepper Motor M101 PCB (K) 48 Voltage Very Low
107/207 Bin Empty, Bin A/B Goto RAP 020 24V/48V very low entry RAP
Goto RAP 107/207

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1020 Stepper Motor M201 PCB (O) 48 Voltage Very Low Goto RAP 018 12/24/48V low or high
Goto RAP 020 24V/48V very low entry RAP 1043 Bin B CPU PCB (L) 12 Voltage Low
1021 Stepper Motor M301 PCB (G) 48 Voltage Very Low Goto RAP 018 12/24/48V low or high
Goto RAP 020 24V/48V very low entry RAP 1044 App CPU (A) 12 Voltage Low
1022 Stepper Motor M101 PCB (K) 48 Voltage Low Goto RAP 018 12/24/48V low or high
Goto RAP 020 24V/48V very low entry RAP 1045 App CPU EEPROM Error
1023 Stepper Motor M201 PCB (O) 48 Voltage Low Goto RAP 007 EEPROM
Goto RAP 020 24V/48V very low entry RAP 1046 Q103 Home Postion Sensor M101 Not Activated in Time
1024 Stepper Motor M301 PCB (G) 48 Voltage Low Goto RAP 008 M101/M201 home position sensor not activated in time/activated
Goto RAP 020 24V/48V very low entry RAP too long
1025 Bin A CPU PCB (H) 24 voltage very low 1047 Q103 Home Postion Sensor M101 Not Deactivated in Time
Goto RAP 022 BIN A 24V very low Goto RAP 008 M101/M201 home position sensor not activated in time/activated
1026 Bin B CPU PCB (L) 24 voltage very low too long
Goto RAP 022 BIN B 24V very low 1048 Q203 Home Postion Sensor M201 Not Activated in Time
1027 Bin A CPU PCB (H) 24 Voltage Low Goto RAP 008 M101/M201 home position sensor not activated in time/activated
Goto RAP 018 12/24/48V low or high too long
1028 Bin B CPU PCB (L) 24 Voltage Low 1049 Q203 Home Postion Sensor M201 Not Deactivated in Time
Goto RAP 018 12/24/48V low or high Goto RAP 008 M101/M201 home position sensor not activated in time/activated
too long
1029 Stepper Motor M101 PCB (K) 48 Voltage Very High
Goto RAP 018 12/24/48V low or high 1054 Interlock Missmatch, No Interlock with Power
Goto RAP 032 Interlock mismatch
1030 Stepper Motor M201 PCB (O) 48 Voltage Very High
Goto RAP 018 12/24/48V low or high
1031 Stepper Motor M301 PCB (G) 48 Voltage Very High 1055 Bin A Didn’t Open
Goto RAP 018 12/24/48V low or high Goto RAP 015 Bin A/B opening
1032 Stepper Motor M101 PCB (K) 48 Voltage High 1056 Bin B Didn’t Open
Goto RAP 018 12/24/48V low or high Goto RAP 015 Bin A/B opening
1033 Stepper Motor M201 PCB (O) 48 Voltage High 1057 Software Versions Machine Mismatch
Goto RAP 018 12/24/48V low or high Check Software version in VF602, (GP 17)
1034 Stepper Motor M301 PCB (G) 48 Voltage High 1058 Software Versions System Mismatch CST500
Goto RAP 018 12/24/48V low or high Check Software version in VF602, (GP 17)
1035 Bin A CPU PCB (H) 24 Voltage Very High 1059 Software Versions System Mismatch BM500
Goto RAP 018 12/24/48V low or high Check Software version in VF602, (GP 17)
1036 Bin B CPU PCB (L) 24 Voltage Very High 1060 Software Versions System Mismatch FTR500
Goto RAP 018 12/24/48V low or high Check Software version in VF602, (GP 17)
1037 Bin A CPU PCB (H) 24 Voltage High 1061 Software Versions System Mismatch SQF500
Goto RAP 018 12/24/48V low or high Check Software version in VF602, (GP 17)
1038 Bin B CPU PCB (L) 24 Voltage High
Goto RAP 018 12/24/48V low or high Fault Codes Only Presented at Performed Diagnostics
1039 Stepper Motor M101 PCB (K) 12 Voltage Low 1064 Q105 Bin Empty Sensor Activated, Bin A Loaded
Goto RAP 018 12/24/48V low or high Check if paper is present in Bin. if not goto RAP 107/207
1040 Stepper Motor M201 PCB (O) 12 Voltage Low 1065 Q205 Bin Empty Sensor Activated, Bin B Loaded
Goto RAP 018 12/24/48V low or high Check if paper is present in Bin. if not goto RAP 107/207
1041 Stepper Motor M301 PCB (G) 12 Voltage Low 1066 Q101 Optical DSD Sensor Bin A Open Circuit
Goto RAP 018 12/24/48V low or high Goto RAP 001
1042 Bin A CPU PCB (H) 12 Voltage Low

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1067 Q201 Optical DSD Sensor Bin B Open Circuit
Goto RAP 001
1068 Q101 Optical DSD Sensor Bin A Paper Present
Check if paper is present at sensor. If not goto RAP 001
1069 Q201 Optical DSD Sensor Bin B Paper Present
Check if paper is present at sensor. If not goto RAP 001
1070 Q303 Exit Sensor, Output Paper Present
Check if paper is present at sensor. If not goto RAP 300
1073 Q102 US DSD Sensor, Paper Detect Bin A Paper Present
Check if paper is present at sensor. If not goto RAP 002
1074 Q202 US DSD Sensor, Paper Detect Bin B Paper Present
Check if paper is present at sensor. If not goto RAP 002
1075 Bin A Open
Goto RAP 025
1076 Bin B Open
Goto RAP 025
1077 Stepper Motor M101 PCB (K) Current Malfunction
Goto RAP 037
1078 Stepper Motor M201 PCB (O) Current Malfunction
Goto RAP 038
1079 Stepper Motor M301 PCB (G) Current Malfunction
Goto RAP 039
1080 Fan105 Bin A Pulse Timeout
Goto RAP 011 Fan x pulse time out
1081 Fan106 Bin A Pulse Timeout
Goto RAP 011 Fan x pulse time out
1082 Fan205 Bin B Pulse Timeout
Goto RAP 011 Fan x pulse time out
1083 Fan206 Bin B Pulse Timeout
Goto RAP 011 Fan x pulse time out
1084 SP Sensor Bin A PCB (X)
Goto RAP 043 SP Sensor
1085 SP Sensor Bin B PCB (Y)
Goto RAP 043 SP Sensor

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VF602 RAPs
RAP 100/200 Misfeed Bin A/B
Misfeed is a paper flow error detection. Misfeed checks if a sheet is moved correctly from
paper pile to optical DSD sensor. Time is measured from the start of the drive roller (used
to feed and separate a sheet from the paper pile) until the optical DSD sensor can see the
leading paper edge. A Misfeed condition is generated if this measured time is too long.
Initial Actions
• Ensure that all connectors to the optical DSD sensor are properly connected
• Ensure that DSD sensor Q101/201 is clean
• Check that there are no obstructions in the paper path
• Ensure that DSD sensor Q101/201 is calibrated (BM500 Operators Manual, VF602
Sensor Calibration Section)

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
• Enter the Service Mode (GP 1)
• Check optical DSD sensor Q101/201 (GP 4)
DSD Sensor (Q101/201) works
Y N
Perform RAP 001 Optical DSD sensor
Check drive clutch, roller and vacuum bands according to RAP 012
Drive clutch and roller works
Y N
Perform RAP 012 Drive clutch and roller
Check M1 Drive Motor (15.30)
M1 Drive motor works
Y N
Perform RAP 013 M301 Drive Motor
Check M2/M3 Elevator Motor according to (15.17)
M2/M3 Elevator motor works
Y N
Perform RAP 014 M101/M201 Elevator Motor
Check Empty Sensor according to GP 4
Empty Sensor works
Y N
Perform RAP 107/207 Empty Sensor
Perform RAP 044 Vacuum Solenoid and Brake Clutch

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RAP 101/201 Jam, Too Long, Bin A/B RAP 105/205 DSD Functionality Uncertain, Bin A/B
Jam is a paper flow error detection. Jam checks if a sheet is moved past the optical DSD DSD functionality uncertain is a warning that can be generated at calibration. DSD func-
sensor correctly. Time is measured from when the optical DSD sensor sees the leading tionality uncertain checks if the sheet thickness is within reading range for the optical DSD
paper edge until the optical DSD sensor sees the trailing paper edge. A Jam condition is sensor.
generated if this measured time is too long. Actions: See RAP 104/204
Actions: See 100/200 RAP
RAP 106/206 Too Thick US DSD, Bin A/B
RAP 102/202 Too Long, Bin A/B
Too thick US DSD is a paper thickness error detection. Too thick US DSD checks if a sheet
Too Long is a paper length error detection. Too long checks if a sheet is too long when it is too thick when it passes the ultrasonic DSD sensor Q102/202. When the ultrasonic DSD
passes the optical DSD sensor Q101/201. Time is measured from when the optical DSD sensor sees the leading paper edge, thickness is measured. A Too Thick condition is gener-
sensor sees the leading paper edge until the optical DSD sensor sees the trailing paper ated if the measured thickness on a sheet is too thick.
edge. A Too Long condition is generated if the measured time is too long, but not long
enough to generate a Jam. Initial Actions
• Enter service mode (GP 1)
Actions: See RAP 100/200
• Check sensor according to GP 4
• Ensure that sensor is clean
RAP 103/203 Too Short, Bin A/B • Ensure that all connectors at the sensor are properly connected
• Ensure that all connectors at PCB CPU (H/L) are properly connected.
Too Short is a paper length error detection. Too Short checks if a sheet is too short when it
passes the optical DSD sensor Q101/201. Time is measured from the situation when the
NOTE!
optical DSD sensor sees the leading paper edge until the optical DSD sensor sees the trail-
For measuring references see BSD (next page)
ing paper edge. A Too Short condition is generated if the measured time is too short.
Actions: See RAP 100/200
Procedure
RAP 104/204 Too Thick, Bin A/B WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
Too Thick is a paper thickness error detection. Too Thick checks if a sheet is too thick when
disconnecting, removing or replacing any electrical components or measuring
it passes the optical DSD sensor Q101/201. When the optical DSD sensor sees the leading
resistance inside the machine.
paper edge, thickness is measured. A Too Thick condition is generated if the measured
thickness on a sheet is too thick compared to the calibration sheet. Swap the faulty USDS sensor with the one in the other bin.
Does the sensor work at new location
Initial Actions
Y N
• Ensure that all connectors to the optical DSD sensor are properly connected
• Ensure that DSD sensor is clean Perform RAP 002 Ultrasonic DSD (Double Sheet Detection)
• Check that there are no obstructions in the paper path Exit
• Ensure that DSD sensor is calibrated (BM500 Operators Manual, VF602 Sensor Calibra-
tion Section)

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
Enter the Service Mode (Service tables)
Check optical DSD sensor Q101/201 according to GP 4
DSD Sensor Q101/201 works OK
Y N
Perform RAP 001 Optical DSD sensor BSD on next page
Exit

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 107/207 Bin Empty, Bin A/B
Bin Empty is a paper present detection. Bin Empty checks if sheets are present in the
activated bin during process. A Bin Empty condition is generated if sensor Q105/205 cannot
see any paper.
Initial Actions
• Enter service mode
• Check sensor according to GP 4
• Ensure that sensor is clean
• Ensure that all connectors at the sensor are properly connected
• Ensure that all connectors at PCB CPU App 32 (L / H) are properly connected.
NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Swap the faulty sensor with the sensor in the other bin. After swapping the sensors check
the Empty sensor functionality.
Sensor works at the new location
Y N
Replace the sensor
At the faulty location, disconnect sensor wire both from PCB and sensor. Check all wires
(red, white, black) for short circuit and continuity.
There is continuity and no short circuit
Y N
Repair/replace harness
Swap PCB (that the faulty Empty sensor is connected to) with the PCB in the other bin.
After swapping the PCB, set the address DIP switches to the settings shown in the circuit
diagram.
Empty sensor works at new PCB location
Y N
Replace the PCB
Exit

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RAP 108/208 Too Thin, Bin A/B
Too Thin is a paper thickness error detection. Too Thin checks if a sheet is too thin when it
passes the optical DSD sensor Q101/201. When the optical DSD sensor sees the leading
paper edge, thickness is measured. A Too Thin condition is generated if the measured
thickness on a sheet is too thin compared to the calibration sheet.
Initial Actions
• Ensure that all connectors to the optical DSD sensor are properly connected
• Ensure that DSD sensor is clean
• Check that there are no obstructions in the paper path
• Ensure that DSD sensor is calibrated (BM500 Operators Manual, VF602 Sensor Calibra-
tion Section)

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
Enter the Service Mode (GP 1)
Check optical DSD sensor Q101/201 according to GP 4
DSD Sensor Q101/201 works OK
Y N
Perform RAP 001 Optical DSD sensor
Exit

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RAP 300 Exit Miss
Exit Miss is a paper flow error detection. Exit Miss checks if a sheet gets stuck between op-
tical DSD sensor Q101/201 and Exit sensor Q303. Time is measured from when the optical
DSD sensor sees the trailing paper edge until the Exit sensor sees the trailing paper edge.
An Exit Miss condition is generated if this measured time is too long.
Initial Actions
• Enter service mode according to GP 1
• Check sensors according to GP 4
• Ensure that Exit sensor is clean
• Ensure that the Exit sensor is properly connected
• Ensure that all connectors at PCB CPU “A” are properly connected.

NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Swap the faulty sensor with one Empty sensor. After swapping, check the sensor function-
ality.
Does the sensor work at new location
Y N
Replace the sensor
At the faulty location, disconnect sensor wire both from PCB and sensor. Check all wires
(red, white, black) for short circuit and continuity.
There is continuity and no short circuit
Y N
Repair/replace harness
Replace PCB “A”

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RAP 301 Exit Error RAP 302 No Feed Sequence
Exit Error is a paper flow error detection. Exit Error checks if a sheet has moved past the No Feed Sequence is a startup error detection. No Feed Sequence checks if a feeding
Exit sensor Q303 correctly. Time is measured from when the Exit sensor sees the leading sequence has been programmed. No Feed Sequence is generated if the machine is started
paper edge until the Exit sensor sees the trailing paper edge. An Exit Error is generated if without a programmed feeding sequence.
this measured time is too long.
Initial Actions This is caused by an operator error. Nothing else can cause this.
• Ensure that the Exit sensor is properly connected
• Ensure that the Exit sensor is clean
• Check that there are no obstructions in the paper path

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Enter service mode

Check exit sensor according to GP 4
Sensor works OK
Y N
Perform RAP 300 Exit miss
Check M301 Drive Motor according to GP 4
Drive Motor (M1) works OK
Y N
Perform RAP 039 Stepper Motor Driver M301 PCB ”G”
Check that transportation drive and idler rollers are in good working order
Drive and idler rollers are OK
Y N
Fix problem
Ensure that VF602 is correctly installed. Check first for paper path misalignment and inter-
face cables
Installation is OK
Y N
Re-install VF602
Exit

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RAP 401 No Answer on PAC (Propose, Accept, Confirm)
When the Feeder wants to start feeding it asks for status from the downstream device (BM
or RCT). If no response is received within a specified time, fault 401 is displayed.

Initial Actions
• Make sure that the communication cable is properly connected
• See Service Manual BM500-3 Section 4 BM-158 or
Service Manual CST500 Section 4 CST-150

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RAP 001 Optical DSD Sensor

Initial Actions
• Enter service mode according to GP 1
• Check sensor according to GP 4
• Ensure that optical DSD LED and DSD PhT is clean
• Ensure that all connectors at the DSD LED and sensor are properly connected
• Ensure that all connectors at PCB ‘H’ and ‘L’ are properly connected.
• Ensure that DSD sensor is calibrated (BM500 Operators Manual, VF602 Sensor Calibra-
tion Section)

NOTE!
For measuring references see BSD
A DSD sensor includes one DSD LED (transmitter) and one DSD PhT (receiver)

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Swap the faulty optical DSD PhT with one in the other bin.
Sensor works at new location
Y N
Replace DSD PhT
Swap the faulty optical DSD LED with one in the other bin
LED works at new location
Y N
Replace DSD LED
At the faulty location, disconnect DSD PhT and DSD LED wires from PCB, DSD LED and
DSD PhT. Check all wires (white, black) to DSD PhT and (red, black) to DSD LED for short
circuits and continuity. Also check for short circuits between wires and chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Swap PCB that faulty optical DSD sensor is connected to with the one in the other bin.
After swapping the PCB, set the address DIP switches to the settings shown in the circuit
diagram. Check sensor functionality.
The optical DSD sensor at new PCB location works
Y N
Replace the original CPU PCB (The one that causes the failure)
Exit

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RAP 002 Ultrasonic DSD (Double Sheet Detection) Still no functionality at the original location (BIN)
This RAP is for troubleshooting the US (Ultrasonic) DSD sensor. Y N
The primary objective is to determine if the failure is related to the PCB, sensor or harness. Replace the original US DSD sensor transmitter/receiver package (The one that
causes the failure).
Initial Actions
Power off, swap the CPU PCB (set DIP switches correctly between the two BINs. After the
• Make sure that plugs/jacks J/P112, J/P211, J/P311, J/P212, P310/J310, J/P107, J/P207,
transmitter, receiver and CPU have been moved to the other bin: power on, recalibrate the
J/P111X, J/P211X and P312/J312 are properly connected
sensor and check functionality.
• Make sure that all connectors connecting to the US (Ultrasonic) DSD sensor (both trans-
mitter and receiver) are properly connected Still no functionality at the original location (BIN)
• Ensure that all connectors to “H”, “I”, “L” and “M” PCBs are properly connected. Y N
• Recalibrate the sensor and check functionality (BM500 Operators Manual, VF602 Sensor Replace the original CPU PCB (The one that causes the failure).
Calibration Section) Exit

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power off the machine, disconnect CPU PCB connector [P1], 24V Distribution PCB con-
nector [P2] and Sensor connectors at US DSD sensor transmitter and receiver. Measure
continuity between all wires from PCB connectors to Sensor connectors.
There is continuity
Y N
Repair/replace harness
Check short circuits between all wires at CPU connectors and between all wires at CPU
connectors to chassis.
There is no short circuit
Y N
Repair/replace harness
Reconnect all connectors, power on and close the door (activate door switch).
LED D1 at the 24V Distribution PCB I or M activates
Y N
Go to RAP 022 / RAP 023 BIN A / B 24V very low
Power off, swap the US DSD sensor receiver between the two BINs, power on, recalibrate
the sensor and check functionality.
Still no functionality at the original location (BIN)
Y N
Replace the original US DSD sensor transmitter/receiver package (The one that
causes the failure)
Power off and swap the US DSD sensor transmitter between the two BINs. After both the
transmitter and receiver have been moved to the other bin: power on, recalibrate the sensor
and check functionality.

DIP settings on previous page

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RAP 003 Ultrasonic DS (Distance Sensor) Q301 / Q302
This RAP is for troubleshooting the US (Ultrasonic) DS sensor.
The primary objective is to determine if the failure is related to the PCB, sensor or harness.
Initial Actions
• Make sure that plugs/jacks A/P2, A/P3, A/P4, A/P5, A/P6 and A/P10 are properly con-
nected.
• Make sure that the connector connecting to the USDS sensor is properly connected.
• Ensure that all connectors to PCB ‘A’ are properly connected.
• Enter service mode according to GP 1 and check functionality of sensor (GP 4)

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
Swap the faulty USDS sensor with the sensor in the other bin. After swapping the sensors,
check USDS sensor functionality.

Does sensor work at new location?

Y N
Replace sensor
At the faulty location, disconnect sensor wire booth from PCB and sensor ([J/P303] or [J/
P304]). Check all wires (red, white, black, grey) for short circuits and continuity. Also check
for short circuits between all wires to chassis.
There is continuity and no short circuit?
Y N
Repair Harness
Reconnect all connectors and Power on, measure VDC on sensor between pin 1 (red) and
pin 4 (black)
The voltage is 5VDC±10%
Y N
Replace PCB “A”
Exit

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RAP 004 No ICAN Communication Entry
This RAP is for troubleshooting a failed ICAN circuit.
The RAP checks wires and PCBs for short/open circuits and if the ICAN termination is OK.
Initial Actions
• Make sure that plugs/jacks J/P309, J/P312, J/P111, J/P111X, J/P211X and J/P211 are
properly connected (reference Master Wiring Diagram)
• Make sure that all DIP switch settings on CPU PCBs and Stepper Motor Driver PCBs are
correct (See GP’s)
• Ensure that all connectors to “A”, “B”, “G”, “H”, “K”, “L”, “O”, “CC”, and “Y” PCBs are
properly connected

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

There are multiple codes related to ICAN communication failure

Y N
Perform the PCB “x” RAP for the PCB “x” mentioned in the failure code
PCB ‘x’ RAP solved the problem
Y N
Perform RAP 006 ICAN Circuit
ICAN Circuit RAP solved the problem
Y N
Replace the PCB “x”
Exit
Exit
Check D5 Blue LED on PCBs “A”, “H” and “L”, D20 LED on PCBs “CC” and “Y”, and D2
Blue LED on PCBs “G”, “K” and “O”. If diode is not activated there is no 12V to the PCB.
All diodes are activated
Y N
Perform the PCB “x” RAP for the PCB “x” with the deactivated LED.
PCB ‘x’ RAP solved the problem
Y N
Perform RAP 006 ICAN Circuit
ICAN Circuit RAP solved the problem
Y N
Replace the PCB “x”
Exit
Exit
Perform RAP 006 ICAN Circuit
BSD on next page

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 005 No XCAN (External) Communication
This RAP is for troubleshooting XCAN communication failure (no communication between
machines in the system).
The primary objective of this RAP is to determine the source of failure.
Initial Actions
• Ensure that plugs/jacks J/P309, J/P312, J/P111, J/P311, J/P23, J/P24, J/P111X, J/P211X
and J/P211 are properly connected (reference Master Wiring Diagram)
• Ensure that all DIP switch settings on PCBs “A”, “G”, “H”, “L”, “K” and “O” are correct
(See GP’s)
• Ensure that all connectors to SW1, PSU (12V) and “A”, “B”, “G”, “H”, “K”, “L”, “O” ,“CC”,
and “Y” PCBs are properly connected

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
WARNING!
Use caution when making the voltage measurements and always disconnect the
Power Cord when it is necessary to work inside the Power Module. AC Power is pre-
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet.

Power on the machine. Measure between [B, P1-6] to [B, P1-1]

The voltage is 12VDC±10%
Y N
Power off and disconnect the Power Cord, check status of fuse F1 located in the
power inlet.
F1 is blown
N Y
Go to RAP 031 F1 Blown Fuse
Go to RAP 034 PSU (12V)
Go to RAP 026 CPU PCB “A”

BSDs on next to next pages

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 006 ICAN Circuit
This RAP is for troubleshooting a failed ICAN circuit related to multiple PCBs. Locate the open circuit by performing following steps:
The primary objective is to check wires and PCBs for short/open circuits and check if the Check open circuit between (CAN termination check) [J5-4] to [J5-6] on
ICAN termination is OK. PCBs “G” and “K”. Replace the failed PCB
Initial Actions Locate the short circuit by performing the following steps:
Harness check:
• Make sure that plugs/jacks J/P309, J/P312, J/P111, J/P111X, J/P211X and J/P211 are 1. Disconnect all [P6] and [P10] connectors on PCBs “A”, “H” and “L”.
properly connected 2. Disconnect all [P5] and [P6] connectors on PCBs “G”, “K” and “O”.
• Make sure that all DIP switch settings on CPU PCBs and Stepper Motor Driver PCBs are 3. Disconnect all [P1] connectors on PCBs “CC”, and “Y”.
correct (See GP’s) 4. Check short circuits between all Red and Black wires, between all White and
• Ensure all connectors to “A”, “B”, “G”, “H”, “K”, “L”, “O” , “CC”, and “Y” PCBs are properly Brown wires, all Yellow and Green wires and all wires to chassis included in the
connected ICAN circuit, check BSD.
PCBs check:
1. Check short circuit between [J6-4] to [J6-6] and [J10-4] to [J10-6] on PCBs “A”,
Procedure “H” and “L”.
WARNING! 2. Check short circuit between [J5-4] to [J5-6] and [J6-4] to [J6-6] on PCBs “G”,
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before “K” and “O”
disconnecting, removing or replacing any electrical components or measuring 3. Check for short circuit between [J1-4] to [J1-6] and [J1-5] to [J1-] on PCBs
resistance inside the machine. “CC” and “Y”
Repair/replace harness or replace PCB depending on the source of short circuit.
Power off the machine, check continuity between wire from [P309-5] to [G, P6-4] and wire
from [P309-7] to [G, P6-4]. (ICAN Start to ICAN End continuity check). Go to RAP 026 CPU PCB A
There is continuity
Y N
Locate the open circuit by performing following steps:
Harness check:
1. Disconnect all [P6] and [P10] connectors on PCBs “A”, “H” and “L”.
2. Disconnect all [P5] and [P6] connectors on PCBs “G”, “K” and “O”.
3. Disconnect all [P1] connectors on PCBs “CC”, and “Y”.
4. Check continuity for all wires included in the ICAN circuit, check BSD.
PCBs check:
1. Check continuity between [J6-4] to [J10-4] and [J6-6] to [J10-6] on PCBs “A”,
“H” and “L”.
2. Check continuity between [J5-4] to [J6-4] and [J5-6] to [J6-6] on PCBs “G”, “K”
and “O”.
3. Check continuity between [J1-4] to [J1-3] and [J1-6] to [J1-5] on PCBs “CC”
and “Y”.
Repair/replace harness or replace PCB depending on the source of open circuit.
Measure resistance between [P309-5] to [P309-7]
The resistance is 50-70 ohms
Y N
The resistance is lower than 50 ohms (short circuit)
Y N
Disconnect [P5] and [P6] on PCB “G” and “K”.
Check DIP switch settings for PCB “G” and “K” (See GP’s)
DIP switch settings are OK
Y N
Set correctly and exit

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RAP 007 EEPROM
This RAP determines if there is corrupted software or if the PCB needs to be replaced.
Initial Actions
No initial action required

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Perform NVM reset according to Service Manual System BM500

Re-load S/W according to Service Manual System BM500
Replace PCB controller according to REP 14.37

RAP 008 M101/M201 Lower Home Position Sensor Not Activated In

Time/Activated Too Long

Initial Actions
• Ensure that all connectors at the home position sensor are properly connected
• Verify that there are no obstructions in the elevator path

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components.

Enter service mode according to GP 1

Check Home Position Sensor according to GP 4
Sensor works OK
Y N
Go to RAP 010 Bin Elevator Upper and Lower Home Position Sensor
Go to RAP 014 M101/M201 Elevator Motor

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RAP 010 Bin Elevator Lower Home Position Sensor

Initial Actions
• Enter service mode (GP 1)
• Check sensors according to GP 4
• Ensure that sensor is clean
• Ensure that all connectors at the sensor are properly connected
• Ensure that all connectors at PCB ‘O’ and PCB ‘K’ are properly connected
NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Swap the faulty sensor with the sensor in the other bin. After swapping the sensors check
the sensor functionality. Does sensor work at new location
Sensor works OK.
Y N
Replace sensor
At the faulty location, disconnect sensor wire both from PCB and sensor. Check all wires
(red, white, black) for short circuit and continuity
There is continuity and no short circuit
Y N
Repair/replace harness
Swap PCB, that the faulty sensor is connected to, with the PCB in the other bin. After swap-
ping the PCB, set the address DIP switches to settings in the circuit diagram. Check sensor
functionality
Does home/outer sensor at new PCB location work
Y N
Replace PCB
Exit

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RAP 011 Fan X Pulse Time Out
Refer to this RAP if any fan in the machine FAN101-FAN106 (upper bin) or FAN201-
FAN206 (lower bin) does not give a pulse.
Initial Actions
• Enter service mode according to GP 1
• Check fan according to GP 4
• Ensure that plug / jack at the side guide are properly connected
• Ensure that all connectors at PCB are properly connected

NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord
before disconnecting, removing or replacing any electrical components or
measuring resistance inside the machine.

Swap the faulty fan with one of the five other fans in bin. After swapping the fan,
check fan functionality.
Fan works at new location
Y N
Replace Fan
At the faulty location, disconnect fan wire both from fan and PCB. Check all wires
between fan and PCB for short circuit and continuity
There is continuity and no short circuit
Y N
Repair/replace harness
Measure 24 volts at Fan location
There are 24 volts at Fan location
Y N
Replace the PCB
Perform RAP 020 24/48 voltage very low entry RAP

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RAP 012 Drive Clutch and Roller
Rotate rollers/vacuum belts and check that shaft
[A] rotates and timing belt [B] does not rotate.
Initial Actions
• Enter service mode (GP 1)
• Ensure that all connectors at the clutch are properly connected
• Ensure that all connectors at PCB ‘K’ and PCB ‘O’ are properly connected

NOTE!
For measuring references see BSD

A B
Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Rotate drive roller manually and check that all drive clutch transmission components are
moving freely.
Transmission works
Y N
Fix problem
Swap the Stepper Motor PCB that the faulty clutch is connected to with the Stepper Motor
PCB in the other bin. After swapping the PCB, set the address DIP switches to the settings
shown in the circuit diagram. Check clutch functionality.
Does the clutch at new PCB location work
Y N
Replace PCB
At the faulty location, disconnect the clutch wire from PCB and clutch. Check all wires
(orange, violet) for short circuits and continuity.
There is continuity and no short circuit
Y N
Replace harness
Swap the faulty clutch with the one in the other bin. Check clutch functionality.
Does clutch at new location work
Y N
Replace clutch
Go to RAP 020 24/48 voltage very low entry RAP

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RAP 013 M301 Drive Motor RAP 014 M101/M201 Elevator Motor

Initial Actions Initial Actions

• Enter service mode according to GP 1 • Enter service mode according to GP 1
• Check motor functionality according to GP 4 • Check motor functionality according to GP 4
• Ensure that all connectors are properly connected to stepper motor PCB • Ensure that all connectors are properly connected to the stepper motor PCB
NOTE! NOTE!
For measuring references see BSD For measuring references see BSD on next page

Procedure Procedure
WARNING! WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine. resistance inside the machine.

Disconnect motor harness from PCB and rotate drive motor M1 manually and check that all Check Bin Interlock according to GP See GP’s.
M1 drive motor transmission components are moving. Does transmission work OK Bin Interlock works
Transmission works Y N
Y N Go to RAP 033 Motor Relay
Fix problem Disconnect motor harness from PCB and rotate elevator belts manually. Check that all M2/
Swap the stepper motor PCB that the faulty motor is connected to with one of the two bin M3 elevator motor transmission components are moving properly.
stepper motor PCB’s. After swapping the PCB, set the address DIP switches to the settings Transmission works
shown in the circuit diagram. Check motor functionality. Y N
Does the motor at new PCB location work Fix problem
Y N Swap the stepper motor PCB that the faulty motor is connected to with the one in the other
Replace PCB bin. After swapping the PCB, set the address DIP switches to settings in the circuit diagram.
At the faulty location, disconnect motor wire from PCB. Check for short circuits between all Check motor functionality.
wires and chassis. Motor works at new location
There are no short circuits Y N
Y N Replace PCB
Repair/replace harness At the faulty location, disconnect motor wire from PCB. Check for short circuits between all
Swap the faulty stepper motor with one of the two bin stepper motors. Check motor func- wires and chassis.
tionality. There are no short circuits
Does motor at new location work Y N
Y N Repair/replace Harness
Replace motor Swap the faulty stepper motor with one of the two bin stepper motors. Check motor func-
Go to RAP 020 24/48 voltage very low entry RAP tionality.
Motor works at new location
Y N
Replace motor
Goto RAP 020 24/48 voltage very low entry RAP

BSD on next page

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 015 Bin A/B Opening
Utilize this RAP when the open bin function does not work for the upper or lower bin
Initial Actions
• Check if bin has actually opened
• Enter service mode (GP 1)
• Check solenoid functionality (GP 4)
• Check bin switch functionality (See GP’s)
• Ensure that all connectors at the solenoid are properly connected
• Ensure that all connectors at PCB ‘I’, ‘H’, ‘M’ and ‘L’ are properly connected

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Manually check that the Damper is strong enough to push the bin out
The damper is strong enough
Y N
Replace damper
Manually check that all solenoid A/B transmission components are easy to move. Also
check that bin moves in and out easily.

Does transmission work OK

Y N
Fix the problem
Swap the faulty solenoid with the one in the other bin. After swapping the solenoids check
the solenoid functionality.
Does solenoid work at new location
Y N
Replace solenoid
Swap PCB that faulty solenoid is connected to with the PCB in the other bin. After swapping
the PCB, set the address DIP switches to settings in the circuit diagram. Check solenoid
functionality.
Does solenoid at new PCB location work
Y N
Replace PCB
Go to RAP 022 / RAP 023 Bin A / B 24V very low

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 RAP 016 Lamp RAP

Initial Actions
Check lamp functionality according to GP See GP’s
Ensure that lamp is clean
Ensure that all connectors at the lamp are properly connected
Ensure that all connectors at PCB ‘H’ and PCB ‘L’ are properly connected.

NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Swap the faulty lamp with the lamp in the other bin. After swapping the lamps, check lamp
functionality.
Lamp works at new location
Y N
Replace lamp (REP 15.22)
At the faulty location, disconnect lamp wires both from PCB and lamp. Check all wires (red,
white, black) to lamp for short circuits and continuity.
There is continuity and no short circuit
Y N
Repair/replace harness
Swap PCB that the faulty lamp is connected to with the one in the other bin. After swap-
ping the PCB, set the address DIP switches to settings in the circuit diagram. Check lamp
functionality.
Does lamp at new PCB location work
Y N
Replace PCB
Exit

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 RAP 017 Counter

Initial Actions
Ensure that all connectors at the counter are properly connected.
Ensure that all connectors at PCB ‘A’ are properly connected.

NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Disconnect Counter and PCB connectors. Check all wires (red, white, black) for short cir-
cuits and continuity. Also check for short circuits between all wires and chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Replace Counter
Replace PCB

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RAP 018 12/24/48V Low or High
This RAP is for troubleshooting a low or high 12V, 24V or 48V
Initial Actions
None

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before 12V
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Adjust to the correct level according to the table below, if there is 48V low, start by checking
and adjusting the 24V level at PSU (24V) before continuing with the PSU (24/48V) adjust- V+ TRIM
ment. V-
12V 12V
NOTE!
Turn the TRIM knob clockwise to increase and counter clockwise to decrease the output
voltage. Note that 1/4 turn is approximately 3,0 VDC.

Ideal level Code alert levels 24/48V

Adjust to
PSU LOW HIGH Measure between
[VDC] [VDC]
[VDC] [VDC]
(12V) 12V <11,5V >12,5V 11.8-12.3 V V- to V+ at PSU(12V)
(24V) 24V 20.0-22.9V 25.1-27.8V 23.8-24.3 V V- to V+ at PSU(24V)
V- at PSU(24V) to V+
(24/48V) 48V 43.6-46.9 V 49.1-66.0 V 47.8-48.3 V
at PSU(24/48V) V- V+
24/48V 24/48V
V+
V-
24V
24V
24V

TRIM

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RAP 019 24/48V Secondary Circuit There is continuity and no short circuit
This RAP is for troubleshooting a very low 24V and/or 48V. Y N
The primary objective is to check the harness between PSUs<>Short Circuit Protection Repair/replace harness
(SCP) PCBs and the functionality of the SCP PCBs.
Leave connectors from previous step disconnected.
Initial Actions Check continuity between [D, P2-5] to [D, P2-12].
• Make sure that plugs/jacks J/P301, P310/J310 and P312/J312 are properly connected There is continuity
(see Master Wiring Diagram) Y N
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL301,
Repair/replace harness
REL302, PSU (24V) and PSU (24/48V) are properly connected
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “I”, “K”, “L”, “M”, “O”, “S” Reconnect [P2] at PCBs “C” and “D.” Leave [P2] at “E”, “F” and [P9] at Stepper Motor Driver
and “R” PCBs are properly connected PCBs “G”, “K” and “O” disconnected. Disconnect [P1] at SCP PCBs “E” and “F”. Power on
the machine and close the door.
Relay at SCP PCB “C” and “D” activates (connectors shorted away from coil) a pe-
riod of time after power on/door closed.
Procedure
Y N
WARNING! Replace PCB “C” and/or “D” depending on which relay that failed.
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before Reconnect [P1] at PCBs “E” and “F,” leave the rest disconnected. Power on the machine
disconnecting, removing or replacing any electrical components or measuring and close the door. Measure voltage (VDC) between [E, J2-1] and [E, J2-3]
resistance inside the machine.
The voltage is 24VDC±10% for at least a short period of time (measure during a peri-
NOTE! od of at least 10 seconds after Power ON). “N” means no reaction at all on the output.
For safety reasons - in case of a “very low/high 24V and/or 48V,” there is a limited time
when voltages are applied to PSU (24V) and PSU (24/48V). This affects the voltage meas- Y N
urements. Please see “24/48 Vdc Interlock/PSU procedure” for further information. Replace PCB “E”
Power off the machine, keep [P2] at “E” and “F” disconnected. Power on the machine and
This RAP assumes that “24V and/or 48V very low entry RAP” has been performed. close the door. Measure voltage (VDC) between [F, J2-1] and [F, J2-3].
Power off the machine, disconnect [P1] at SCP PCBs “D”, “E” and “F”. The voltage is 24VDC±10% for at least a short period of time (measure during a peri-
Measure continuity between wires from PSU (24V) to [P1] for all three PCBs and check for od of at least 10 seconds after Power ON). “N” means no reaction at all on the output.
short circuits between black and red wires. Also, check for short circuits from red wires to Y N
chassis. Replace PCB “F”
There is continuity and no short circuit Exit
Y N
Repair/replace harness
Disconnect [C, P1]. Measure continuity between wires from PSU (24/48V) to [C, P1], check
for short circuits between Orange and Red wires. Also, check for short circuits from Red and
Orange wires to chassis
There is continuity and no short circuit
Y N
Repair/replace harness
Reconnect all connectors, disconnect [P2] at SCP PCBs “C”, “D”, “E” and “F”. Measure
continuity between wires from [C, P2-7] to [D, P2-1]
There is continuity
Y N
Repair/replace harness
Leave connectors from previous step disconnected and disconnect [P9] at Stepper Motor
Driver PCBs “G”, “K” and “O”, check for short circuits between all wires on [C, P2] to chassis
and continuity between position [C, P2-5] to [C, P2-12]. Also check for short circuit between
all Orange wires at [C, P2] to all Black wires at [D, P2]. BSD on next page

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 020 24V/48V Very Low Entry RAP RAP 021 24V/48V Very Low
This RAP gives directions to correct RAP in the case of multiple or single codes This RAP is for troubleshooting a very low 24V and/or 48V.
The primary objective is to to determine if the source of failure is related to the primary or
Initial Actions secondary circuit of the PSUs or if one of the PSUs is broken.
• Make sure that plugs/jacks J/P310, J/P312, J/P112 and J/P212 are properly connected
(reference Master Wiring Diagram)
Initial Actions
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL301, • Make sure that plugs/jacks J/P310, J/P312, J/P112 and J/P212 are properly connected
REL302, PSU (24V) and PSU (24/48V) are properly connected (reference Master Wiring Diagram)
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “I”, “K”, “L”, “M”, “O”,“S” • Make sure that all connectors connecting to the Door Switch(S301/S302), REL301,
and “R” PCBs are properly connected REL302, PSU (24V) and PSU (24/48V) are properly connected
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “I”, “K”, “L”, “M”, “O”,“S”
Procedure and “R” PCBs are properly connected

WARNING! Procedure BSD on previous page

Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before WARNING!
disconnecting, removing or replacing any electrical components or measuring Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
resistance inside the machine. disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
NOTE!
Check service codes For safety reasons - in case of a “very low/high 24V and/or 48V,” there is a limited time
Code is a single code very low 24V at BIN “x” (A or B) when voltages are applied to PSU (24V) and PSU (24/48V). This affects the voltage meas-
Y N urements. Please see “24/48 Vdc Interlock/PSU procedure” for further information.
Code is a single very low 48V at PCB “x”
Y N WARNING!
Go to RAP 021 24V/48V very low Use caution when making the voltage measurements and always disconnect the
Power Cord when it is necessary to work inside the Power Module. AC Power is pre-
24V/48V very low RAP solved the problem
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet.
Y N
Power on the machine and close the door. Measure voltage (VAC) between L and N on the
Perform RAPs in following order: PSU (24V) input
1. RAP 042 Stepper Motor M301 PCB 48V very low
The voltage is 90-264VAC
2. RAP 041 Stepper Motor M201 PCB 48V very low
3. RAP 040 Stepper Motor M101 PCB 48V very low Y N
4. RAP 022 BIN A 24V very low Go to RAP 035 REL301
5. RAP 023 BIN B 24V very low Power off the machine, wait 5 seconds, Power on the machine and close the door. Measure
If no success, replace PCBs in same order. (BINs: replace voltage (VAC) between L and N on the PSU (24/48V) input
both CPU and 24V Distribution PCBs) The voltage is between 90-264VAC
Exit Y N
Perform RAP 040, 041, or 042 Stepper Mot. (M101, M201 or M301) PCB 48V Go to RAP 036 REL302
very low
Power off the machine, wait 5 seconds, disconnect V+ and V- from both PSU (24V) and
Perform RAP 022 or 023 BIN A or B 24V very low PSU (24/48V). Disconnect diodes, power on the machine and close the door. Measure volt-
BIN x 24V very low RAP solved the problem age (VDC) between V+ and V- on the PSU (24V) output
Y N The voltage is 24VDC±10% for at least a short period of time (measure during a
Go to RAP 021 24V/48V very low RAP period of at least 10 seconds after Power ON). “N” means no reaction at all on the
24V/48V very low RAP solved the problem output
Y N Y N
Replace CPU and 24V Distribution PCBs Replace PSU (24V) (REP 3.7.2)
Exit Power off the machine. Keep V+ and V- disconnected, wait 5 seconds, Power on the ma-
chine and close the door. Measure voltage (VDC) between V+ and V- on the PSU (24/48V)
Exit BSD on previous page
output

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The voltage is 24VDC±10% for at least a short period of time (measure during a Reconnect all connectors except [E, P1]. Disconnect SOL101/SOL102 connectors and
period of at least 10 seconds after Power ON). “N” means no reaction at all on the check for short circuits between [I, P1] Red and Black wires.
output There is no short circuit
Y N Y N
Power off the machine, measure resistance for the two diodes when disconnected Disconnect [E, P2], check for short circuits between [I, P1] Red and Black wires
from PSU There is no short circuit
One or both diodes are shorted (resistance<1000 Ohms) N Y
Y N Replace PCB “E”
Replace PSU (24/48V) Disconnect all FAN connectors and Q102 connector. Check for short circuits
Replace diode/diodes between FAN connectors on the FAN side, Black wires to Red wires and between
Go to RAP 019 24/48V secondary circuit Q102 chassis connector pin 3 to pin 6
There is no short circuit
N Y
Disconnect SOL101 and SOL102 connectors. Measure resistance
between connectors on the solenoid for both SOL101 and SOL102.
The resistance is lower than 10 ohms
RAP 022 BIN A 24V Very Low N Y
This RAP is for troubleshooting a very low 24V related to BIN A Replaced the failed solenoid SOL101 or SOL102
Initial Actions Disconnect [S, P1] check for short circuit on PCB connector [S, J1]
• Make sure that plugs/jacks J/P310 and J/P112 are properly connected. between pin 1 and pin 3.
• Ensure that all connectors to “E”, “H”, “I”, “K” and “S” PCBs are properly connected There is no short circuit
Y N
Procedure
Replace PCB “S”
WARNING! Disconnect all connectors to PCB “I”, [S, P1], SOL101/SOL102 connec-
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
tors and leave FAN connectors disconnected. Check for short circuits
disconnecting, removing or replacing any electrical components or measuring
between following positions:
resistance inside the machine.
[I, P1] all Red to all Black wires, all Orange to all Black wires, all Red
and Orange wires to chassis.
Power off the machine, disconnect [E, P1] and [E, P2], measure continuity between PCB [I, P2] all White to all Green wires, all Red to Black wires, all White and
connectors [E, J2-1] and [E, J1-1] (Checking blown fuse at PCB “E”). Red wires to chassis.
There is continuity [I, P3] White to Black wires, White wire to chassis
Y N [I, P4] all Red to all Black wires, all Red wires to chassis
Replace PCB “E” There is no short circuit
The fuse at PCB “E” blows up again at Power on Y N
Y N Repair/replace harness
Exit Disconnect [K, P8] and check for short circuits on PCB connector [K, J8]
Proceed to the next step in this RAP between pin 7 and pin 8
Leave [E, P1] and [E, P2] disconnected and disconnect [I, P1], [I, P3], [I,P4] and [H, P1]. There is no short circuit
Measure continuity for all wires between [E, P2] and [I, P1], check continuity for all wires Y N
between [I, P3] and [H, P1].
Replace PCB “K”
There is continuity
Replace PCB “I”
Y N
Replace the failed FAN/Q102
Repair/replace harness

BSD on next page

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Power off, reconnect [E, P1], swap CPU PCB “H” with CPU PCB “L”, make sure to set DIP
switches correctly (See GP’s) and that all connectors at both PCBs are properly installed
before powering on the machine. Power on machine.
Still “BIN A 24V very low”
Y N
Replace the original CPU PCB “H”
Power off, swap PCB “M” with PCB “I”, make sure all connectors at both PCBs are
properly installed before powering on the machine. Power on machine.
Still “BIN A 24V very low”
Y N
Replace the original 24V Distribution PCB “I”
Go to RAP 020 24V/48V very low entry RAP

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RAP 023 BIN B 24V Very Low
This RAP is for troubleshooting a very low 24V related to BIN B Disconnect SOL201 and SOL202 connectors. Measure resistance
between connectors on the solenoid for both SOL201 and SOL202.
Initial Actions
The resistance is lower than 10 ohms
• Make sure that plugs/jacks J/P312 and J/P212 are properly connected.
• Ensure that all connectors to “F”, “L”, ”M”, “O” and “R” PCBs are properly connected N Y
Replaced the failed solenoid SOL201 or SOL202
Procedure
Disconnect [R, P1] check for short circuits on PCB connector [R, J1]
WARNING! between pin 1 and pin 3.
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before There is no short circuit
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine. Y N
Replace PCB “R”
Power off the machine, disconnect [F, P1] and [F, P2], measure continuity between PCB Disconnect all connectors to PCB “M”, [R, P1], SOL201/SOL202
connectors [F, J2-1] and [F, J1-1] (Checking blown fuse at PCB “F”). connectors and leave FAN connectors disconnected. Check for short
There is continuity circuits between following positions:
Y N [M, P1] all Red to all Black wires, all Orange to all Black wires, all Red
and Orange wires to chassis.
Replace PCB “F”
[M P2] all White to all Green wires, all Red to Black wires, all White and
The fuse at PCB “F” blows up again at Power on Red wires to chassis.
Y N [M, P3] White to Black wires, White wire to chassis
Exit [M, P4] all Red to all Black wires, all Red wires to chassis
Proceed to the next step in this RAP
There is no short circuit
Leave [F, P1] and [F, P2] disconnected and disconnect [M, P1], [M, P3], [M,P4] and [L, P1].
Y N
Measure continuity for all wires between [F, P2] and [M, P1], check continuity for all wires
between [M, P3] and [L, P1]. Repair/replace harness
There is continuity Disconnect [O, P8] check for short circuits on PCB connector [O, J8]
between pin 7 and pin 8
Y N
There is no short circuit
Repair/replace harness
Y N
Replace PCB “O”
Reconnect all connectors except [F, P1], disconnect SOL201/SOL202 connectors and
check for short circuits between [M, P1] Red and Black wires. Replace PCB “M”
There is no short circuit Replace the failed FAN/Q202
Y N Power off, reconnect [F, P1], swap CPU PCB “L” with CPU PCB “H”, make sure to set DIP
switches correctly (See GP’s) and that all connectors at both PCBs are properly installed
Disconnect [F, P2], check for short circuits between [M, P1] Red and Black wires
before powering on the machine. Power on the machine.
There is no short circuit
Still “BIN B 24V very low”
N Y
Y N
Replace PCB “F”
Replace the original CPU PCB “L”
Disconnect all FAN connectors and Q202 connector, check for short circuit
Power off, swap PCB “I” with PCB “M”, make sure all connectors at both PCBs properly
between FAN connectors on the FAN side, Black wires to Red wires and between
installed before powering on the machine. Power on the machine.
Q202 chassis connector pin 3 to pin 6
Still “BIN B 24V very low”
There is no short circuit
Y N
N Y
Replace the original 24V Distribution PCB “M”
Go to RAP 020 24V/48V very low entry RAP

BSD on previous page

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RAP 024 Antistatic Bars There is continuity
This RAP is for troubleshooting the Antistatic Bars. No fault code exists for this RAP. If Y N
papers are statically charged after printing, refer to this RAP. Repair/replace harness
The primary objective is to determine why the Antistatic Bars are not functioning properly. Power on, close the door and activate REL303 in component control
Initial Actions REL303 activates
• Make sure that plugs/jacks J/P27, J/P34 and J/P301 are properly connected Y N
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL301, Measure VDC between [REL303, A1] and [REL303, A2].
REL302, REL303, TR1, PSU (24V) and PSU (24/48V) are properly connected The voltage is 12VDC±10%
• Ensure that all connectors to “A”, “B” and “G” PCBs are properly connected
Y N
• Check that the voltage selector on TR1 is in correct position
• Ensure that the built in fuse for TR1 has not tripped Replace PCB “G“
• REL303 is activated upon startup (Door Switch must be activated). Listen closely to Replace REL303
BAR1 and BAR2. If there is a 50Hz sound when REL303 is activated, BAR1 and BAR2 Listen to BAR1
are working. If there is only sound at one of the BARs, replace the one that does not emit There is a 50Hz sound
any sound
Y N
Procedure Listen to BAR2
There is a 50Hz sound
WARNING! Y N
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring Replace transformer TR1 (REP 15.44)
resistance inside the machine. Replace BAR1
WARNING! Listen to BAR2
Use caution when making the voltage measurements and always disconnect the There is a 50Hz sound
Power Cord when it is necessary to work inside the Power Module. AC Power is pre- Y N
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet Replace BAR2
Exit
Power on the machine close the door.
Does REL301 and/or REL302 activate
Y N
Go to REL301 and/or REL302
Power off the machine, disconnect the Power Cord. Measure continuity between [SW1,1] to
[REL303, 31] and [SW1,4] to [REL301, 11]
There is continuity
Y N
Repair/replace harness
Keep machine Powered off and the Power Cord disconnected. Measure continuity between
[G, P8-6] to [REL303, A2] and between [REL302, A1] to [REL303, A1].
There is continuity
Y N
Repair/replace harness
Keep machine Powered off and the Power Cord disconnected. Measure continuity between
connector [TR1-1] to [REL303, 14] and between [TR1-2] to [REL303, 34].

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 025 BIN Switch Software Signal
This RAP is for troubleshooting a BIN Switch software signal circuit.
The primary objective is to determine if the BIN Switch or CPU PCB has failed.
This procedure may be applied on either bin.
Initial Actions
• Make sure that plugs/jacks J/P301, J/P310, J/P312, J/P112, J/P106, J/P206 and J/P212
are properly connected (reference Master Wiring Diagram)
• Make sure that all connectors connecting to the BIN Switch are properly connected
• Ensure that all connectors to CPU PCB H/L are properly connected

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components.

Power off the machine, disconnect the Power Cord. Leave Door Switch deactivated, meas-
ure resistance from BIN Switch pos. 3 to 4.
There is open circuit, resistance > 1 Mohm
Y N
Replace BIN Switch
Activate Door Switch, measure resistance from Door Switch pos. 3 to 4.
There is continuity
Y N
Replace the BIN Switch
Disconnect CPU PCB H/L connector [P4] and deactivate BIN Switch. Measure continuity
from BIN Switch pos. 3 to [P4-20] and BIN Switch pos. 4 to [P4-21]. Check for short circuits
between Black and White wire, and between Black/White wires and chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Replace CPU PCB H/L

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RAP 026 CPU PCB ”A” Measure VDC between GND and 3,3VDC (see image on following page).
This RAP is for troubleshooting a failed CPU PCB “A” The voltage is 3,3VDC±5%
The primary objective is to check if the PCB communicates correctly and logic voltages are Y N
OK. Replace PCB “A”
Initial Actions Previous performed RAP was No XCAN Communication RAP
• Ensure that plugs/jacks J/P309, J/P312, J/P111, J/P311, J/P111X, J/P211X and J/P211 Y N
are properly connected (reference Master Wiring Diagram) Go to RAP 004 No ICAN Communication entry RAP
• Ensure that all DIP switch settings on PCBs “A”, “G”, “H”, “L”, “K”, “CC”, “Y” and “O” are
Power off the whole system and VF602, disconnect [A, P7], [A, P8], [J/P23] and [J/P24].
correct (See GP’s)
Check continuity for all wires from [A, P7] to [J23] and all wires from [A, P8] to [P24].
• Ensure that all connectors to “A”, “B”, “G”, “H”, “K”, “L”, “O”, “CC”, “Y” PCBs are properly
connected There is continuity
Y N
Procedure Repair/replace harness
WARNING! Keep the whole system and VF602 powered off and [A, P7], [A, P8], [J/P23] and [J/P24]
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before disconnected. Check for short circuits between all wires connected to [J23] and [P24] and
disconnecting, removing or replacing any electrical components or measuring all wires from [J23] and [P24] to chassis. Pin 3 for both [J23] and [P24] are connected to
resistance inside the machine. chassis
There is no short circuit except for pin 3
Power on the machine. If D5 Blue LED on PCB “A” is deactivated, go directly to N (it means Y N
no 12VDC). If D5 is activated, measure VDC between [A, P6-1] and [A, P6-10]. Repair/replace harness
The voltage is 12VDC±10% Check the XCAN communications cables (one or two) for continuity and short circuits. The
Y N positions that need to be checked are pins 1,2,3,5 and 7
Power off, disconnect [A, P2], power on. There is continuity and no short circuit
D5 Blue LED at PCB “A” is activated Y N
N Y Repair /replace harness
Go to RAP 017 Counter Disconnect XCAN terminations (two) connected to the system and check resistance be-
Power off, disconnect [A, P6] and [B, P2], check continuity between all wires from tween pin 2 and 7.
[A, P6] to [B, P2], check short circuits between all wires connected to [A, P6], and The resistance is between 110-130 ohms
between all wires from [A, P6] to chassis. Y N
There is continuity and no short circuit Repair /replace termination(s)
Y N Go to and perform XCAN communication RAPs in service manuals for the machines con-
Repair/replace harness nected to VF602
Leave [A, P6] and [B, P2] disconnected, power on. If D6 Blue LED on PCB “B” is Success
deactivated go directly to N, it means no 12VDC. If D6 activated, measure VDC at Y N
PCB connector [B, J2] between [B, J2-23] to [B, J2-22]. Replace PCB “A”
The voltage is 12VDC±10% Exit
Y N
Replace PCB “B”
Replace PCB “A”
Measure VDC between GND and VCC (see image on following page).
The voltage is 5VDC±10%
Y N
Replace PCB “A”

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 LED D1, CPU
controlled LED
LED D10,
VCC (+5VDC) GND measur-
Sensors. ing point, all four
Deactivated=no plated holes are
voltage present. connected to
Activated= volt- GND
age present, not
necessary the +3,3VDC
correct voltage measuring point
level.
VCC (+5VDC)
measuring point

LED D5

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RAP 027 CPU PCB ”H” Power off, disconnect [H, P5], power on
This RAP is for troubleshooting a failed CPU PCB H. D5 Blue LED at PCB “H” is activated
The primary objective is to determine if the PCB communicates correctly and logic voltages N Y
are OK.
Power off, disconnect [S, P2] and leave [H, P5] disconnected. Check
Initial Actions for short circuits between all wires connected to [S, P2] and between all
• Ensure that plugs/jacks J/P309, J/P312, J/P111, J/P311, J/P111X, J/P211X, J/P125 and wires to chassis.
J/P211 are properly connected (reference Master Wiring Diagram) There is no short circuit
• Ensure that all DIP switch settings on PCBs “A”, “G”, “H”, “L”, “K”, “CC”, “Y” and “O” are
Y N
correct (See GP’s)
• Ensure that all connectors to “A”, “B”, “G”, “H”, “K”, “L”, “O”, “CC”, “Y” and “S” PCBs are Repair/replace harness
properly connected Replace PCB “S”
Power off, disconnect [J/P125], power on
Procedure D5 Blue LED at PCB “H” is activated
WARNING! N Y
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before Go to RAP 043 SP Sensor (pay attention to short circuit measurements).
disconnecting, removing or replacing any electrical components or measuring
Power off, disconnect [H, P6] and [J/P125], check continuity between all wires
resistance inside the machine.
from [H, P6] to [J/P125], check short circuits between all wires connected to [J/
P125], and between all wires from [J/P125] to chassis.
Power on the machine. If D5 Blue LED on PCB “H” is deactivated, go directly to N (it means There is continuity and no short circuit
no 12VDC). If D5 is activated, measure VDC between [H, P6-1] to [H, P6-10].
Y N
The voltage is 12VDC±10%
Y N Repair/replace harness
Power off, disconnect [H, P10], power on. Power off, disconnect [H, P6] and [B, P2], and check continuity between all wires
D5 Blue LED at PCB “H” is activated from [H, P6] to [B, P2]. Check for short circuits between all wires connected to [H,
P6], and between all wires from [H, P6] to chassis.
N Y
There is continuity and no short circuit
Power off, disconnect [H, P10], [J/P125] and [B,P2]. Check for short
circuits between all wires connected to [H,P10] and between all wires Y N
from [H,P10] to chassis. Repair/replace harness
There is no short circuit Leave [H, P6] and [B, P2] disconnected, power on. If D3 Blue LED on PCB “B” is
Y N deactivated go directly to N, it means no 12VDC. If D3 activated, measure VDC at
PCB connector [B, J2] between [B, J2-10] to [B, J2-9].
Repair/replace harness
The voltage is 12VDC±10%
Go to RAP 037. Stepper Motor Driver M101 PCB “K” RAP
Y N
Power off, disconnect [H, P1], power on.
Replace PCB “B”
D5 Blue LED at PCB “H” is activated Replace PCB “H”
N Y Measure VDC between GND and VCC (see image on next page).
Go to RAP 002 Ultrasonic DSD (pay attention to short circuit measure- The voltage is 5VDC±10%
ments).
Y N
Power off, disconnect [H, P3], keep [H, P1] disconnected, power on.
Replace PCB “H”
D5 Blue LED at PCB “H” is activated
Measure VDC between GND and 3,3VDC (see image on next page).
N Y
The voltage is 3,3VDC±5%
Go to RAP 016 LAMP (pay attention to short circuit measurements).
Y N
Replace PCB “H”
Exit
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 LED D1, CPU
controlled LED
LED D10,
VCC (+5VDC) GND measur-
Sensors. ing point, all four
Deactivated=no plated holes are
voltage present. connected to
Activated= volt- GND
age present, not
necessary the +3,3VDC
correct voltage measuring point
level.
VCC (+5VDC)
measuring point

LED D5

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RAP 028 CPU PCB ”L”
This RAP is for troubleshooting a failed CPU PCB H. Power off, disconnect [L, P5], power on
The primary objective is to determine if the PCB communicates correctly and logic voltages D5 Blue LED at PCB “L” is activated
are OK N Y
Initial Actions Power off, disconnect [R, P2] and leave [L, P5] disconnected. Check for
• Ensure that plugs/jacks J/P309, J/P312, J/P111, J/P311, J/P111X, J/P211X, J/P125 and short circuits between all wires connected to [R, P2] and between all
J/P211 are properly connected (reference Master Wiring Diagram) wires to chassis.
• Ensure that all DIP switch settings on PCBs “A”, “G”, “H”, “L”, “K”, “CC”, “Y” and “O” are There is no short circuit
correct (See GP’s) Y N
• Ensure that all connectors to “A”, “B”, “G”, “H”, “K”, “L”, “O”, “CC”, “Y” and “R” PCBs are Repair/replace harness
properly connected
Replace PCB “R”
Procedure Power off, disconnect [J/P225], power on
WARNING! D5 Blue LED at PCB “L” is activated
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before N Y
disconnecting, removing or replacing any electrical components or measuring Go to RAP 043 SP Sensor (pay attention to short circuit measurements).
resistance inside the machine. Power off, disconnect [L, P6] and [J/P225], check continuity between all wires
from [L, P6] to [J/P225], check for short circuits between all wires connected to [J/
Power on the machine. If D5 Blue LED on PCB “L” is deactivated, go directly to N (it means P225], and between all wires from [J/P225] to chassis.
no 12VDC). If D5 activated, measure VDC between [L, P6-1] to [L, P6-10]. There is continuity and no short circuit
The voltage is 12VDC±10%
Y N
Y N
Repair/replace harness
Power off, disconnect [L, P10], power on.
D5 Blue LED at PCB “L” is activated Power off, disconnect [L, P6] and [B, P2], check continuity between all wires from
N Y [L, P6] to [B, P2], check for short circuits between all wires connected to [L, P6],
and between all wires from [L, P6] to chassis.
Power off, disconnect [L, P10], [J/P225] and [B,P2]. Check for short
circuits between all wires connected to [L,P10] and between all wires There is continuity and no short circuit
from [L,P10] to chassis. Y N
There is no short circuit Repair/replace harness
Y N Leave [L, P6] and [B, P2] disconnected, power on. If D3 Blue LED on PCB “B”
is deactivated, go directly to N (it means no 12VDC). If D3 is activated, measure
Repair/replace harness
VDC at PCB connector [B, J2] between [B, J2-10] and [B, J2-9].
Go to RAP 038. Stepper Motor Driver M201 PCB “O” RAP
The voltage is 12VDC±10%
Power off, disconnect [L, P1], power on. Y N
D5 Blue LED at PCB “L” is activated Replace PCB “B”
N Y Replace PCB “L”
Go to RAP 002 Ultrasonic DSD (pay attention to short circuit measure- Measure VDC between GND and VCC (see image on following page).
ments). The voltage is 5VDC±10%
Power off, disconnect [L, P3], keep [L, P1] disconnected, power on. Y N
D5 Blue LED at PCB “L” is activated Replace PCB “L”
N Y Measure VDC between GND and 3,3VDC (see image on following page).
Go to RAP 016 LAMP (pay attention to short circuit measurements). The voltage is 3,3VDC±5%
Y N
Replace PCB “L”
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 LED D1, CPU
controlled LED
LED D10,
VCC (+5VDC) GND measur-
Sensors. ing point, all four
Deactivated=no plated holes are
voltage present. connected to
Activated= volt- GND
age present, not
necessary the +3,3VDC
correct voltage measuring point
level.
VCC (+5VDC)
measuring point

LED D5

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RAP 029 Door Switch Interlock Circuit There are no short circuits
This RAP is for troubleshooting when the Door Switch Interlock circuit does not activate Y N
REL301 and/or REL302. The primary objective is to determine which part of the Door Repair/replace harness
Switch Interlock circuit fails. Leave connectors disconnected, Measure resistance between harness connectors
Initial Actions [REL301, A1] to [REL301, A2] ,[REL302, A1] to [REL302, A2] and [REL303, A1] to [REL303,
A2]
• Ensure that plugs/jacks J/P301, J/P310, J/P312, J/P112 and J/P212 are properly con-
nected (reference Master Wiring Diagram) Resistance > 200 ohms
• Make sure that all connectors connecting to the Door Switch (S301/S302), REL301, Y N
REL302, REL303 and PSU (24V) and PSU (24/48V) are properly connected Repair/replace the Harness
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N”, “O” Leave connectors disconnected, Measure resistance between relay connectors A1 to A2 at
PCBs are properly connected REL301, A1 to A2 at REL302 and A1 to A2 at REL303.
Resistance 30-60 ohms
Procedure Y N
Replace the failed Relay
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before Reconnect all connectors, Power on, measure VDC between [B, P2-18,20] and [B, P1-7].
disconnecting, removing or replacing any electrical components or measuring The voltage is 12VDC±10%
resistance inside the machine. Y N
Note! If there is no Antistatic BAR Kit installed, skip all measuring related to REL303. Replace PCB “B”
Power off the machine, disconnect the Power Cord and all four wires connected to Door Replace PCB “A”
Switch. Leave Door Switch deactivated, measure resistance from Door Switch pos. 1 to 2
(not harness connectors).
There is an open circuit, resistance > 1 Mohm
Y N
Replace Door Switch
Activate Door Switch, measure resistance from Door Switch pos. 1 to 2 (not harness con-
nectors)
There is continuity
Y N
Replace Door Switch
Disconnect [A, P4], [A, P5], [B, P2] and all Relay connectors marked A1 and A2 (six total).
Deactivate Door Switch, measure continuity between the following positions:
1. [A, P5-3,4] to [REL302, A2] and [A, P5-1,2] to [REL301, A2]
2. [B, P2-18,20] to Door Switch pos. 1
3. Door Switch pos. 2 to [REL302, A1] and [REL301, A1]
There is continuity
Y N
Repair/replace harness
Leave connectors disconnected, Check for short circuits between the following positions:
1. [A, P4-23,24], [A, P5-1,2,3,4] and [B, P2] to chassis.
2. All Relay wires (six total) marked A1 and A2 to chassis

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RAP 030 Door Switch Software Signal Power off the machine and disconnect the Power Cord. Leave Door Switch deactivated and
measure resistance from Door Switch pos. 3 to 4.
This RAP is for troubleshooting Door Switch software signal circuit.
Target is to find the out if the Door Switch or PCB “A” has failed. There are open circuits, resistance > 1 Mohm
Y N
Initial Actions Replace Door Switch (REP 15.43)
• Make sure that plugs/jacks J/P301, J/P310, J/P312, J/P112 and J/P212 are properly con- Activate Door Switch, measure resistance from Door Switch pos. 3 to 4.
nected (reference Master Wiring Diagram) There is continuity
• Make sure that all connectors connecting to the Door Switch(S301/S302) are properly Y N
connected Replace the Door Switch (REP 15.43)
• Ensure that all connectors to “A” PCB are properly connected
Disconnect [A, P4], deactivate Door Switch and measure continuity from Door Switch pos.
3 to [A, P4-23] and Door Switch pos. 4 to [A, P4-24]. Check for short circuits from Black to
White wire and from Black and White wires to chassis.
Procedure There is continuity and no short circuit
WARNING! Y N
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before Repair/replace harness
disconnecting, removing or replacing any electrical components or measuring
Replace PCB “A”
resistance inside the machine.

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RAP 031 F1 Blown Fuse Locate and Repair/replace harness between SW1 and REL301/REL302/J27/PSU
(12V)
This RAP is for troubleshooting when fuse F1 frequently blows up.
The primary objective is to find the source that makes fuse F1 to blow up Leave all connectors in previous steps disconnected. Disconnect L and N from PSU (24V),
check for short circuits from L to N, and L/N to chassis at the PSU (24V).
Initial Actions
There are no short circuits
• Ensure that there is proper voltage at the wall outlet
Y N
• Check all connectors related to Power Entry, SW1, REL301, REL302, REL303/TR1 (op-
tion) and input side of PSU (24V), PSU (24/48V) Replace PSU (24V) (REP 15.37)
Leave all connectors in previous steps disconnected. Check for short circuits between
wire from [REL301,14] to wire from [REL301,34] and between wires from [REL301,14] and
Procedure [REL301,34] to chassis.
WARNING! There are no short circuits
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before Y N
disconnecting, removing or replacing any electrical components or measuring Repair/replace harness
resistance inside the machine. Leave all connectors in previous steps disconnected, disconnect L and N from PSU
WARNING! (24/48V). Check for short circuits from L to N, and L/N to chassis at the PSU (24/48V).
Use caution when making the voltage measurements and always disconnect the There are no short circuits
Power Cord when it is necessary to work inside the Power Module. AC Power is pre- Y N
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet. Replace PSU (24/48V) (REP 15.38)
Leave all connectors in previous steps disconnected. Check for short circuits between
For the duration of this RAP: power off the machine, disconnect the Power Cord (very wire from [REL302,14] to wire from [REL302,34] and between wires from [REL302,14] and
important!) and leave Door Switch deactivated. Disconnect [POW,3] and [POW,4] from the [REL302,34] to chassis.
Power Entry, check short circuits from positions 3 to 4 and chassis to position 3 and 4 at the There are no short circuits
Power Entry
Y N
There are no short circuits
Repair/replace harness
Y N
There is an Antistatic KIT installed
Replace Power Entry
Y N
Leave all connectors in previous step disconnected. Check for short circuits between wires
Exit
from [SW1,2] to [SW1,5] and between wires from [SW1,2] and [SW1,5] to chassis.
Leave all connectors in previous steps disconnected. Check for short circuits between wire
There are no short circuits
from [P27,1] to wire from [P27,2] and between wires from [P27,1] and [P27,2] to chassis
Y N
There are no short circuits
Repair/replace harness
Y N
Leave all connectors in previous steps disconnected, and disconnect [J/P27]. Check for
Repair/replace harness
short circuits between wires from [SW1,1] to [SW1,4] and between wires from [SW1,1] and
[SW1, 4] to chassis. Leave all connectors in previous steps disconnected and disconnect TR,1 connector. Check
for short circuits between wire from [REL303,14] to wire from [REL303,34] and between
There are no short circuits
wires from [REL303,14] and [REL303,34] to chassis
Y N
There are no short circuits
Leave all connectors in previous steps disconnected. Disconnect L and N from
Y N
PSU (12V) input. Check for short circuits from L to N, and L/N to chassis at the
PSU (12V) input. Repair/replace harness
There are no short circuits Replace TR1 (REP 15.44)
Y N
Replace PSU (12V) (REP 15.36)

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 032 Interlock Mismatch
This RAP is for troubleshooting a failed Interlock circuit; i.e. voltage is present when the
Interlock circuit should be open.
The primary objective is to determine the source of failure: relay, harness or PCB.
Initial Actions
• Make sure that plugs/jacks J/P310, J/P312, J/P112 and J/P212 are properly connected
(reference Master Wiring Diagram)
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL301,
REL302, PSU (24V) and PSU (24/48V) are properly connected
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N”, “O”
PCBs are properly connected
Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
WARNING!
Use caution when making the voltage measurements and always disconnect the
Power Cord when it is necessary to work inside the Power Module. AC Power is pre-
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet.

Power on the machine and leave the Door switch deactivated (door open). Measure voltage
(VAC) between L and N on the PSU (24V) input.
The voltage is 90-264VAC.
Y N
Power on the machine and leave the Door Switch deactivated (door open). Meas-
ure voltage (VAC) between L and N on the PSU (24/48V) input.
The voltage is 90-264VAC.
Y N
Replace the PCB mentioned in the failure code (REP 15.40 15.41)
Replace REL302 (REP 15.39)
Power on the machine and leave the Door Switch deactivated (door open). Measure volt-
age (VAC) between L and N on the PSU (24/48V) input.
The voltage is 90-264VAC.
Y N
Replace REL301 (REP 15.39)
Perform RAP 030 Door Switch software signal
Success
Y N
Perform RAP 029 Door Switch Interlock circuit
Succes
Y N
Replace Door switch
Exit BSD on next page
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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 033 Motor Relay Y N
This RAP is for troubleshooting why the Motor Relay does not work. Replace RELAY (REP 15.39)
The primary objective is to determine the cause of failure: PCB, Relay, BIN Switch or har- Keep machine powered off, leave BIN Switch deactivated and leave connectors discon-
ness nected. Measure resistance between BIN Switch pos. 1 to 2 (not harness connectors).
Initial Actions There is an open circuit (Resistance > 1 Mohm)
• Make sure that plugs/jacks J/P301, J/P310, J/P312, J/P112 and J/P212 are properly Y N
connected. Replace BIN Switch (REP 15.42)
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL301, Activate BIN Switch, measure resistance between BIN Switch pos. 1 to 2 (not harness con-
REL302, PSU (24V) and PSU (24/48V) are properly connected. nectors)
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N”, “O” There is continuity
PCBs are properly connected.
Y N
Replace BIN Switch (REP 15.42)
Procedure
Disconnect Stepper Motor Driver PCB connector [P7] and Motor connector. Check continu-
WARNING! ity between all wires from [P7] to RELAY, [P7] to Motor Connector and RELAY to Motor
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before connector.
disconnecting, removing or replacing any electrical components or measuring There is continuity
resistance inside the machine. Y N
Repair/replace harness
Power off the machine, disconnect the Power Cord. Disconnect [P6] at the Stepper Motor Check short circuit between all wires at [P7] and Motor connector (harness connector),
Driver PCB. Measure continuity between following positions: between all wires at [P7] to chassis and all wires at Motor connector (harness connector) to
1. PCB Connector [P6-1] to BIN Switch pos. 1. chassis.
2. PCB Connector [P6-10] to RELAY pos. A2.
3. BIN Switch pos. 2 to RELAY pos. A1. There is no short circuit
There is continuity Y N
Y N Repair/replace harness
Repair/replace harness Reconnect all connectors, activate BIN Switch and power on. Measure VDC between
RELAY A1 to A2.
Keep [P6] disconnected, disconnect BIN Switch pos. 1, 2 and RELAY pos. A1, A2. Check
short circuit between following positions: The voltage is 12VDC±10%
1. [P6-1] to [P6-10]. Y N
2. [P6-1, 10], RELAY harness connectors A1, A2, BIN Switch pos. 1 and 2 to chassis Replace Stepper Motor Driver PCB (REP 15.40)
RELAY activates
There is no short circuit Y N
Y N Replace RELAY (REP 15.39)
Repair/replace harness Exit
Leave connectors disconnected, Measure resistance between RELAY harness connectors
A1 to A2.
Resistance > 200 ohms
Y N
Repair/replace the Harness
Leave connectors disconnected, Measure resistance between RELAY connectors (not har-
ness connectors) A1 to A2.
Resistance is 30-60 ohms

BSD on next page

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 034 PSU (12V) Repair/replace harness
This RAP is for troubleshooting the 12V circuit. Replace the Power entry
The primary objective is to determine if the failure is related to the primary circuit, PCB “B” Power off, disconnect wires from V- and V+ at PSU, power on.
or PSU (12V). Measure VDC between V- to V+ at PSU (12V).
The voltage is 12VDC±10%
Initial Actions Y N
• Ensure that plugs/jacks J/P309, J/P312, J/P111, J/P311, J/P23, J/P24, J/P111X, J/P211X, Replace PSU (12V)
J/P125 and J/P211 are properly connected Power off, keep wires from V- and V+ at PSU (12V) disconnected and disconnect [B, P1].
• Ensure that all DIP switch settings on PCBs “A”, “G”, “H”, “L”, “K”, “CC”, “Y” and “O” are Check continuity between all wires from V- and V+ to [B, P1], check short circuits between
correct (See GP’s). Black to Red wires and between Black and Red wires to chassis.
• Ensure that all connectors to SW1, PSU (12V) and “A”, “B”, “G”, “H”, “K”, “L”, “O”, “CC” There is continuity and no short circuit
and “Y” PCBs are properly connected
Y N
Procedure Repair/replace harness
Replace PCB “B”
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
WARNING!
Use caution when making the voltage measurements and always disconnect the
Power Cord when it is necessary to work inside the Power Module. AC Power is pre-
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet.

Power on the machine. Measure VAC between L to N on PSU (12V)

The voltage is between 90-264VAC
Y N
Power off and disconnect the Power Cord, check status of F1 located in the
power inlet.
F1 is blown
N Y
Go to RAP 031 F1 Blown Fuse
Keep the machine off and Power Cord disconnected. Measure continuity between
L Black1 wire to SW1,4 and between N Black2 wire to SW1,1.
There is continuity
Y N
Repair/replace harness
Keep Power Cord disconnected set SW1 to on. Measure continuity between
SW1,4 to SW1,5 and SW1,1 to SW1,2.
There is continuity
Y N
Replace SW1
Keep the machine off and Power Cord disconnected. Measure continuity between
SW1,5 Black1 wire to POW,1 and SW1,2 Black2 wire to POW,4.
There is continuity
Y N BSD on next page

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 035 REL301 Power off the machine and disconnect the Power Cord. Measure continuity between wires
from REL301 and PSU (24V) input.
This RAP is for troubleshooting the REL301 primary circuit.
The primary objective is to determine why there is not 90-240VAC at the PSU (24V) input. There is continuity
Y N
Initial Actions
Repair/replace harness
• Make sure that plugs/jacks J/P301, J/P310, J/P312, J/P112 and J/P212 are properly con-
nected (reference Master Wiring Diagram) Keep machine Powered off and the Power Cord disconnected. Measure continuity all the
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL301, way between wires from REL301 and SW1.
REL302, PSU (24V) and PSU (24/48V) are properly connected There is continuity
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N”, and Y N
“O” PCBs are properly connected Repair/replace harness
Connect the Power Cord and Power on the machine keep the door open, pay close atten-
Procedure tion to REL301. Close the door.
The REL301 activates for at least a short period of time.
WARNING! Y N
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring Power off the machine, wait 5 seconds, Power on the machine and close the
resistance inside the machine. door. Measure VDC between [REL301, A1] and [REL301, A2].
NOTE! The voltage is 12VDC±10% for at least a short period of time.
For safety reasons in case of a “very low/high 24V and/or 48V” there is a limited time when Y N
voltage are applied to PSU (24V) and PSU (24/48V), this affects the voltage measure- Go to RAP 029 Door Switch Interlock circuit
ments, please see “24/48VDC Interlock/PSU procedure” for further information. Replace REL301
WARNING! Power off the machine and wait 5 seconds. Power on the machine and close the door.
Use caution when making the voltage measurements and always disconnect the Measure voltage (VAC) between L and N on the PSU (24V) input.
Power Cord when it is necessary to work inside the Power Module. AC Power is pre- The voltage is 90-264VAC for at least a short period of time.
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet. Y N
Replace REL301 (REP 15.39)
Exit

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RAP 036 REL302 Power off the machine and disconnect the Power Cord. Measure continuity between wires
from REL302 and PSU (24/48V) input.
This RAP is for troubleshooting the REL302 primary circuit.
The primary goal is to determine why there is not 90-240VAC at the PSU (24/48V) input. There is continuity
Y N
Initial Actions
Repair/replace harness
• Make sure that plugs/jacks J/P301, J/P310, J/P312, J/P112 and J/P212 are properly con-
nected (reference Master Wiring Diagram) Keep machine powered off and the Power Cord disconnected. Measure continuity all the
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL302, way between wires from REL302 and SW1.
REL302, PSU (24V) and PSU (24/48V) are properly connected There is continuity
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N”, and Y N
“O” PCBs are properly connected Repair/replace harness
Connect the Power Cord and Power on the machine. Keep the door open; pay close atten-
Procedure tion to REL302. Close the door.
The REL302 activates for at least a short period of time.
WARNING! Y N
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring Power off the machine, wait 5 seconds. Power on the machine and close the
resistance inside the machine. door. Measure VDC between [REL302, A1] and [REL302, A2].
NOTE! The voltage is 12VDC±10% for at least a short period of time.
For safety reasons - in case of a “very low/high 24V and/or 48V,” there is a limited time Y N
when voltages are applied to PSU (24V) and PSU (24/48V). This affects the voltage meas- Go to RAP 029 Door Switch Interlock circuit
urements - please see “24/48VDC Interlock/PSU procedure” for further information. Replace REL302 (REP 15.39)
WARNING! Power off the machine, wait 5 seconds, Power on the machine and close the door. Measure
Use caution when making the voltage measurements and always disconnect the voltage (VAC) between L and N on the PSU (24/48V) input.
Power Cord when it is necessary to work inside the Power Module. AC Power is pre- The voltage is 90-264VAC for at least a short period of time.
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet. Y N
Replace REL302 (REP 15.39)
Exit

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RAP 037 Stepper Motor Driver M101 PCB ”K” Go to RAP 008 M101/M201 home position sensor not activated in time/activated
too long (pay attention to short circuit measurements).
This RAP is for troubleshooting a failed Stepper Motor Driver M101 PCB.
The primary objective is to check whether the PCB communicates correctly and logic volt- Measure VDC between GND and 3,3VDC (see image on following page).
ages are OK. The voltage is 3,3VDC±5%
Initial Actions Y N
• Ensure that plugs/jacks J/P309, J/P312, J/P111, J/P311, J/P111X, J/P211X, J/P125 and Replace PCB “K” (REP 15.40)
J/P211 are properly connected (reference Master Wiring Diagram) Go to RAP 004 No ICAN Communication entry
• Ensure that all DIP switch settings on PCBs “A”, “G”, “H”, “L”, “K”, “CC”, ”Y” and “O” are
correct (See GP’s)
• Ensure that all connectors to “A”, “B”, “G”, “H”, “K”, “L”, “O”, “CC” and “Y” PCBs are
properly connected

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power on the machine. If D2 Blue LED on PCB “K” is deactivated, go directly to N (it means
no 12VDC). If D2 is activated, measure VDC between [K, P5-1] to [K, P5-10].
The voltage is 12VDC±10%
Y N
Power off, disconnect [H, P10]. Power on.
D5 Blue LED at PCB “H” is activated
Y N
Go to RAP 027 CPU PCB “H”
Power off, disconnect [K, P5] and keep [H, P10] disconnected. Check continuity
between all wires from [H, P10] to [K, P5]. Check short circuits between all wires
connected to [K, P5], and between all wires from [K, P5] to chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Reconnect [H, P10] and [K, P5], disconnect [K, P6], power on.
D2 Blue LED at PCB “K” is activated
Y N
Replace PCB “K” (REP 15.40)
Go to RAP 033 Motor Relay
Measure VDC between GND and VCC (see image on following page).
The voltage is 5VDC±10%
Y N
Power off, disconnect [K, P3], measure VDC between GND and VCC.
The voltage is 5VDC±10%
Y N
Replace PCB “K” (REP 15.40) Image, measuring points on next page

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M21H Stepper Motor PCB LEDs and Measuring Points

LED D31, VCC (+5VDC).

Deactivated=no voltage present. Activated= LED D1, CPU controlled LED GND measuring point
voltage present, not necessary the correct
voltage level.

LED D2, 12V logic Power in.

Deactivated=no voltage present. Acti-
vated= voltage present, not necessary
the correct voltage level.

VCC (+5VDC) measuring point

+3,3VDC measuring point

LED D30, motor Power in.

Deactivated=no voltage
present. Activated= voltage
present, not necessary the
correct voltage level.

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RAP 038 Stepper Motor Driver M201 PCB ”O” Power off, disconnect [O, P5] and keep [L, P10] disconnected. Check continuity
between all wires from [L, P10] to [O, P5]. Check for short circuits between all
This RAP is for troubleshooting a failed Stepper Motor Driver M201 PCB
wires connected to [O, P5], and between all wires from [O, P5] to chassis.
The primary objective is to check whether PCB communicates correctly and logic voltages
are OK. There is continuity and no short circuit
Y N
Initial Actions
Repair/replace harness
• Ensure that plugs/jacks J/P309, J/P312, J/P111, J/P311, J/P111X, J/P211X, J/P125 and
J/P211 are properly connected Reconnect [L, P10] and [O, P5], disconnect [O, P6], power on.
• Ensure that all DIP switch settings on PCBs “A”, “G”, “H”, “L”, “K”, “CC”, ”Y” and “O” are D2 Blue LED at PCB “K” is activated
correct (See GP’s) Y N
• Ensure that all connectors to “A”, “B”, “G”, “H”, “K”, “L”, “O”, “CC” and “Y” PCBs are prop- Replace PCB “O” (REP 15.40)
erly connected
Go to RAP 033 Motor Relay
Measure VDC between GND and VCC (see image on previous page).
Procedure
The voltage is 5VDC±10%
WARNING! Y N
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
Power off, disconnect [O, P3], measure VDC between GND and VCC.
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine. The voltage is 5VDC±10%
Y N
Power on the machine. If D2 Blue LED on PCB “O” is deactivated, go directly to N (it means Replace PCB “O” (REP 15.40)
no 12VDC). If D2 activated, measure VDC between [O, P5-1] to [O, P5-10]. Go to RAP 008 M101/M201 home position sensor not activated in time/activated
The voltage is 12VDC±10% too long (pay attention to short circuit measurements).
Y N Measure VDC between GND and 3,3VDC (see image on previous page).
Power off, disconnect [L, P10]. Power on. The voltage is 3,3VDC±5%
D5 Blue LED at PCB “L” is activated Y N
Y N Replace PCB “O” (REP 15.40)
Go to RAP 028 CPU PCB “L” Go to RAP 004 No ICAN Communication entry RAP

Image measuring points on previous page

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RAP 039 Stepper Motor Driver M301 PCB ”G” There is continuity and no short circuit
This RAP is for troubleshooting a failed Stepper Motor Driver M301 PCB Y N
Target is to check if the PCB communicates correctly and logic voltages are OK. Repair/replace harness
Initial Actions Leave [G, P5] and [B, P2] disconnected, power on. If D4 Blue LED on PCB “B”
is deactivated, go directly to N (it means no 12VDC). If D4 is activated, measure
• Ensure that plugs/jacks J/P309, J/P312, J/P111, J/P311, J/P111X, J/P211X, J/P125 and
VDC at PCB connector [B, J2] between [B, J2-14] and [B, J2-13].
J/P211 are properly connected (reference Master Wiring Diagram)
• Ensure that all DIP switch settings on PCBs “A”, “G”, “H”, “L”, “K”, “CC”, ”Y” and “O” are The voltage is 12VDC±10%
correct (See GP’s) Y N
• Ensure that all connectors to “A”, “B”, “G”, “H”, “K”, “L”, “O”, “CC” and “Y” PCBs are Replace PCB “B”
properly connected Replace PCB “G”
Measure VDC between GND and VCC (see image on page 4-328).
Procedure
The voltage is 5VDC±10%
WARNING! Y N
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before Replace PCB “G”
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine. Measure VDC between GND and 3,3VDC (see image on page 4-328).
The voltage is 3,3VDC±5%
Power on the machine. If D2 Blue LED on PCB “G” is deactivated, go directly to N (it means Y N
no 12VDC). If D2 is activated, measure VDC between [G, P5-1] to [G, P5-10] Replace PCB “G”
The voltage is 12VDC±10% Go to RAP 004 No ICAN Communication entry RAP
Y N
Power off, disconnect [G, P5] and [B, P2], and check continuity between all wires
from [G, P5] to [B, P2]. Check for short circuits between all wires connected to [H,
P5], and between all wires from [H, P5] to chassis.

Image, measuring points on page 4-59

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RAP 040 Stepper Motor M101 PCB 48V Very Low RAP 041 Stepper Motor M201 PCB 48V Very Low
This RAP is for troubleshooting a very low 48V related to Stepper Motor M101 PCB “K”. This RAP is for troubleshooting a very low 48V related to Stepper Motor M201 PCB “O”.
The primary objective is to determine if the failure is related to the PCB or the harness. The primary objective is to determine if the failure is related to the PCB or the harness.
Initial Actions Initial Actions
• Make sure that plugs/jacks P310/J310 and P312/J312 are properly connected • Make sure that plugs/jacks P310/J310 and P312/J312 are properly connected
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL301, • Make sure that all connectors connecting to the Door Switch(S301/S302), REL301,
REL302, PSU (24V) and PSU (24/48V) are properly connected REL302, PSU (24V) and PSU (24/48V) are properly connected
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N”, “O” • Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N”, and
PCBs are properly connected “O” PCBs are properly connected

Procedure Procedure
WARNING! WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine. resistance inside the machine.

Power off the machine, disconnect [C, P2], [D, P2] and [K, P9]. Measure continuity between Power off the machine, disconnect [C, P2], [D, P2] and [O, P9]. Measure continuity between
[K, P9] Orange and Black wires to [C, P2] and [D, P2]. Check for short circuits between [O, P9] Orange and Black wires to [C, P2] and [D, P2]. Check for short circuits between
Black and Orange wires, also check for short circuits from Orange wire to chassis. Black and Orange wires, also check for short circuits from Orange wire to chassis.
There is continuity and no short circuit There is continuity and no short circuit
Y N Y N
Repair/replace harness Repair/replace harness
Disconnect all connectors connected to PCB “K”. Disconnect all connectors connected to PCB “O”.
Check short circuit between [J9-1] to [J9-2] (PCB connector). Check short circuit between [J9-1] to [J9-2] (PCB connector).
There is no short circuit There is no short circuit
Y N Y N
Replace PCB “K” Replace PCB “O”
Keep connectors disconnected and disconnect M101 Motor Connector. Check short circuit Keep connectors disconnected and disconnect M201 Motor Connector. Check for short cir-
between all wires at [P7] and Motor connector (harness connector), between all wires at cuits between all wires at [P7] and Motor connector (harness connector), between all wires
[P7] to chassis and all wires at Motor connector (harness connector) to chassis. at [P7] to chassis and all wires at Motor connector (harness connector) to chassis.
There is no short circuit There is no short circuit
Y N Y N
Repair/replace harness Repair/replace harness
Swap the Stepper Motor M101 PCB “K” with Stepper Motor M201 PCB “O”, make sure that Swap the Stepper Motor M201 PCB “O” with Stepper Motor M101 PCB “K”, make sure
DIP-switches are correctly set (See GP’s) and all connectors are properly installed at both SW1 is correctly set and all connectors are properly installed at both PCBs before power on
PCBs before powering on the machine. Power on the machine. the machine. Power on the machine.
Still “Stepper Motor M101 PCB 48V very low” Still “Stepper Motor M201 PCB 48V very low”
Y N Y N
Replace the original Stepper Motor M101 PCB “K” Replace the original Stepper Motor M201 PCB “O”
Exit Exit

Image measuring points on page 4-328 BSD’s on next page Image measuring points on page 4-328 BSD’s on next page

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 042 Stepper Motor M301 PCB 48V Very Low
This RAP is for troubleshooting a very low 48V related to Stepper Motor M301 PCB “G”.
The primary objective is to determine if the failure is related to the PCB or the harness.
Initial Actions
• Make sure that plugs/jacks P310/J310 and P312/J312 are properly connected
• Make sure that all connectors connecting to the Door Switch(S301/S302), REL301,
REL302, PSU (24V) and PSU (24/48V) are properly connected
• Ensure that all connectors to “A”, “B”, “C”, “D”, “E”, “F”, “G”, “H”, “J”, “K”, “L”, “M”, “N”, and
“O” PCBs are properly connected

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power off the machine, disconnect [C, P2], [D, P2] and [G, P9]. Measure continuity between
[G, P9] Orange and Black wires to [C, P2] and [D, P2]. Check for short circuits between
Black and Orange wires, also check for short circuits from Orange wire to chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Disconnect all connectors connected to PCB “G”.
Check for short circuits between [J9-1] to [J9-2] (PCB connector).
There is no short circuit
Y N
Replace PCB “G”
Keep connectors disconnected and disconnect M301 Motor Connector. Check for short cir-
cuits between all wires at [P7] and Motor connector (harness connector), between all wires
at [P7] to chassis and all wires at Motor connector (harness connector) to chassis.
There is no short circuit
Y N
Repair/replace harness
Swap the Stepper Motor M301 PCB “G” with Stepper Motor M101 PCB “K”, make sure
SW1 is correctly set and all connectors are properly installed at both PCBs before power on
the machine. Power on the machine.
Still “Stepper Motor M301 PCB 48V very low”
Y N
Replace the original Stepper Motor M301 PCB “G”
Exit

BSD’s on next page Image measuring points on page 4-328

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 043 SP Sensor
This RAP is for troubleshooting a non functional SP Sensor.
The primary objective is to decide if the failure is related to PCBs, the sensor or harness.
Initial Actions
• Enter service mode according to GP 1
• Check sensor (GP 4)
• Ensure that the sensor is clean
• Ensure that all connectors at the SP Sensor are properly connected
• Ensure that all connectors at PCBs are properly connected
• Ensure that DSD sensor is calibrated (BM 500 Operators Manual, VF602 Sensor Calibra-
tion Section)

NOTE!
For measuring references and connectors identification see BSD

Procedure
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power off the machine, disconnect connectors described in the BSD at both CPU PCBs
and at the SP Sensor. Measure continuity for wires between SP Sensor and both CPU
PCBs. Check for short circuits between all wires and between all wires to chassis described
in the BSD:
There is continuity and no short circuit
Y N
Repair/replace harness
Swap the faulty SP sensor with one in the other bin.
After swapping the sensor, set the address DIP switches to settings in the circuit diagram.
Check sensor functionality
Sensor works at new location
Y N
Replace sensor
Perform RAP 006 ICAN Circuit
Success
N Y
Exit
Perform RAPs for both related CPU PCBs (skip the part that guides you back to RAP SP
Sensor)
Success
Y N
Replace the SP Sensor (REP 15.35)
Exit

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RAP 044 Vacuum Solenoid and Brake Clutch Power off and disconnect the following:
1. Connectors to CPU PCB, 24V Distribution PCB and SOL Driver PCB.
2. Sol/clutch connector.
Initial Actions
Measure continuity between following positions: (see BSD)
• Enter service mode (GP 1) and check solenoid functionality (See GP’s)
• Ensure that all connectors at the clutch/solenoid are properly connected 1. All wires between CPU PCB and SOL Driver PCB.
• Ensure that all connectors at PCBs are properly connected 2. All wires between 24V Distribution PCB and SOL Driver PCB.
3. All wires between SOL Driver PCB and sol/clutch connector.
NOTE! Check for short circuits between all wires above and between all wires above to chassis.
For measuring references and connectors identification see BSD There is continuity and no short circuit
Y N
Procedure Repair/replace harness
Check for mechanical problems.
WARNING!
Turn off the VF602 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Check LED D5 on the SOL Driver PCB ‘S’

Is it activated
Y N
Go to RAP 020 24/48 voltage very low entry RAP
Power off, swap the SOL Driver PCB with the PCB from the other BIN. Check solenoid
functionality
Does the SOL Driver PCB work at the new location
Y N
Replace the faulty SOL Driver PCB
Power off, swap the SOL Driver back to the original location, swap the CPU PCB with the
one from the other bin. After swapping the PCB, set the address DIP switches to settings in
the circuit diagram. Check solenoid functionality
Does the CPU PCB work at the new location
Y N
Replace the faulty CPU PCB
Power off, swap the CPU PCB back to the original location. After swapping the PCB, set the
address DIP switches to settings in the circuit diagram.
Swap the 24V Distributor PCB with the one from the other bin. Check solenoid functionality.
Does the 24V Distribution PCB work at the new location
Y N
Replace the faulty 24V Distribution PCB
Power off, swap the sol/clutch with the one from the other bin. Check solenoid functionality
Does the sol/clutch work at the new location
Y N
Replace the faulty sol/clutch

Harness check:

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 DIP Switch Settings

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CR500 Fault Code Descriptions CR-115 Stepper motor driver CR-M1 PCB “G” too high / too low
Goto RAP 025 12/24/48V low or high
CR-001 Entrance sensor CR-Q2 Blocked without a preceding Sheet
exit signal
CR-116 Stepper motor driver CR-M1 PCB “H” too high / too low
Goto RAP 001 Edge detection sensor RAP
Goto RAP 025 12/24/48V low or high

CR-002 Entrance sensor CR-Q2 Not activated in time

CR-117 Stepper motor CR-M1 Short / Open circuit
Goto RAP 001 Edge detection sensor RAP
Goto RAP 006 CR-M1 Motor RAP

CR-003 Sensor CR-Q1, CR-Q2, CR-Q3 or CR-Q4 Activated too long

CR-118 Stepper motor CR-M2 Short / Open circuit
Goto RAP 001 Edge detection sensor RAP
Goto RAP 007 CR-M2 Motor RAP

CR-005 Exit sensor CR-Q5 Activated too long

CR-119 Stepper motor CR-M3 Short / Open circuit
Goto RAP 002 CR_Q5 Exit sensor RAP
Goto RAP 008 CR-M3 Motor RAP

CR-101 Creaser tools home position sensor CR-Q5 Not activated

CR-120 Sensor CR-Q1 Activated too long
intime after start of CR-M3
Goto RAP 001 Edge detection sensor RAP
Goto RAP 004 CR-Q6 Home position CR-M3 sensor RAP

CR-121 Sensor CR-Q3 Activated too long

CR-102 Lead screw motor CR-M2 home position sensor CR-Q7 Not
Goto RAP 001 Edge detection sensor RAP
activated in time after start of CR-M2
Goto RAP 003 CR-Q7 Home position CR-M2 sensor RAP
CR-122 Sensor CR-Q4 Activated too long
Goto RAP 001 Edge detection sensor RAP
CR-103 Lead screw motor CR-M2 home position sensor CR-Q7 Acti-
vated too long after start of CR-M2
CR-140 Interlock circuit Mismatch CR-SW2, CRSW3 state with volt-
Goto RAP 003 CR-Q7 Home position CR-M2 sensor RAP
age
Goto RAP 017 Interlock mismatch
CR-111 Stepper motor driver CR-M1 PCB “E” No CAN communica-
tion
CR-141 Bad EEPROM
Goto RAP 010 No ICAN Communication RAP
Goto RAP 032 EEPROM

CR-112 Stepper motor driver CR-M1 PCB “G” No CAN communica-

CR-150 CAN communication with Booklet Maker Interrupted
tion
Goto RAP 013 No XCAN Communication
Goto RAP 010 No ICAN Communication RAP

CR-113 Stepper motor driver CR-M1 PCB “H” No CAN communica-

tion
Goto RAP 010 No ICAN Communication RAP

CR-114 Stepper motor driver CR-M1 PCB “E” too high / too low
Goto RAP 025 12/24/48V low or high

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CR500 RAPs

RAP 001 Edge detetection sensor RAP

This RAP is for troubleshooting a faulty Edge detection sensor, cause of failure could be
harness, sensor (Pht and/or LED part) or PCB “A”.
Initial Actions
• Enter service mode according to GP 1
• Check sensor according to GP4.
• Ensure that Edge detection sensor LED and Pht are clean
• Ensure that all connectors at the Edge detection sensor LED and Pht are properly con-
nected
• Ensure that all connectors at PCB “A” are properly connected.

NOTE!
For measuring references see BSD
One Edge detection sensor includes both a PhT (phototransistor) and a LED.
PhT is connected by black/white wires, LED is connected by black/red wires.
Q1, Q2, Q3 and Q4 are in an electrical way exactly the same, this means you can move
one sensor or a part of the sensor (PhT or LED) to another position to help you find the
faulty part.

Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Swap the faulty optical sensor PhT with one next to it.
Sensor PhT works at the new location
Y N
Replace sensor PhT (PL 1.6)
Swap the faulty optical sensor LED with one next to it
Sensor LED works at the new location
Y N
Replace sensor LED (PL 1.6)
At the faulty location, disconnect sensor PhT and sensor LED wire both from PCB and sen-
sor. Check all wires to sensor PhT and to sensor LED for short circuit and continuity. Also
check for short circuits between all wires and chassis.
There is continuity and no short circuit
Y N
Repair/replace harness (PL1.9)
Replace CPU PCB “A” (PL1.8)

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RAP 002 Q5 Exit sensor RAP
This RAP is for troubleshooting a faulty Q5 sensor, cause of failure could be harness, sen-
sor or PCB “A”.

Initial Actions
• Enter service mode according to GP 1.
• Check sensor according to GP4.
• Ensure that Q5 sensor is clean
• Ensure that connector at the Q5 sensor is properly connected
• Ensure that all connectors at PCB “A” are properly connected.

NOTE!
For measuring references see BSD
Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Disconnect [A,P4] and [J/PQ5] Check all wires for continuity and for short circuits between
all wires and between all wires and chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Reconnect [A,P4] and leave [J/PQ5] disconnected, power on the machine, measure VDC
between [A,P4-1] and [A,P4-3] and between [A,P4-2] and [A,P4-3]
The voltage in both cases are 5VDC ±10%
Y N
Repair/replace harness
Power off, reconnect [J/PQ5] power on the machine, make sure nothing is covering the
sensor, measure VDC between [A,P4-2] and [A,P4-3]
The voltage is 5VDC ±10%
Y N
Replace Exit sensor
Cover the sensor with a piece of paper, measure VDC between [A,P4-2] and [A,P4-3]
The voltage is lower than 0,8VDC
Y N
Replace Q5 sensor
Replace CPU PCB “A” (PL 1.8)

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RAP 003 Q7 Home position M2 sensor RAP
This RAP is for troubleshooting a faulty Q7 sensor, cause of failure could be harness, sen-
sor or PCB “G”.

Initial Actions
• Enter service mode according GP 1
• Check sensor according to GP 4
• Ensure that Q7 sensor is clean
• Ensure that connector at the Q7 sensor is properly connected
• Ensure that all connectors at PCB “G” are properly connected.

NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Disconnect [G,P3] and [J/PQ7] Check all wires for continuity and for short circuits between
all wires and between all wires and chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Swap positions for PCB “G” and PCB “H” . After swapping the PCBs, set the address dip
switches to settings in the circuit diagram. Check sensor functionality.
The sensor works
Y N
Replace sensor Q7 (PL 1.5)
Replace original PCB “G” (PL1.8)

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RAP 004 Q6 Home position M3 sensor RAP
This RAP is for troubleshooting a faulty Q6 sensor, cause of failure could be harness, sen-
sor or PCB “H”.

Initial Actions
• Enter service mode according to GP 1
• Check sensor according to GP 4
• Ensure that Q6 sensor is clean
• Ensure that connector at the Q6 sensor is properly connected
• Ensure that all connectors at PCB “H” are properly connected.

NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Disconnect [H,P3], [H,P1] and [J/PQ6] Check all wires for continuity and for short circuits
between all wires and between all wires and chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Swap positions for PCB “H” and PCB “G” . After swapping the PCBs, set the address dip
switches to settings in the circuit diagram. Check sensor functionality.
The sensor works
Y N
Replace sensor Q6 (PL1.6)
Replace original PCB “H” (PL 1.8)

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RAP 005 Counter
This RAP is for troubleshooting a faulty Counter, cause of failure could be harness, Counter
or PCB “A”
Initial Actions
Ensure that connector at the counter is properly connected
Ensure that all connectors at PCB “A” are properly connected.

NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Disconnect [A,P3] and [J/PCNT] Check all wires for continuity and for short circuits be-
tween all wires and between all wires and chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Replace Counter, test Counter functionallity
The Counter works
Y N
Replace PCB “A” (PL 1.8)
Exit

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RAP 006 M1 motor RAP
This RAP is for troubleshooting a faulty M1 motor, cause of failure could be harness, motor
or PCB “E”.
Initial Actions
• Enter service mode according to GP 1
• Check motor according to GP 4
• Ensure that connector at the M1 motor is properly connected
• Ensure that all connectors at PCB “E” are properly connected.
• Check dip switch settings at PCB “E”

NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power off, disconnect motor harness from PCB and rotate motor manually and check that
all motor transmission components are moving.
Transmission works
Y N
Fix problem
Reconnect motor harness, power on and check D30 on PCB “E”.
The LED is activated
Y N
Go to RAP024 48V too high/low entry RAP
Disconnect [E,P7] and motor connector. Check for short circuit between all wires to chas-
sis.
There is continuity and no short circuit
Y N
Repair/replace harness
Swap positions for PCB “E” and PCB “G” After swapping the PCBs, set the address dip
switches to settings in the circuit diagram. Check motor functionality.
The motor works
Y N
Replace motor M1 (PL 1.2)
Replace original PCB “E” (PL 1.8)

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RAP 007 M2 motor RAP
This RAP is for troubleshooting a faulty M2 motor, cause of failure could be harness, motor
or PCB “G”.
Initial Actions
• Enter service mode according to GP 1
• Check motor according to GP4.
• Ensure that connector at the M2 motor is properly connected
• Ensure that all connectors at PCB “G” are properly connected.
• Check dip switch settings at PCB “G”

NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power off, disconnect motor harness from PCB and rotate motor manually and check that
all motor transmission components are moving.
Transmission works
Y N
Fix problem
Reconnect motor harness, power on and check D30 on PCB “G”.
The LED is activated
Y N
Go to RAP 024 48V too high/low entry RAP
Disconnect [G,P7] and motor connector. Check all wires for continuity and for short circuits
between all wires and between all wires and chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Swap positions for PCB “G” and PCB “H” After swapping the PCBs, set the address dip
switches to settings in the circuit diagram. Check motor functionality.
The motor works
Y N
Replace motor M2 (PL1.5)
Replace original PCB “G” (1.8)

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RAP 008 M3 motor RAP
This RAP is for troubleshooting a faulty M8 motor, cause of failure could be harness, motor
or PCB “H”.
Initial Actions
• Enter service mode according to GP1.
• Check motor according to GP4.
• Ensure that connector at the M3 motor is properly connected
• Ensure that all connectors at PCB “H” are properly connected.
• Check dip switch settings at PCB “H”

NOTE!
For measuring references see BSD

Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power off, disconnect motor harness from PCB and rotate motor manually and check that
all motor transmission components are moving.
Transmission works
Y N
Fix problem
Reconnect motor harness, power on and check D30 on PCB “H”.
The LED is activated
Y N
Go to RAP 024 48V too high/low entry RAP
Disconnect [H,P7] and motor connector. Check for short circuits between all wires to chas-
sis.
There is continuity and no short circuit
Y N
Repair/replace harness
Swap positions for PCB “H” and PCB “G” After swapping the PCBs, set the address dip
switches to settings in the circuit diagram. Check motor functionality.
The motor works
Y N
Replace motor M3 (PL1.6)
Replace original PCB “H” (PL1.8)

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RAP 010 No ICAN Communication entry RAP
This RAP is for troubleshooting a failed ICAN circuit
Target is to give a direction to what part of the ICAN circuit that failed.
Initial Actions
• Make sure that all dip switch settings on CPU PCBs and Stepper Motor Driver PCBs are
correct according to GP4.
• Ensure that all connectors to “A”, “E”, “G”, “H”, “K”, “L” PCBs are properly connected

Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

There are multiple codes related to ICAN communication failure

Y N
Perform the PCB “x” RAP for the PCB “x” mentioned in the failure code
PCB RAP solved the problem
Y N
Perform RAP 011 ICAN Circuit
ICAN Circuit RAP solved the problem
Y N
Replace the PCB “x” (PL 1.8)
LED D5, 12V logic Power in.
Exit Deactivated=no voltage present. Acti-
Exit vated= voltage present, not necessary
Check D5 Blue LED on PCBs “A” and D2 Blue LED on PCBs “E”, “G” and “H”. If diode is not the correct voltage level.
activated there is no 12V to the PCB.
All diodes are activated
Y N
Perform the PCB “x” RAP for the PCB “x” with the deactivated LED.
PCB RAP solved the problem
Y N
Perform RAP 011 ICAN Circuit
ICAN Circuit RAP solved the problem LED D2, 12V logic Power in.
Deactivated=no voltage present. Acti-
Y N
vated= voltage present, not necessary
Replace the PCB “x” (PL 1.8) the correct voltage level.
Exit
Exit
Perform RAP 011 ICAN Circuit

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RAP 011 ICAN Circuit Locate the open circuit by performing following steps:
Check open circuit between (CAN termination check) [A,J10-4] to
This RAP is for troubleshooting a failed ICAN circuit related to multiple PCBs.
[A,J10-6] and between [H,P5-4] to [H,P5-6]. Replace the failed PCB
Target is to checks wires and PCBs for short/open circuit and check if the ICAN termination
is OK. Locate the short circuit by performing the following steps:
Harness check:
Initial Actions 1. Disconnect all [P6] and [P10] connectors on PCBs “E”, “G” and “H”.
• Make sure that all dip switch settings on CPU PCBs and Stepper Motor Driver PCBs are 2. Disconnect [A,P10].
correctly according to GP4 3. Check short circuits between all Red and Black wires and all wires to chassis
• Ensure all connectors to “A”, “E”, “G”, “H”, “K”, “L” PCBs are properly connected. included in the ICAN circuit, check BSD.
PCBs check:
1. Check short circuit between [J6-4] to [J6-6] and [J5-4] to [J5-6] on PCBs “E”,
“G” and “H”.
2. Check short circuit between [A,J10-4] and [A,J10-6]
Procedure Repair/replace harness or replace PCB depending on the source of short circuit.

WARNING! Go to RAP 012 CPU PCB A, no success replace PCB “A”

Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power off the machine, check continuity between wire from [A,P10-4] to [H,P5-4] and wire
from [A,P10-6] to [H, P5-6]. (ICAN Start to ICAN End continuity check.).
There is continuity
Y N
Locate the open circuit by performing following steps:
Harness check:
1. Disconnect [A,P10] .
2. Disconnect all [P5] and [P6] connectors on PCBs “E”, “G” and “H”.
3. Check continuity for all wires included in the ICAN circuit, check BSD.
PCBs check:
1. Check continuity between [J5-4] to [J6-4] and [J5-6] to [J6-6] on PCBs “E”, “G”
and “H”.
Repair/replace harness or replace PCB depending on the source of open circuit.
Measure resistance between [A,P10-4] to [A,P10-6] (ICAN termination check)..
The resistance is 50-70 ohm
Y N
The resistance lower than 50 ohm (short circuit)
Y N
Disconnect [H,P5], [H,P6] and [A,P10].
Check dip switch settings for PCB “A” and “H”.
Dip switch settings are OK
Y N
Set correctly and exit

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RAP 012 CPU PCB ”A” Measure VDC between GND and VCC (see image). The voltage is 5VDC±10%
This RAP is for troubleshooting a failed CPU PCB “A” Y N
Target is to check if the PCB communicates correctly and logic voltages are OK. Power of, disconnect [A,P4], power on, Measure VDC between GND and VCC (see
image). The voltage is 5VDC±10%
Initial Actions
Y N
• Ensure that all dip switch settings on PCBs “A”, “E”, “G” and “H” are correct according to
GP4 Replace PCB “A” (PL 1.8)
• Ensure that all connectors to “A”, “E”, “G”, “H”, “K”, and L” PCBs are properly connected. Go to RAP 002 Q5 Exit sensor RAP (pay attention to short circuit measurements)
Procedure Measure VDC between GND and 3,3VDC (see image). The voltage is 3,3VDC±5%
Y N
WARNING!
Replace PCB “A” (PL 1.8)
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring Previous performed RAP was No XCAN Communication RAP
resistance inside the machine. Y N
Perform RAP 011 ICAN Circuit
Power on the machine. If D5 Blue LED on PCB “A” is deactivated go directly to N, it means Success
no 12VDC. If D5 activated, measure VDC between [A, P6-1] to [A, P6-10]. Y N
The voltage is 12VDC±10% Replace PCB “A” (PL 1.8)
Y N Exit
Power off, disconnect [A, P3], power on. Power off the whole system and CR500, disconnect [A, P7], [A, P8], [J/P23] and [J/P24]. Check
D5 Blue LED at PCB “A” is activated continuity for all wires between [A, P7] to [J23] and all wires between [A, P8] to [P24].
N Y There is continuity
Go to RAP 005 Counter (pay attention to short circuit measurements). Y N
Power off disconnect [A,P10], power on. Repair/replace harness
D5 Blue LED at PCB “A” is activated Keep the whole system and CR500 powered off and [A, P7], [A, P8], [J/P23] and [J/P24] discon-
N Y nected. Check for short circuits between all wires connected to [J23] and [P24] and all wires from
[J23] and [P24] to chassis, pin 3 for both [J23] and [P24] are connected to chassis
Power off, disconnect [E,P5], leave [A,P10] disconnected. Check for
short circuits between all wires connected to [A, P10], and between all There is no short circuit except pin 3
wires from [A, P10] to chassis Y N
There is no short circuit. Repair/replace harness
Y N Check the XCAN communications cables (one or two) for continuity and short circuits, positions
Repair/replace harness that needs to be checked are pins 1,2,3,5 and 7
Replace PCB “E” (PL 1.8) There is continuity and no short circuit
Power off, disconnect [A, P6] and [K, P2], check continuity between all wires from Y N
[A, P6] to [K, P2], check short circuits between all wires connected to [A, P6], and Repair /replace harness
between all wires from [A, P6] to chassis. Disconnect XCAN terminations (two) connected to the system, check resistance between pin 2
There is continuity and no short circuit and 7.
Y N The resistance is between 110-130 ohm
Repair/replace harness (PL 1.9) Y N
Leave [K, P2] disconnected, power on. Repair /replace termination(s)
Measure VDC between [K, J2-1] to [K, J2-4] (PCB connector) Go to and perform XCAN communication RAPs in service manuals for the machines connected
The voltage is 12VDC±10% to CR500
Y N Success
Go to RAP 020 SCP PCB ”K” Y N
Replace PCB “A” (PL 1.8) Replace PCB “A” (PL 1.8)
Exit BSDs on next to next pages

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LED D10,
VCC (+5VDC)
Sensors.
Deactivated=no
voltage present.
Activated= volt-
age present, not
necessary the
correct voltage
level.
GND measur-
ing point, all four
plated holes are
LED D1, CPU connected to
controlled LED GND

+3,3VDC
measuring point

VCC (+5VDC)
measuring point

LED D5, 12V logic Power in.

Deactivated=no voltage present. Acti-
vated= voltage present, not necessary
the correct voltage level.

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RAP 013 No XCAN Communication
This RAP is for troubleshooting XCAN communication failure, no communication with
machines in the system.
Target is to give directions to possible source of failure
Initial Actions
• Ensure that plugs/jacks J/P23 and J/P24 are properly connected.
• -Ensure that all dip switch settings on PCBs “A”, “E”, “G”, and “H” are correct according
to GP4
• Ensure that all connectors to SW1, PSU (12V) and “A”, “E”, “G”, “H”, “K”, “L” PCBs are
properly connected
• Make sure the CAN-terminations in the system are properly connected, two D-sub con-
nectors normally connected to the first and last machine in the system.

Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
WARNING!
Use caution when making the voltage measurements and always disconnect the
Power Cord when it is necessary to work inside the Power Module. AC Power is pre-
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet.

Power on the machine. Measure between [K, P1-1] to [K, P1-4]

The voltage is 12VDC±10%
Y N
Power off and disconnect the Power Cord, check status of F1 located in the
power inlet.
F1 is blown
N Y
Go to RAP 023 F1 Blown Fuse
Go to RAP 012 CPU PCB “A”
Go to RAP 012 CPU PCB “A”

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RAP 014 Stepper Motor Driver M1 PCB ”E”
This RAP is for troubleshooting a failed Stepper Motor Driver M1 PCB
Target is to check if the PCB communicates correctly and logic voltages are OK.
Initial Actions
• Ensure that all dip switch settings on PCBs “A”, “”E, “G”, “L”, “K” and “H” are correct ac-
cording to GP4
• Ensure that all connectors to “A”, “E”, “G”, “H”, “K” and “L” PCBs are properly connected

Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power on the machine. If D2 Blue LED on PCB “E” is deactivated go directly to N, it means
no 12VDC. If D2 activated, measure VDC between [E, P5-1] to [E, P5-10].
The voltage is 12VDC±10%
Y N
Perform RAP 012 CPU PCB ”A”
Success
Y N
Replace PCB “E” (PL 1.8)
Exit
Measure VDC between GND and VCC (see image). The voltage is 5VDC±10%
Y N
Replace PCB “E” (PL 1.8)
Measure VDC between GND and 3,3VDC (see image). The voltage is 3,3VDC±5%
Y N
Replace PCB “E” (PL 1.8)
Goto RAP 010 No ICAN Communication entry RAP

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 LED D31, VCC (+5VDC).
Deactivated=no voltage present. Activated=
voltage present, not necessary the correct
voltage level.
LED D1, CPU controlled LED GND measuring point

LED D2, 12V logic Power in.

Deactivated=no voltage present. Acti-
vated= voltage present, not necessary
the correct voltage level.

VCC (+5VDC) measuring point

+3,3VDC measuring point

LED D30, motor Power in.

Deactivated=no voltage
present. Activated= voltage
present, not necessary the
correct voltage level.

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RAP 015 Stepper Motor Driver M1 PCB ”G” Measure VDC between GND and VCC (see image). The voltage is 5VDC±10%
This RAP is for troubleshooting a failed Stepper Motor Driver M2 PCB Y N
Target is to check if the PCB communicates correctly and logic voltages are OK. Power of, disconnect [G,P3], power on, Measure VDC between GND and VCC (see
Initial Actions image). The voltage is 5VDC±10%
• Ensure that all dip switch settings on PCBs “A”, “”E, “G”, “L”, “K” and “H” are correct ac- Y N
cording to GP4 Replace PCB “G” (PL 1.8)
• Ensure that all connectors to “A”, “E”, “G”, “H”, “K” and “L” PCBs are properly connected Go to RAP 003 Q7 Home position M2 sensor RAP (pay attention to short circuit meas-
urements)
Procedure Measure VDC between GND and 3,3VDC (see image). The voltage is 3,3VDC±5%
WARNING! Y N
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before Replace PCB “G” (PL 1.8)
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine. Goto RAP 010 No ICAN Communication entry RAP

Power on the machine. If D2 Blue LED on PCB “G” is deactivated go directly to N, it means
no 12VDC. If D2 activated, measure VDC between [G, P5-1] to [G, P5-10].
The voltage is 12VDC±10%
Y N
Power off disconnect [G,P6], power on.
D5 Blue LED at PCB “A” is activated
N Y
Power off, disconnect [H,P5], leave [G,P6] disconnected. Check for
short circuits between all wires connected to [G, P6], and between all
wires from [G, P6] to chassis
There is no short circuit.
Y N
Repair/replace harness
Go to RAP 016 Stepper Motor Driver M3 PCB ”H”
Power off, disconnect [G, P5] and [L, P2], check continuity between all wires from
[G, P5] to [L, P2], check short circuits between all wires connected to [G, P5], and
between all wires from [G, P5] to chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Leave [L, P2] disconnected, power on.
Measure VDC between [L, J2-1] to [L, J2-4] at PCB “L”.(PCB Connector)
The voltage is 12VDC±10%
Y N
Go to RAP 021 SCP PCB ”L”
Perform RAP 018 Top Cover Switch Interlock circuit
Succes
Y N
Replace PCB “G” (PL 1.8)
Exit

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RAP 016 Stepper Motor Driver M3 PCB ”H”
This RAP is for troubleshooting a failed Stepper Motor Driver M3 PCB
Target is to check if the PCB communicates correctly and logic voltages are OK.
Initial Actions
• Ensure that all dip switch settings on PCBs “A”, “”E, “G”, “L”, “K” and “H” are correct ac-
cording to GP4
• Ensure that all connectors to “A”, “E”, “G”, “H”, “K” and “L” PCBs are properly connected

Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power on the machine. If D2 Blue LED on PCB “H” is deactivated go directly to N, it means
no 12VDC. If D2 activated, measure VDC between [H, P5-1] to [H, P5-10].
The voltage is 12VDC±10%
Y N
Power off, disconnect [H,P6] and [J/P307] if connected. Check for short circuits
between all wires connected to [H, P6], and between all wires from [H, P6] to
chassis
There is no short circuit.
Y N
Repair/replace harness
Perform RAP 015 Stepper Motor Driver M1 PCB ”G”
Success
Y N
Replace PCB “H” (PL 1.8)
Exit
Measure VDC between GND and VCC (see image). The voltage is 5VDC±10%
Y N
Replace PCB “H” (PL 1.8)
Measure VDC between GND and 3,3VDC (see image). The voltage is 3,3VDC±5%
Y N
Replace PCB “H” (PL 1.8)
Goto RAP 010 No ICAN Communication entry RAP

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RAP 017 Interlock mismatch
This RAP is for troubleshooting a failed Interlock circuit, voltage present when Interlock
circuit is supposed to be opened.
Target is to find the source of failure, relay, harness or PCB.
Initial Actions
• Make sure that plugs/jacks J/P29, J/P25, J/P26 and J/P28 are properly connected.
• Make sure that all connectors connecting to the Top Cover Switch(SW2/SW3), REL1,
PSU (24V) and PSU (24/48V) are properly connected.
• Ensure that all connectors to “A”, “E”, “G”, “H”, “L”, “M”, “N” and “K” PCBs are properly
connected.

Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
WARNING!
Use caution when making the voltage measurements and always disconnect the
Power Cord when it is necessary to work inside the Power Module. AC Power is pre-
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet.

Power on the machine and leave the Top Cover Switch deactivated (cover open). Measure
voltage (VAC) between L and N on the PSU (24V) input.
The voltage is 90-264VAC.
Y N
Replace the Stepper Motor Driver PCB mentioned in the failure code
Perform RAP 018 Top Cover Switch Interlock circuit
Success
Y N
Perform RAP 019 Top Cover Switch software signal
Success
Y N
Replace REL1 (PL 1.7)
Exit
Exit

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
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RAP 018 Top Cover Switch Interlock circuit Leave connectors disconnected, Measure resistance between harness connectors [REL1-
A1] to [REL1- A2].
This RAP is for troubleshooting when the Top Switch Interlock circuit doesn’t work properly.
Target is to find the out what part of the Top Cover Switch Interlock circuit that fails. Resistance > 200 ohm
Y N
Initial Actions
Repair/replace the Harness (may be the diode included in harness)
• Make sure that plugs/jacks J/P29, J/P25, J/P26 and J/P28 are properly connected.
• Make sure that all connectors connecting to the Top Cover Switch(SW2/SW3), REL1, Leave connectors disconnected, Measure resistance between relay connectors A1 to A2 on
PSU (24V) and PSU (24/48V) are properly connected. REL1 (not the harness connectors).
• Ensure that all connectors to “A”, “E”, “G”, “H”, “L”, “M”, “N” and “K” PCBs are properly Resistance 30-60 ohm
connected. Y N
Replace REL1 (PL 1.7)
Procedure
Leave connectors disconnected, Power on, measure VDC between [L,J2-1] and [L,J2-4] at
WARNING! PCB “L” (PCB connector).
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before The voltage is 12VDC±10%
disconnecting, removing or replacing any electrical components or measuring Y N
resistance inside the machine.
Go to RAP 021 SCP PCB ”L”
Replace PCB “A” (PL 1.8)
Power off the machine, disconnect the Power Cord and all four wires connected to Top
Cover Switch. Leave Top Cover Switch deactivated, measure resistance between Door
Switch pos. 1 to 2 (not harness connectors).
There is open circuit, resistance > 1 Mohm.
Y N
Replace Top Cover Switch (PL 1.4)
Activate Top Cover Switch, measure resistance between Top Cover Switch pos. 1 to 2 (not
harness connectors).
There is continuity
Y N
Replace Top Cover Switch (PL 1.4)
Disconnect [A, P4], [A, P5], [L, P2], [REL1-A1] and [REL1-A2]. Deactivate Top Cover
Switch, measure continuity between following positions:
1. [A,P5-1,2] to [REL1-A2]
2. [L,P2-1] to Top Cover Switch pos. 1
3. [REL1-A1] to Top Cover Switch pos. 2
There is continuity
Y N
Repair/replace harness (PL 1.9)
Leave connectors disconnected, Check for short circuits between following positions:
1. [A,P4-23] and [A, P4-24]
2. [A,P4-23] and [A,P4-24] to chassis,
3 [L,P2-1] and chassis,
4 [REL1-A1] and [REL1-A2] to chassis
5 [REL1-A1] and [REL1-A2]
6. [A,P5-1,2] and chassis,
There are no short circuits
Y N
Repair/replace harness (PL 1.9)

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RAP 019 Top Cover Switch software signal
This RAP is for troubleshooting Top Cover Switch software signal circuit.
Target is to find the out if the Top Cover Swicth or PCB “A” has failed.

Initial Actions
• Make sure that plugs/jacks J/P29, J/P25, J/P26 and J/P28 are properly connected.
• Make sure that all connectors connecting to the Top Cover Switch(SW2/SW3), REL1,
PSU (24V) and PSU (24/48V) are properly connected.
• Ensure that all connectors to “A”, “E”, “G”, “H”, “L”, “M”, “N” and “K” PCBs are properly
connected.

Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power off the machine, disconnect the Power Cord. Leave Top Cover Switch deactivated,
measure resistance between Top Cover Switch pos. 3 to 4.
There are open circuits, resistance > 1 Mohm.
Y N
Replace Top Cover Switch (PL 1.4)
Activate Top Cover Switch, measure resistance between Door Switch pos. 3 to 4.
There is continuity
Y N
Replace the Top Cover Switch (PL 1.4)
Disconnect [A, P4], deactivate Top Cover Switch, measure continuity between Top Cover
Switch pos. 3 to [A, P4-23] and Top Cover Switch pos. 4 to [A, P4-24]. Check short circuit
between Black to White wire and between Black and White wires to chassis.
There is continuity and no short circuit
Y N
Repair/replace harness (PL 1.9)
Replace PCB “A” (PL 1.8)

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RAP 020 SCP PCB ”K”
This RAP is for troubleshooting a failed SCP PCB “K” (no 12V on [K,P2].
Target is to guide you to the correct RAP
When there is no 12V out from the PCB “K” it is most likely a short circuit related to the har-
ness or PCBs connected to [K,P2] or a broken PSU (12V).
SCP = Short Circuit Protection
Initial Actions
• Ensure that all connectors to “A”, “E”, “G”, “H”, “K” and “L” PCBs are properly connected

Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before There is continuity and no short circuit
disconnecting, removing or replacing any electrical components or measuring
Y N
resistance inside the machine.
Repair/replace harness (PL 1.9)
Go to RAP 022 PSU (12V)
Power on the machine, measure VDC between [K, P2-1] to [K, P2-3] and between [K, P2-2]
to [K, P2-4]. Success
The voltage is 12VDC±10% Y N
Y N Replace PCB “K” (PL 1.8)
Power off, disconnect [K,P2], power on, measure VDC between [K, J2-1] to [K, Exit
J2-3] and between [K, J2-2] to [K, J2-4], (PCB connector). Go to RAP 012 CPU PCB ”A” (pay attention to short circuit measurements)
The voltage is 12VDC±10% Success
Y N Y N
Power off, disconnect [K,P1], measure continuity between all wires from Replace PCB “K” (PL 1.8)
PSU (12V) to [K,P1] also measure for short circuit between all red wires Exit
from PSU (12V) to chassis and from all red wires to black wires. Exit

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RAP 021 SCP PCB ”L”
This RAP is for troubleshooting a failed SCP PCB “L” (no 12V on [L,P2].
Target is to guide you to the correct RAP
When there is no 12V out from the PCB “L” it is most likely a short circuit related to the har-
ness or PCBs connected to [L,P2] or a broken PSU (12V).
SCP = Short Circuit Protection
Initial Actions
• Ensure that all connectors to “A”, “E”, “G”, “H”, “K” and “L” PCBs are properly connected
There is continuity and no short circuit
Y N
Procedure
Repair/replace harness (PL 1.9)
WARNING! Go to RAP 022 PSU (12V))
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
Success
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine. Y N
Replace PCB “L” (PL 1.8)
Power on the machine, measure VDC between [L, P2-1] to [L, P2-3] and between [L, P2-2] Exit
to [L, P2-4]. Go to RAP 015 Stepper Motor Driver M1 PCB ”G”(pay attention to short circuit
The voltage is 12VDC±10% measurements)
Y N Success
Power off, disconnect [L,P2], power on, measure VDC between [L, J2-1] to [L, Y N
J2-3] and between [L, J2-2] to [L, J2-4], (PCB connector). Go to RAP 018 Top Cover Switch Interlock circuit. (pay attention to
The voltage is 12VDC±10% short circuit measurements)
Y N Success
Power off, disconnect [L,P1], measure continuity between all wires from Y N
PSU (12V) to [L,P1] also measure for short circuit between all red wires Replace PCB “L” (PL 1.8)
from PSU (12V) to chassis and from all red wires to black wires. Exit
Exit
Exit

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RAP 022 PSU (12V)
This RAP is for troubleshooting a failed PSU (12V) (no 12V out).
When there is no 12V out from the PSU it is most likely a blown F1 or a broken PSU.

Initial Actions
• Ensure that [J/P25], Power Entry, REL1 and PSU are connected properly.

Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power off and disconnect the Power Cord, check status of F1 located in the Power Entry
inlet
F1 is blown
N Y
Go to RAP 023 F1 Blown Fuse
Reconnect power cord and power on, measure VAC at the PSU (12V) input between [L] and
[N].
The voltage is 90-264VAC
N Y
Replace PSU (12V) (PL 1.8)
Power off and disconnect the Power Cord, measure continuity for all wires between Power
Entry to input at PSU (12V) ([L] and [N]). Set SW1 (Main switch) on. Important: The Power
Cord must be disconnected!
There is continuity
N Y
Replace PSU (12V) (PL 1.8)
Repair/replace harness between Power Entry to PSU (12V). (PL 1.9)

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RAP 023 F1 Blown Fuse Leave all connectors in previous steps disconnected, disconnect L and N from PSU (24V),
check short circuit between L to N, L and N to chassis at the PSU (24V).
This RAP is for troubleshooting when F1 frequently blows up.
Target is to find the source that makes fuse F1 to blow up There are no short circuits
Y N
Initial Actions
Replace PSU (24V) (REPx) (PL 1.8)
• Ensure that there is proper voltage at the wall outlet.
• Check all connectors related to Power Entry, SW1, REL1, and input side of PSU (12V), Leave all connectors in previous steps disconnected, disconnect L and N from PSU
PSU (24V) and PSU (24/48V). (24/48V), check short circuit between L to N, L and N to chassis at the PSU (24/48V).
There are no short circuits
Y N
Procedure Replace PSU (24/48V) (REPx) (PL 1.8)
WARNING! Repair/replace harness between REL1 and PSU (24V)/PSU (24/48V)
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
WARNING!
Use caution when making the voltage measurements and always disconnect the
Power Cord when it is necessary to work inside the Power Module. AC Power is pre-
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet.

During this whole RAP, power off the machine, disconnect the Power Cord (very important!)
and leave Top Cover Switch deactivated. Disconnect Black,1 and Black,2 wires from the
Power Entry, check short circuit between positions 3 to 4 (Power Entry) and between chas-
sis to position 3 and 4 at the Power Entry
There are no short circuits
Y N
Replace Power Entry (PL 1.8)
Leave all connectors in previous step disconnected. Check short circuit between wires from
[SW1,2] to [SW1,5] and between wires from [SW1,2] and [SW1,5] to chassis.
There are no short circuits
Y N
Repair/replace harness (PL 1.9)
Leave all connectors in previous steps disconnected, check short circuit between wires
from [SW1,1] to [SW1,4] and between wires from [SW1,1] and [SW1, 4] to chassis.
There are no short circuits
Y N
Leave all connectors in previous steps disconnected, disconnect L and N from
PSU (12V) input. Check short circuit between L to N, L and N to chassis at the
PSU (12V) input.
There are no short circuits
Y N
Replace PSU (12V) (REPx) (PL 1.8)
Locate and Repair/replace harness between SW1 and REL1/PSU (12V)

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RAP 024 48V to high/low entry RAP
This RAP gives directions to correct RAP in case of multiple or single code Go to RAP 029 48V to low
48V to low RAP solved the problem
Initial Actions N Y
• Make sure that plugs/jacks J/P25, J/P26, J/P28 and J/P29 are properly connected.
Exit
• Make sure that all connectors connecting to the Top Cover Switch, REL1, PSU (24V) and
PSU (24/48V) are properly connected. Perform RAPs in following order:
• Ensure that all connectors to “A”, “E”, “G”, “H”, “K”, “L”, “M” and “N” PCBs are properly 1. RAP 026 Stepper Motor M1 PCB 48V to low
connected. 2. RAP 027 Stepper Motor M2 PCB 48V to low
3. RAP 028 Stepper Motor M3 PCB 48V to low
If no success, replace PCBs in same order.
Procedure
WARNING! Depending on error code, go to RAP 026, 027 or 028
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
Important! For safety reasons in case of a “to low/high 48V” there is a limited time when
voltage are applied to PSU (24V) and PSU (24/48V), this affects the voltage measure- RAP 025 12/24/48V low or high
ments, please see “48VDC Interlock/PSU procedure” for further information This RAP is for troubleshooting a low or high 12V, 24V or 48V

Power off, open the Top Cover, pay attentionen to REL1, power on and close the Top Initial Actions
Cover None
REL1 activates within 10 seconds (you can hear and see if it activates)
Y N Procedure
Go to RAP 018 Top Cover Switch Interlock circuit WARNING!
Power off, close the Top Cover, power on, measure VDC between [M,P2-7] and [N,P2-1]. Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
The voltage is over 55VDC disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
N Y
The voltage is over 57VDC
Adjust to the correct level according to the table below, if there is 48V low, start by checking
Y N
and adjust the 24V level at PSU (24V) before continuing with the PSU (24/48V) adjustment.
Go to RAP 025 12/24/48V low or high, adjust to correct value
Power off, close the Top Cover, power on, measure VDC between [M,P2-7] and NOTE!
[M,P2-1]. This is only one turn trimmers, a ¼ turn is about 3,0 Vdc. Turn clock wise to increase and
The voltage is over 28,5VDC counter clockwise to decrease the output voltage
Y N
Replace PSU (24/48V) (PL1.8) Ideal level Code alert levels
Replace PSU (24V) (PL 1.8) Adjust to
PSU LOW HIGH Measure between
The voltage is 48VDC±10% [VDC] [VDC]
[VDC] [VDC]
N Y
(12V) 12V <11,5V >12,5V 11.8-12.3 V V- to V+ at PSU(12V)
Depending on error code, go to RAP 026, 027 or 028
Run diagnostics and check service codes (24V) 24V <22V >26V 23.8-24.3 V V- to V+ at PSU(24V)
Code is a single code V- at PSU(24V) to V+
(24/48V) 48V <40 V >55V 47.8-48.3 V
Y N at PSU(24/48V)

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RAP 026 Stepper Motor M1 PCB 48V to low RAP 027 Stepper Motor M2 PCB 48V to low
This RAP is for troubleshooting a to low 48V related to Stepper Motor M1 PCB “E”. This RAP is for troubleshooting a to low 48V related to Stepper Motor M2 PCB “G”.
Target is to decide if the failure is related to PCB or harness. Target is to decide if the failure is related to PCB or harness.
Initial Actions Initial Actions
• Make sure that plugs/jacks J/P25, J/P26, J/P28 and J/P29 are properly connected. • Make sure that plugs/jacks J/P25, J/P26, J/P28 and J/P29 are properly connected.
• Make sure that all connectors connecting to the Top Cover Switch, REL1, PSU (24V) and • Make sure that all connectors connecting to the Top Cover Switch, REL1, PSU (24V) and
PSU (24/48V) are properly connected. PSU (24/48V) are properly connected.
• Ensure that all connectors to “A”, “E”, “G”, “H”, “K”, “L”, “M” and “N” PCBs are properly • Ensure that all connectors to “A”, “E”, “G”, “H”, “K”, “L”, “M” and “N” PCBs are properly
connected. connected.
Procedure Procedure
WARNING! WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine. resistance inside the machine.

Power off the machine, disconnect [M, P2], [N, P2] and [E, P11]. Measure continuity be- Power off the machine, disconnect [M, P2], [N, P2] and [G, P11]. Measure continuity be-
tween [E, P11] Orange and Black wires to [M, P2] and [N, P2]. Check short circuit between tween [G, P11] Orange and Black wires to [M, P2] and [N, P2]. Check short circuit between
Black and Orange wires, also check short circuit from Orange wire to chassis. Black and Orange wires, also check short circuit from Orange wire to chassis.
There is continuity and no short circuit There is continuity and no short circuit
Y N Y N
Repair/replace harness (PL 1.9) Repair/replace harness (PL 1.9)
Disconnect all connectors connected to PCB “E”. Disconnect all connectors connected to PCB “G”.
Check short circuit between [J11-1] to [J11-2] (PCB connector). Check short circuit between [J11-1] to [J11-2] (PCB connector).
There is no short circuit There is no short circuit
Y N Y N
Replace PCB “E” (PL 1.8) Replace PCB “G” (PL 1.8)
Keep connectors disconnected and disconnect M1 Motor Connector. Check short circuit Keep connectors disconnected and disconnect M2 Motor Connector. Check short circuit
between all wires at to chassis. between all wires at [G,P7] and Motor connector (harness connector), between all wires at
There is no short circuit [G,P7] to chassis and all wires at Motor connector (harness connector) to chassis.
Y N There is no short circuit
Repair/replace harness (PL 1.9) Y N
Swap the Stepper Motor M1 PCB “E” with Stepper Motor M2 PCB “G”, make sure that Repair/replace harness (PL 1.9)
DIP-switches are correctly set (GPx) and all connectors are properly installed at both PCBs Swap the Stepper Motor M2 PCB “G” with Stepper Motor M3 PCB “H”, make sure that
before power on the machine. Power on. DIP-switches are correctly set (GPx) and all connectors are properly installed at both PCBs
Still “Stepper Motor M1 PCB 48V to high/low” before power on the machine. Power on.
Y N Still “Stepper Motor M2 PCB 48V very high/low”
Replace the original Stepper Motor M1 PCB “E” (PL 1.8) Y N
Exit Replace the original Stepper Motor M2 PCB “G” (PL 1.8)
Exit

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RAP 028 Stepper Motor M3 PCB 48V to low
This RAP is for troubleshooting a to low 48V related to Stepper Motor M3 PCB “H”.
Target is to decide if the failure is related to PCB or harness.
Initial Actions
• Make sure that plugs/jacks J/P25, J/P26, J/P28 and J/P29 are properly connected.
• Make sure that all connectors connecting to the Top Cover Switch, REL1, PSU (24V) and
PSU (24/48V) are properly connected.
• Ensure that all connectors to “A”, “E”, “G”, “H”, “K”, “L”, “M” and “N” PCBs are properly
connected.
Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Power off the machine, disconnect [M, P2], [N, P2] and [H, P11]. Measure continuity be-
tween [H, P11] Orange and Black wires to [M, P2] and [N, P2]. Check short circuit between
Black and Orange wires, also check short circuit from Orange wire to chassis.
There is continuity and no short circuit
Y N
Repair/replace harness
Disconnect all connectors connected to PCB “H”.
Check short circuit between [J11-1] to [J11-2] (PCB connector).
There is no short circuit
Y N
Replace PCB “H” (PL 1.8)
Keep connectors disconnected and disconnect M3 Motor Connector. Check short circuit
between all wires at to chassis.
There is no short circuit
Y N
Repair/replace harness (PL 1.9)
Swap the Stepper Motor M3 PCB “H” with Stepper Motor M1 PCB “E”, make sure that DIP-
switches are correctly set according to BSD on next page and all connectors are properly
installed at both PCBs before power on the machine. Power on.
Still “Stepper Motor M1 PCB 48V to high/low”
Y N
Replace the original Stepper Motor M3 PCB “H” (PL 1.8)
Exit

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 BSD on previous page
RAP 029 48V to low Power off the machine, measure resistance for the two diodes when disconnected
from PSU
This RAP is for troubleshooting a to low 48V
Target is to find out if the source of failure is related to the primary or secondary circuit of One or both diodes are shorted, resistance<1000 Ohm
the PSUs or if one of the PSU is broken Y N
Initial Actions Replace PSU (24/48V) (PL 1.8)
• Make sure that plugs/jacks J/P25, J/P26, J/P28 and J/P29 are properly connected. Replace diode/diodes (PL 1.8)
• Make sure that all connectors connecting to the Top Cover Switch, REL1, PSU (24V) and Go to RAP 030 48V secondary circuit
PSU (24/48V) are properly connected.
• Ensure that all connectors to “A”, “E”, “G”, “H”, “K”, “L”, “M” and “N” PCBs are properly
connected.
Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
Important! For safety reasons in case of a “very low/high 24V and/or 48V” there is a limited
time when voltage are applied to PSU (24V) and PSU (24/48V), this affects the voltage
measurements, please see “48VDC Interlock/PSU procedure” for further information

WARNING!
Use caution when making the voltage measurements and always disconnect the
Power Cord when it is necessary to work inside the Power Module. AC Power is pre-
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet.

Power on the machine and close the Top Cover. Measure voltage (VAC) between L and N
on the PSU (24V) and on the PSU (24/48V) inputs
The voltage is 90-264VAC
Y N
Go to RAP 031 REL1
Power off the machine, wait 5 seconds, disconnect V+ and V- from both PSU (24V) and
PSU (24/48V), disconnect diodes as well, Power on the machine and close the door. Meas-
ure voltage (VDC) between V+ and V- on the PSU (24V) output
The voltage is 24VDC±10% for at least a short period of time (measure during a
period of at least 10 seconds after Power ON). “N” means no reaction at all on the
output
Y N
Replace PSU (24V) (PL 1.8)
Power off the machine, keep V+ and V- disconnected wait 5 seconds, Power on the ma-
chine and close the door. Measure voltage (VDC) between V+ and V- on the PSU (24/48V)
output
The voltage is 24VDC±10% for at least a short period of time (measure during a
period of at least 10 seconds after Power ON). “N” means no reaction at all on the
output
Y N
Replace PSU (24/48) (PL 1.8)

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RAP 030 48V secondary circuit There is continuity and no short circuit
This RAP is for troubleshooting to low 48V related to the secondary circuit. Y N
RAP target: Repair/replace harness (PL 1.9)
To check harness between PSUs<>SCP PCBs and function of the SCP PCBs
Leave connectors from previous step disconnected.
Initial Actions Check continuity between [M, P2-5] to [M, P2-12].
• Make sure that plugs/jacks J/P25, J/P26, J/P28 and J/P29 are properly connected. There is continuity
• Make sure that all connectors connecting to the Top Cover Switch, REL1, PSU (24V) and Y N
PSU (24/48V) are properly connected.
. Repair/replace harness (PL 1.9)
• Ensure that all connectors to “A”, “E”, “G”, “H”, “K”, “L”, “M” and “N” PCBs are properly
connected. Reconnect [M,P1] and [N,P1] leave [M,P2], [N,P2] and [P11] at Stepper Motor Driver PCBs
“E”, “G” and “H” disconnected, disconnect [P1] at SCP PCBs “E” and “F”. Power on the
machine and close the Top Cover
Procedure Relay at SCP PCB “M” and “N” activates (connectors shorted away from coil) a pe-
WARNING! riod of time after power on/Top Cover closed.
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before Y N
disconnecting, removing or replacing any electrical components or measuring Replace PCB “M” and/or “N” depending on which relay that failed. (PL 1.8)
resistance inside the machine. Exit
NOTE!
For safety reasons in case of a to low 48V” there is a limited time when voltage are applied
to PSU (24V) and PSU (24/48V), this affects the voltage measurements, please see 48VDC
Interlock/PSU procedure” for further information.

This RAP presupposes that 48V to low entry RAP” has been performed.
Power off the machine, disconnect [M,P1] and [N,P1]. Measure continuity between wires
from PSU (24V) to [M,P1] PCBs, check short circuit between Black and Red wires, also
check short circuit from Red wires to chassis
There is continuity and no short circuit
Y N
Repair/replace harness (PL 1.9)
Leave connectors disconnected, measure continuity between wires from PSU (24/48V) to
[N, P1], check short circuit between Orange and Red wires, also check short circuit from
Red and Orange wires to chassis
There is continuity and no short circuit
Y N
Repair/replace harness (PL 1.9)
Reconnect all connectors, disconnect [M,P2] and [N,P2]. Measure continuity between wires
from [N, P2-7,8] to [M, P2-1,2]
There is continuity
Y N
Repair/replace harness (PL 1.9)
Leave connectors from previous step disconnected and disconnect [P11] at Stepper Motor
Driver PCBs “E”, “G” and “H”, check for short circuit between all wires on [N, P2] to chassis
and continuity between position [N, P2-5] to [N, P2-12]. Also check for short circuit between
all Orange wires at [N, P2] to all Black wires at [M, P2]

BSD on next page

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Plockmatic BM500 system 20 May 2019 4. Troubleshooting (RAP)
4-443
RAP 031 REL1
This RAP is for troubleshooting REL1 primary circuit. Power off the machine, disconnect the Power Cord. Measure continuity between wires from
Target is to find the out why there is no 90-240VAC to PSU (24V) and PSU (24/48V) inputs. REL1 to PSU (24V) input and between REL1 to PSU (24/48V) input.
Initial Actions There is continuity
• Make sure that plugs/jacks J/P25, J/P26, J/P28 and J/P29 are properly connected. Y N
• Make sure that all connectors connecting to the Top Cover Switch, REL1, PSU (24V) and Repair/replace harness (PL 1.9)
PSU (24/48V) are properly connected. Keep machine Powered off and the Power Cord disconnected. Measure continuity all the
• Ensure that all connectors to “A”, “E”, “G”, “H”, “K”, “L”, “M” and “N” PCBs are properly way between wires from REL1 and SW1.
connected.
There is continuity
Y N
Repair/replace harness (PL 1.9)
Procedure Replace REL1. (PL 1.7)
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.
NOTE!
For safety reasons in case of a “to low/high 48V” there is a limited time when voltage are
applied to PSU (24V) and PSU (24/48V), this affects the voltage measurements, please see
“48VDC Interlock/PSU procedure” for further information.
WARNING!
Use caution when making the voltage measurements and always disconnect the
Power Cord when it is necessary to work inside the Power Module. AC Power is pre-
sent in the Line Module whenever the Power Cord is plugged into the Wall Outlet.

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RAP 032 EEPROM
This RAP determines if there is corrupted software or if PCB needs top be replaced
Initial Actions
No initial action

Procedure
WARNING!
Turn off the CR500 Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components or measuring
resistance inside the machine.

Perform NVM reset according to GP20

Re-load S/W according to GP4
Replace PCB controller according to REP 16.25.

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5 SERVICE TABLES (GP)
Contents
GP 1 Entering Service Mode.................................................................................5-3 GP 30 Controller PCB ”A” LEDs and Test Points...............................................5-36
GP 2 Resetting / Changing the Service Mode Password....................................5-4 GP 31 MD6DC PCB Test points.............................................................................5-36
GP 3 Diagnostics....................................................................................................5-5 GP 32 4IN 4OUT PCB ”J” LEDs.............................................................................5-37
GP 4 Check Motors / Solenoids / Sensors...........................................................5-6 GP 33 Addon PCB ”F” Testpoints........................................................................5-38
GP 5 Service Program Mode Tables.....................................................................5-7 GP 34 Set Size Guide.............................................................................................5-39
GP 6 Voltmeter......................................................................................................5-14 GP 35 Tag Matrix and Serial Plate Location BM .................................................5-40
GP 7 Dead Cycle ..................................................................................................5-17 GP 36 Tag Matrix and Serial Plate Location Trimmer.........................................5-41
GP 8 Not in use.....................................................................................................5-17 GP 37 Tag Matrix and Serial Plate Location Square Folder...............................5-41
GP 9 Not in use.....................................................................................................5-17 GP 38 Tag Matrix and Serial Plate Location CT ..................................................5-42
GP 10 NVM Values..................................................................................................5-18 GP 39 Tool location ...............................................................................................5-42
GP 11 BM Fold Delay.............................................................................................5-22 GP 40 Interlock cheater location...........................................................................5-43
GP 12 BM Paper Size Reset...................................................................................5-22 GP 41 CST CPU / Controller PCB “A“ LEDs........................................................5-44
GP 13 Trimmer Service (Trimmer Module) ..........................................................5-25 GP 42 CST Solenoid Driver PCB “B“ LEDs.........................................................5-44
GP 14 Enabling CF (Cover Feeder Module) ........................................................5-25 GP 43 CST Stepper Motor Driver .........................................................................5-45
GP 15 SQF Service Adjust stop gate (Square Folder Module) ..........................5-26 GP 44 CST PCB Printer Interface, PCB “F“ LEDs...............................................5-45
GP 16 Counters .....................................................................................................5-26 GP 45 CST I/O 4IN4OUT PCB “G“.........................................................................5-46
GP 17 Fault code Structure ..................................................................................5-27 GP 46 CST CPU / Controller PCB “A“ Test points..............................................5-46
GP 18 Checking Versions of Installed Software..................................................5-27 GP 47 CST MD3DC Solenoid Driver PCB “B“ Test points..................................5-47
GP 19 Update Software..........................................................................................5-28 GP 48 CST Stepper Motor Driver..........................................................................5-47
GP 20 NVM Reset...................................................................................................5-30 GP 49 CST Controller PCB CPU “A“....................................................................5-48
GP 21 BM Calibrate Transport Pressure..............................................................5-32 GP 50 CST PCB MD3DC “B“.................................................................................5-49
GP 22 Cheat Trimmer cover 15min.......................................................................5-32 GP 51 CST PCB MD1SM “C“.................................................................................5-49
GP 23 BM and CST Printer Interface Check.........................................................5-32 GP 52 CST PCB MD1SM “D“.................................................................................5-50
GP 24 SQF Adjust Mode........................................................................................5-33 GP 53 CST PCB MD1SM “H“.................................................................................5-50
GP 25 Trimmer. Adjustment, compressor air stream trim GP 54 CST PCB MD1SM “J“..................................................................................5-51
waste kit.......................................................................................................5-33
GP 55 PCB CPU APP 32 “A” AF602/VF602..........................................................5-52
GP 26 30Vdc PSU (Power Supply SP-750-27) LED..............................................5-34
GP 56 PCB CPU APP 32 “H” (Upper Bin) AF602/VF602......................................5-52
GP 27 12 VDC PSU (Power Supply RS-35-12) LED.............................................5-34
GP 57 PCB CPU APP 32 “L” AF602/VF602...........................................................5-53
GP 28 PCB Printer Interface PCB ”E” LEDs........................................................5-35
GP 58 PCB M21 “K” (Upper Bin M101) AF602/VF602..........................................5-53
GP 29 MD6DC PCB LEDs.......................................................................................5-35
GP 59 PCB M21 “O” (Lower Bin) AF602/VF602...................................................5-54

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GP 60 PCB M21 “G” (Feed Motor M301) AF602/VF602.......................................5-54
GP 61 SP Sensor PCB “CC” (Upper Bin) VF602..................................................5-55
GP 62 SP Sensor PCB “Y” (Lower Bin) VF602....................................................5-55
GP 63 PCB CPU APP 32 “A” CR500.....................................................................5-56
GP 64 PCB M21 “E” (Motor M1) CR500................................................................5-56
GP 65 PCB M21 “G” (Motor M2) CR500................................................................5-57
GP 66 PCB M21 “H” (Motor M3) CR500................................................................5-57

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GP 1 Entering Service Mode
4. Type in password: 1974 and press the [OK] button to get to the next screen “Service
Purpose menu, select target”.
The Service Mode (SP) is used to check electrical data, 5. Select target (module)
check electrical components and adjust values.
6. Exit the Service mode by switching off the main power or press the [Exit] button once to
The Service Mode is provided and controlled from the User Interface (UI) on the Booklet go back to the “Service menu, select target” screen. Press the [Exit] button once more to
Maker. Peripheral units are embedded in this service program. leave Service menu and enter the operator mode.

Where applicable, a sub menu appears after a function is selected listing the peripherals.
Note, if machine is left unattended in service mode for more than 20 minutes it will automati-
cally go into Disable mode and require a Power Off/On to restart.

Procedure
There are two ways to enter the service mode either from the Operator Mode or
directly from a switched off machine.
NOTE: Insert interlock cheater if +UNREG (voltage for motors) is needed.

WARNING!

Always use extreme caution when operating the machine with any interlock switch cheated.

Operator Mode
1. With main power switched on, press the [Tools] button.
NOTE: Insert interlock cheater(s) if 30/27 VDC (voltage for motors) is needed.
2. Press the [Service] button.
3. Type in password: 1974 and press the [OK] button to get to the next screen “Service
menu, select target”.
4. Select target (module)
5. Exit the Service mode by switching off the main power or
press the [Exit] button once to return to the “Service menu, select target” screen.

Press the [Exit] button once more to leave Service menu and enter the operator mode.

Switched Off machine

1. Make sure the main power is switched off.
NOTE: Insert interlock cheater(s) if 30VDC (voltage for motors) is needed.
NOTE: When entering SP mode, password is reset to the default value 107.
2. Turn on the main power.
3. When the text “Loading...” appears, press and hold a finger on the screen.

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GP 2 Resetting / Changing the Service Mode Password
Purpose
To reset the Service Program Mode Password to the Factory setting or change it to another value.

Procedure
Resetting the password
1. Use Switched Off machine procedure in GP 1 to reset the Password to the Factory Setting.
2. Password is now reset to default value: 107

WARNING!
Always use extreme caution when operating the machine with any interlock switch cheated.

Changing the password

1. Enter Service Mode (GP 1).

2. Select target (module) BM
3. Select “NVM” and press the [OK] button.
4. Scroll to “Password”.
5. Use the + (plus) and - (minus) buttons to enter a new password.
6. Press the [OK] button to store the new password.
Press the [Cancel] button to exit without storing.
7. Press the [Exit] button to leave the “NVM” screen.
8. Exit the Service mode by switching off the main power or press the [Exit] button once to go back to
the “Service menu,
select target” screen.

Press the [Exit] button once more to leave Service menu and enter the operator mode.

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GP 3 Diagnostics
Purpose
The main self-diagnostic mode, Diagnostics, is available from the service program mode.
Diagnostics checks the EEPROM, the sensors and the motors.

If a fault is found a fault code will be displayed.

To remedy the fault, go to Fault code Description (section 4).

Procedure

WARNING!
Reflecting paper path sensors can be faulty although not detected by the diagnostics.
However If they have a failure state equal to constantly unblocked, it will not be in its correct
home position state, and therefore be detected by the run time diagnostics.

ALWAYS POWER OFF THE SYSTEM WHEN EXITING THE DIAGNOSTIC MODE.

1. Enter the service program mode (GP 1).

2. Select target (module) to enter the “service components” screen.
NOTE: If you are performing Diagnostics on a Booklet Maker:
- remove the two stapler cartridges (REP 4.0).
- if a Cover Feeder is installed,
make sure the adjustable side guides are in their innermost position.
3. Close top covers.
4. With the arrow buttons, select “Diagnostics”. Press the [Enter] button.
5. When ready, press the [Start] button.
While performing diagnostics, the message “Checking...” is shown in the UI.
6. If a fault code is displayed, go to Fault code Descriptions (section 2) and follow the
procedure.
7. When the fault has been remedied, repeat step 1-7 until the message:
“Complete
0 errors found”
is displayed.
8. If the two stapler cartridges were removed,
reinstall them (REP 4.0 Stapler Heads, Stapler Assy and Clincher).
9. Dock the Booklet Maker to the upstream device.

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GP 4 Check Motors / Solenoids / Sensors How to use the software cheater
Purpose
This procedure is intended to provide the instructions needed to access and 1. Enter service mode as described above and select Trimmer.
control components from the UI for diagnostic purposes.
2. Mount the blue plastic interlock cheater in the Trimmer.
3. Scroll down to: “Cheat Trimmer Cover 15 minutes: No”
Procedure
4. Press the [Change] button and alter the parameter value to Yes
Check Motors and Solenoids The cheater is now activated.

WARNING! This enables the trim knife to cycle with open cover for 15 minutes.
Never turn off the main power during motors are cycling. To avoid damaging the circuitry, 5. To run the system and make booklets with the Trimmer cover open:
stop the motor / motors running under the Check Motors menu, and then turn off main power. Exit service mode by using the [Exit] buttons.
6. Do not exit service by using the power switch.
1. Select Module: 7. If the system is turned off by the power switch,
2. Go to Motors or Solenoids or if the cheater is removed from the Trimmer,
the software for cheater activation will be automatically disabled.
3. Go to the motor/solenoid to be checked
Checking Sensors
4. Depending on the selected motor, different action buttons and parameters (voltage,
position etc.) are displayed and updated frequently, at the bottom of the screen. 1. All sensors can be checked individually by blocking/unblocking sensors.
NOTE:
While blocking/unblocking, view the display for response.
When checking BM-M9 or TR-M4, Displayed is the parameters value: 1 or: 0.
you have to press the cycle button before being able to press the Arrow buttons
(In order to reach the position of the motor). Which state corresponding to blocked/unblocked sensor is depending on
whether the sensor has inverted function or not.
NOTE:
2. For status definition, see Service Program Mode Tables (GP 5).
There are two ways to run the trim knife motor TR-M2.
Either via service mode or when running the system for booklet making.
For the later option:
1. Close the Trimmer Top Cover.
2. Install The interlock cheater and the software for cheater activation.

WARNING!
For safety reasons you have to press the [Unlock knife] button to be able to start TR-M2.
Also you have to press the [Unlock knife] button between every cycle.

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GP 5 Service Program Mode Tables BM-M9 14 V ±2 V, Primary Infeed Motor transports the sheets through the
≈ 975 mm/s infeed assembly.

Purpose BM-M20 N.A. Stapler motor drives the staples through the set.
This Service Program Mode Tables explains each components normal voltage reading as BM-M21 (M20 Stapler Left, M21 Stapler Right)
well as each Stacker Motor transports the set on the Belt Stacker.
BM-M22 N.A. Staple stop gate motor moves the transport wheels and
stop gate up and down.
Procedure
BM-M23 Thick set motor controls the thickness of the set.
Go to the desired function (GP 4):
• Check Motors and function
• Check Solenoids and function
• Check Sensors/Switches and function

Motors

Booklet Maker
Motor Normal Function
Reading

BM-M1 14 V ±2 V, Infeed Motor transports the set to the stapling section.

≈ 900 mm/s

BM-M2 9 V ±2 V Back Jogger Motor jogs the sheets together lengthwise.

BM-M3 200 - 325 mm Side Jogger Motor adjusts the position of the side guides for
different paper sizes.

It also jogs the sheets together sidewise and guides the set
through the machine.

BM-M5 12 V ±2 V , Set Transport Motor transports the set from the stapling
≈ 600 mm/s area to the folding area.

BM-M6 18 V ±2 V, Fold Roller Motor folds and compresses the set and trans-
265 mm/s port it out of the Booklet Maker.

BM-M7 28 V ±2 V Fold Knife Motor pushes the set up through the fold rollers.

BM-M8 N.A. Fold Stop Gate Motor makes a slight jog to ensure set is
straightened up before folding.

BM-M9 ≈269mm - Staple/Fold Position Motor adjusts the position of the staple
≈460mm stop,
fold stop and back jogger for different paper sizes.
Continued on next page

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GP 5 Service Program Mode Tables, continued

Square Folder Trimmer

Motor Normal Function Motor Normal Function
Reading Reading

SQF-M1 20 V ± 2 V Transport Belt motor transports the booklet in and out of the TR-M1 22 V ±2 V, Transport/Knife Motor transports the booklet in and out
Square Folder. ≈ 400 mm/s ≈0.70m/s of the Trimmer unit.

It also functions as a second Trim Knife Motor when

SQF-M2 N.A. Stop gate motor moves the stop gate up and down to stop reversed.
the booklet in correct position. In Service mode, only transport direction can be run.
SQF-M3 N.A. Clamp motor opens and closes the Set clamp, holding the TR-M2 28V ±2V Trim Knife Motor cycles knife to cut the booklet.
booklet in place when the Roller motor are performing the
square folding action.

TR-M3 N.A. Stop Gate Motor moves the stop gate up to stop the book-
SQF-M4 4 V ± 2 V, Roller motor performs the square folding action. let to be trimmed and down when transporting it out.
≈ 200 mm/s

ST-M1 15V ±2V or Stacker Motor transports the set on the Belt Stacker.
24V ±2V or TR-M4 10 V ± 2 V, Length Adjustment Motor adjusts the position of the stop
≈120 - 220 gate for different booklet sizes.
29V ±2V mm

TR-M5/M6 N.A. Blower Motor blows the trimmed single (cut paper edge)
down to the scrap bin.

TR-M8 Lifter motor

ST-M1 15V ±2V or Stacker Motor transports the set on the Belt Stacker.
24V ±2V or
29V ±2V

Continued on next page

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GP 5 Service Program Mode Tables, continued

Rotator Creaser Trimmer VF602

Motor Normal Function Motor Normal Reading Function
Reading
M101/201 48V Elevator motors. Moves the bin trays up
CT-M1 N.A. Main drive motor. Transport sheets through the system. and down

M301 48V Transport motor. Run all the belt transports

CT-M3 N.A. Rotator motor. Rotates sheets from long edge feed to in the machine.
short edge feed.

CT-M4 N.A. Registration motor. Positiion the registration module to FAN101-106 24V Bin blowers, separation fan and vacuum fan.
the width of the sheets and image offset. FAN201-206 Air separates the sheets and assists in the
feeding process.

CT-M6 N.A. Creaser motor. Drives the creaser tool action.

CT-M7 N.A. Trimmer knife motor. Position the Bleed Trimmer knifes
according to width.

FAN 1 N.A. Cooling Blower. Cooling down Stepper Motor Driver

PCB “E”.

AF602
Motor Normal Reading Function

M101/201 48V Elevator motors. Moves the bin trays up and

down.

M301 48V Transport motor. Run all the belt transports in

the machine.

FAN101-104 24V Bin blowers. Air separates the sheets.

FAN201-204

Continued on next page

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GP 5 Service Program Mode Tables, continued
Solenoids
Booklet maker CST
Solenoid Normal Reading Function Solenoid Normal Reading Function

CLINCH N.A. Clincher for right staples CT-SOL1 N.A. Rotator disengage solenoid.
Disengage SOL 1 idler roller for rotation and
Right
sheet registration.
CLINCH N.A. Clincher for left staples
CT-SOL2 N.A. Rotator disengage solenoid.
Left Disengage SOL 2 idler roller for rotation and
sheet registration.

CT-SOL3 N.A. Bleed Trimmer disengage solenoid.

Square Folder Disengage the Bleed Trimmer knifes to save
wear.
Solenoid Normal Reading Function
CT-SOL4 N.A. Transportation disengage solenoid.
SQF-SOL1/2 Will be actuated Belt drive engagement solenoid. Disengage SOL4 idler rollers for sheet
Clutch lower. registration.
until sensor Q6 is
actuated. CT-SOL5 N.A. Registration disengage solenoid.
Disengages SOL5 idler rollers for sheet
SQF-SOL3/4 Will be actuated Belt drive engagement solenoid. registration.
Clutch upper.
until sensor Q6 is COUNTER N.A. Set counter.
actuated. Counts the number of sets passing through
the RCB.

Solenoids, AF602 Solenoids, VF602

Solenoid Function Solenoid Function

SOL101, Drive clutch. Clutch engages the shaft and rotates the feed rollers when the SOL101, Drive clutch. Clutch engages the shaft and rotates the feed rollers when
SOL201 main transport motor is running. SOL201 the main transport motor is running.

SOL102, Bin lock release. Releases the spring loaded bin lock. Enables operator to SOL102, Bin lock release. Releases the spring loaded bin lock. Enables operator to
SOL202 slide out bin. SOL202 slide out bin.

SOL103, Vacuum release solenoid. Actuates the vacuum gasket plate open and
SOL203 closed.

SOL104, Brake Clutch. Stops the vacuum belts when engaged. This must be test-
SOL204 ed manually, by rolling the vacuum belts and turning on the clutch.

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GP 5 Service Program Mode Tables, continued
Sensors (including Switches) BM-Q34 0 or 1 Primary Infeed Motor BM-M19 sensor. Toggles when
rotating shaft.
Booklet Maker
BM-Q36 - Thick set motor home sensor.
Sensor Normal State Function
BM-Q40 0 or 1 Set Transport Motor (M5) Sensor.
BM-Q1 0 = Unblocked Paper Infeed Sensor Toggles when rotating shaft

BM-Q2 0 or 1 Infeed Motor sensor. Toggles when rotating shaft BM-Q41a 0 or 1 Stop Gate Stapler Motor (M22) Sensor. Toggles when
rotating shaft
BM-Q3 0 = Unblocked Back Jogger Home Position Sensor
BM-Q41b 0 or 1 Stop Gate Stapler Motor (M22) Sensor. Toggles when
BM-Q4 0 = Unblocked Start Sensor Saddle Stapling Sensor rotating shaft
BM-Q7 0 = Unblocked Stop Gate Folder Sensor BM-Q42 Home Position Stop Gate Stapler (M22)
BM-Q8 0 = Unblocked Exit Sensor BM-Q43 0 or 1 Stop Gate Folder Motor Sensor (M8).
Toggles when rotating shaft
BM-Q9 0 or 1 Fold Roller Sensor. Toggles when rotating shaft
BM-Q44 1=Blocked/ Home Position Stop Gate Folder Motor Sensor (M8)
BM-Q10A 0 or 1 Staple/Fold Position Motor Sensor A. Toggles when rotat- Home
ing shaft
BM-Q45 0 or 1 Back Jogger Motor Sensor. Toggles when rotating shaft
BM-Q10B 0 or 1 Staple/Fold Position Motor Sensorl B. Toggles when rotat-
ing shaft BM-Q46 0=Blocked Low Staple Right. 1=Staples low. 0=Staples inside the
cartridge. Staples press the plastic tongue down, inside
BM-Q11 0 = Unblocked Staple/Fold Home Position Sensor the stapler.
BM-Q12A 0 or 1 Side jogger Motor M3 sensor A. Toggles when rotating BM-Q47 1=Stapler up/ Staple Home Position Sensor Right
shaft Home
BM-Q12B 0 or 1 Side jogger Motor M3 sensor B. Toggles when rotating BM-Q48 0=Stapler Clinch Trig Sensor Right
shaft Up/ 1= Trig
BM-Q13 0 = Unblocked Side Jogger Home Position Sensor Activated

BM-Q15 1 = Blocked Fold Knife Home Position Sensor BM-Q49 0=Blocked Low Staple Left. 1=Staples low. 0=Staples inside the
cartridge. Staples press the plastic tongue down, inside
BM-SW17 0=Unblocked Interlock switch SW17 soft. the stapler.
0=Cover open. 1= Cover closed.
SW16 hard (BM) and SW9 hard (TR) are serial con- BM-Q50 1=Stapler up/ Staple Home Position Left
1 = BM nected. Home
cover closed. The Relay-1 in BM will be activated and turn on the power BM-Q51 0=Stapler Clinch Trig Sensor Left
0 = BM supply 30V when Both covers (BM, TR) are closed. Up/ 1= Trig
cover open If not using TR, Use Termination plug 12-p Molex Minifit Activated
5557 for J25, shortcuts pin 3 and 4.
BM-Q53 0 = Unblocked Infeeder, paper path sensor
BM-Q19 0 = No staple Staple detection clinch left

BM-Q20 0 = No staple Staple detection clinch right

Continued on next page

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GP 5 Service Program Mode Tables, continued
Trimmer
Square Folder Sensor Normal State Function
Sensor Normal State Function TR-SW1 (incl. 0 = Unblocked Interlock switch. 0=Cover open. 1= Cover closed.
SQF-SW1 (incl 0=unblocked Interlock switch. 0=Cover open. 1= Cover closed. TR-SW10 (TR-SW10) Interlock switch SW10. SW9 hard (TR) and SW16 hard
SQF-SW2 Soft, (SQF-SW2) soft, (BM) are serial connected.
SQF-SW3 hard) Interlock switch SW2 soft. SW3 hard are connected to TR-SW9 The Relay-1 in BM will be activated and turn on the
coil at Relay-1.Realy-1 turns on the power supply 27V hard). power supply 30V when both covers (BM, TR) are
when SW2 and SW3 are activated closed.
TR-SW2/SW3 0 = In-feed/exit Detects whether Infeed or Exit belts are in up or down
SQF-Q1 1 = Blocked Stop Gate Sensor belts down. 1=up. position.
SQF-Q2 1 = Blocked* SQF-M4 Roller motor Rear/front sensor. If one is TR-SW11 1= At end point Sensor activated at end point.
blocked, the other is unblocked and vice versa. Length adjustment home position switch.
SQF-Q3
SQF-Q4 0 = Unblocked Home Position Sensor. 0=unblocked when clamp TR-Q1 0 = Unblocked Interlock switch. 0=cover open, 1=cover closed.
beam is up (Clamp motor SQF-M3). TR-Q4 0 or 1 Transport Motor M1 Encoder. Toggles 0/1 when rotating
SQF-Q5 0 = Unblocked Infeed Sensor shaft.

SQF-Q6 0 = Unblocked Clamp Sensor (in paper path) TR-Q5 1 = Blocked Trim Knife Home Position Sensor

SQF-Q7 0 = Unblocked Exit Sensor TR-Q6 0 = Unblocked Exit Sensor

SQF-Q8 0 or 1 M4 Sensor. Toggles when rotating shaft TR-Q7 0 = Unblocked Stop Gate Home Position Sensor

SQF-Q10A 0 or 1 Stop Gate Motor M2 Motor A. Toggles when rotating TR-Q8 0 = Unblocked Trim Bin Full Sensor
shaft TR-Q12A 0 or 1 Length Adj. Motor M4 Sensor A.
SQF-Q10B 0 or 1 Stop Gate Motor M2 Motor B. Toggles when rotating Toggles 0/1 when rotating shaft.
shaft TR-Q12B 0 or 1 Length Adj. Motor M4 Sensor B.
Toggles 0/1 when rotating shaft.
* NOTE: TR-Q13 0 = Unblocked Infeed Sensor
If one is blocked, the other must be unblocked and vice versa.
TR-Q11 1 = At end point Sensor activated at end point.
Length Adjustment Home Position Switch
TR-Q14 0 = Unblocked Paper path sensor
TR-Q15 1 = Motor home Lift motor home position sensor

Continued on next page

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GP 5 Service Program Mode Tables, continued Sensors/Switches, AF602
Sensor Normal State Function
CST
Q101 0=Unblocked Upper bin Optical DSD sensor
Sensor Normal State Function
Q102 Analogue value Upper bin Ultrasonic DSD sensor
CT-Q1 0 = Unblocked Entrance Sensor.
Q103 0=Unblocked Upper bin Home down position sensor
CT-Q2 0 = Unblocked Rotator Sensor. Q104 0=Unblocked Upper bin Home up position sensor
Q105 0=Unblocked Upper bin Empty sensor
CT-Q3 0 = Unblocked Registration CT-M4 home position sensor.
Q201 0=Unblocked Lower bin Optical DSD sensor
CT-Q4 0 = Unblocked Creaser trigger sensor. Q202 Analogue value Lower bin Ultrasonic DSD sensor
Q203 0=Unblocked Lower bin Home down position sensor
CT-Q5 0 = Unblocked Creaser CT-M6 home position sensor.
Q204 0=Unblocked Lower bin Home up position sensor
CT-Q6 0 = Unblocked Bleed Trimmer CT-M7 home position sensor. Q205 0=Unblocked Lower bin Empty sensor

CT-Q7 0 = Unblocked Exit sensor. Q301 Analogue value Upper bin Ultrasonic distance meter
Q302 Analogue value Lower bin Ultrasonic distance meter
CT-Q8, 0 = Door opened Slide door sensor.
Q303 0=Unblocked Paper exit sensor
CT-SW2 1 = Door closed
S301/S302 0 = Closed Interlock Door Switch
CT-Q9, 0 = Door opened Top cover sensor (Switch).
CT-SW3 1 = Door closed S101/S102 0 = Closed Interlock Upper Bin (A)
CT-Q10 0 = Unblocked Registration solenoid (CT-SOL5) trigger sensor S201/S202 0 = Closed Interlock Lower Bin (B)

CT-Q11 0 = Unblocked Waste bin sensor.

Sensors/Switches, VF602
CT-Q12 0 = Unblocked Docking sensor (optional). Sensor Normal State Function
Q101 0=Unblocked Upper bin Optical DSD sensor
CT-Q13 10 mVo/C Temperature sensor. Limited values 0.08-0.65 VDC.
(analogue) Q102 Analogue value Upper bin Ultrasonic DSD sensor
Q103 0=Unblocked Upper bin Home down position sensor
Q105 0=Unblocked Upper bin Empty sensor
Q201 0=Unblocked Lower bin Optical DSD sensor
Q202 Analogue value Lower bin Ultrasonic DSD sensor
Q203 0=Unblocked Lower bin Home down position sensor
Q205 0=Unblocked Lower bin Empty sensor
Q301 Analogue value Upper bin Ultrasonic distance meter
Q302 Analogue value Lower bin Ultrasonic distance meter
Q303 0=Unblocked Paper exit sensor
S301/S302 0 = Closed Interlock Door Switch
S101/S102 0 = Closed Interlock Upper Bin (A)
S201/S202 0 = Closed Interlock Lower Bin (B)

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GP 6 Voltmeter
Purpose Booklet maker
The voltmeter provides voltage range and distribution
within the entire system. Voltage at Range

BM MD6DC (H) 30 V Regulated 30 V (after interlock relay) distributed from PCB D in Booklet Maker.
Procedure UPPER
Voltage supplies: BM-M8 Fold stop gate motor
1. Enter Service Mode (GP 1).
BM-M22 Stop gate stapler motor
2. Select Voltmeter
Left & right clincher
3. Select the desired area
4. Press Cancel to exit the Voltmeter.
BM MD6DC (B) 30 V Regulated 30 V (after interlock relay) distributed from PCB D in Booklet Maker.
MIDDLE
Voltage supplies: BM-M1 Infeed motor
BM-M5 Set transport motor
BM-M7 Fold knife motor
BM-M9 Staple/fold pos. mot.
BM-M22 Left stapler motor
ST-M1 Stacker motor

BM 30 V Regulated 30V (after interlock relay) distributed from PCB D in Booklet Maker.
MD6DC (C) Voltage supplies: BM-M2 Back jogger motor
LOWER
BM-M3 Side jogger motor
BM-M6 Fold roller motor
BM-M21 Right stapler
CF-M16 Drive Motor
Ground only to: BM Set counter

Continued on next page

Plockmatic BM500 system 20 May 2019 5. Service tables (GP)

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GP 6 Voltmeter, continued

Booklet maker
Voltage at Range

CT 21.6- 26.4 Regulated 24VDC distributed through PCB “M” from 24V Power Supply Unit (1),
MD3DC PCB “B” VDC 24V is only present when the interlock relay (REL1) is activated. Voltage supplies:
SOL1 Rotator disengage solenoid
SOL 2 Rotator disengage solenoid
SOL3 Bleed Trimmer disengage solenoid
SOL4 Transportation disengage solenoid
SOL5 Registration disengage solenoid
COUNTER
FAN 1 Cooling Fan

CT-M7 43.2-52.8 Regulated 48VDC distributed through PCB “M” from 24V Power Supply Unit (1)
MD1SM PCB “C” VDC 24V (48V) Power Supply Unit (2), 48V is only present when the interlock relay
(REL 1) is activated. Voltage supplies: M7 Trimmer knife afjustment motor.

CT-M4 43.2-52.8 Regulated 48VDC distributed through PCB “M” from 24V Power Supply Unit (1)
MD1SM PCB “D” VDC 24V (48V) Power Supply Unit (2), 48V is only present when the interlock relay
(REL 1) is activated. Voltage supplies: M4 Registration afjustment motor.

CT-M1 43.2-52.8 Regulated 48VDC distributed through PCB “M” from 24V Power Supply Unit (1)
MD1SM PCB “E” VDC 24V (48V) Power Supply Unit (2), 48V is only present when the interlock relay
(REL 1) is activated. Voltage supplies: M1 Cycle motor

CT-M6 43.2-52.8 Regulated 48VDC distributed through PCB “M” from 24V Power Supply Unit (1)
MD1SM PCB “H” VDC 24V (48V) Power Supply Unit (2), 48V is only present when the interlock relay
(REL 1) is activated. Voltage supplies: M6 Cycle motor

CT-M3 43.2-52.8 Regulated 48VDC distributed through PCB “M” from 24V Power Supply Unit (1)
MD1SM PCB “J” VDC 24V (48V) Power Supply Unit (2), 48V is only present when the interlock relay
(REL 1) is activated. Voltage supplies: M3 Cycle motor

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GP 6 Voltmeter, continued

AF602/VF602
Voltage at Range

M301 Motor PCB(G) 47.8V-48.3V Regulated 48V Supplying Transport motor M301

M101 Motor PCB(K) 47.8V-48.3V Regulated 48V Supplying Elevator motor M101

M201 Motor PCB(O) 47.8V-48.3V Regulated 48V Supplying Elevator motor M201

CPU PCB(H) 23.8V-24.3V Regulated 24V on PCB (H)

CPU PCB(L) 23.8V-24.3V Regulated 24V on PCB (L)

CPU PCB(A) 11.8V-12.3V Regulated 12V on PCB (A)

CPU PCB(H) 11.8V-12.3V Regulated 12V on PCB (H)

CPU PCB(L) 11.8V-12.3V Regulated 12V on PCB (L)

M301 Motor PCB(G) 11.8V-12.3V Regulated 12V on PCB (G)

M101 Motor PCB(K) 11.8V-12.3V Regulated 12V on PCB (K)

M201 Motor PCB(O) 11.8V-12.3V Regulated 12V on PCB (O)

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GP 7 Dead Cycle GP 9 Not in use
Purpose
This procedure is a modified machine cycle.
All functions in the machine are run such as motors and solenoids.

The program is basically made for factory testing,

but can be of some use when trouble shooting.

Procedure
Warning!
Changing NVM values can jeopardize the way the machine operates considerably.

Be sure that changing the NVM value is the correct solution before doing so.

If changes are made which cause the unit to operate incorrectly,

perform the NVM reset procedure (GP 20).

Running Dead Cycling (free run)

1. Select Module:
2. Remove the two stapler heads.
3. Go to Dead Cycle.
4. Press START to start the dead cycling.
5. Press STOP to stop the dead cycling.

GP 8 Not in use

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 GP 10 NVM Values
Purpose
This procedure will provide factory settings table as well as instructions on
how to adjust the various values and locations.

Procedure

NOTE:
The EEProm Values are subject to change between S/W releases.
Refer to the Software Release Document for respective software version.
Values in this Table are for BM CPU(A) 1.00 S/W version.

1. Enter Service Mode (GP 1).

2. Select target module.
3. Select item [NVM].
4. Press [up/down] buttons to access desired Index to be changed.
5. Press [±] buttons to change value.
6. Press green check mark to confirm.
7. Press [Go back] to reach XX Service Components menu.
8. Press [Home] to reach Target selection menu.
9. Press [Exit Service] when ready to exit service mode.

continued on next page

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GP 10 NVM Values, continued 30 BM M1 (Speed 3) Default 1100
31 BM M1 (Speed 4) Default 1260
NVM Values (Accessed via BM) 32 BM M1 (Speed 5) Default 1700
33 BM M1 (Speed 6) Default 1900
Index Name Function 34 BM M1 (Speed 7) Default 2000
1 Password Default 107 35 BM M1 (Speed 8) Default 2000
36 BM M19 (Speed 2) Default 1780
37 BM M19 (Speed 3) Default 2260
38 BM M19 (Speed 4) Default 2600
2 BM SideJogger in Default 3210
(Offset) ± 39 BM M19 (Speed 5) Default 2800

3 BM RearJogger up Default 2700 40 Thick set jam active Default 0

(Offset) ±
4 BM Staple stop Rx (Offset) Default 68
5 BM Staple stop Tr Default 242
(Offset)
6 BM SideJogger pos. max Default 3270
7 BM Fold stop (Offset) Default 68
8 BM M1 (Speed1) Default 800
9 BM M1 (Speed2) Default 880
10 BM M6 (Speed2) Default 2600
11 TR Knife (Zero) Default 30
12 BM M16 (Speed1) Default 600
13 BM M16 (Speed2) Default 1100
14 BM M19 (Speed 1) Default 1560
19 TR M1 (Speed1) Default 2450
20 Service Timeout Default 30
21 CF sub. feed length Default 100
22 BM Dead cycle SPH Default 3600
23 Air blast delay Default 35
24 Air blast duration Default 100
25 Power save timeout Default 20
26 BM M6(Speed2) Default 2400
27 TR M1(Speed2) Default 1850
28 BM M8 up fast speed Default 1200
continued on next page
29 BM M8 up slow speed Default 500

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GP 10 NVM Values, continued

NVM Values ( Accessed via CST ) 13 CT Interface IN Interface type to Upstream Device.
0=No Interface, 1=ECAN Interface, 2=Printer Interface
Default value: 2
Index Name Function 14 CT Interface OUT Interface type to Downstream Device.
1 CT VSYS System Line Speed. 0=No Interface, 1=ECAN Interface, 2=Printer Interface
Default value after NVM reset: 1000 [mm/s]. Actual value Default value: 1
shown is latest line speed run. 15 Rotated (cnt) Counter for Rotated Sheets
2 CT Creasing offset Offset Value for position of Crease. 16 Creased (cnt) Counter for Creased Sheets
Same for Fine and Coarse Tool.
Smallest adjustable unit: 0.1 [mm] 17 Bleed trimmed Counter for Bleed Trimmed
Default value: 1032 [mm] (cnt)
3 CT M4 Offset Offset Value for Image Offset. 18 Hardware (cnt) Intermediate Counter for Cassies Counter
Smallest adjustable unit: 0.1 [mm]
Default value: 690 [mm]
4 CT M7 Offset Offset Value for Bleed Trimmer Offset. NVM Values ( Accessed via CR)
Smallest adjustable unit: 0.1 [mm]
Default value: 3580 [mm] Index Name Default Function

5 CT SOL2 On Delay from lead Edge to SOL2 On, 1 Fine Offset 500 Offset Value for position of Crease in pro-
Distance cess direction for the Fine Crease tool.
when rotating 135 [mm]. Resolution: 0.1 [mm]
6 CT M3 Speed M3 Speed when not rotating. 2 Coarse Offset 500 Offset Value for position of Crease in pro-
Default value after NVM reset: 100%. Actual value shown cess direction for the Coarse Crease tool.
is percentage of line speed, index 1. Resolution: 0.1 [mm]
7 CT M3 Speed of M3 when rotating 206 mm wide media. 3 Angle Offset 1000 Offset Value for the Crease angle.
Min rotation speed Default value after NVM reset: 85%. Actual value shown is The angle is defined as linear displacement
percentage of half line speed, index 1. at the lead screw.
8 CT M3 Speed of M3 when rotating 232 mm wide media. Resolution: 0.1 [mm]
Max rotation Default value after NVM reset: 95%. Actual value shown is 4 Init Angle 245 Position of lead screw nut at init. Angle from
speed percentage of half line speed, index 1. Q7 home sensor.
9 CT Q10 to SOL4 Delay from Lead Edge to SOL4 On. The angle is defined as linear displacement
On Smallest adjustable unit: 0.1 [mm] at the lead screw.
Default value: 11000 [mm] 5 Max Angle 445 Max. permitted angle from Q7 home sensor
10 CT SOL4 On Delay from Lead Edge to SOL4 On. without tripping CR-008.
Distance Smallest adjustable unit: 0.1 [mm] The angle is defined as linear displacement
Default value: 10 000 [mm] at the lead screw.

11 CT Antistatic Out On/Off switch for Antistatic device in Exit. 6 Min Angle 45 Min. permitted angle from Q7 home sensor
0=Off without tripping CR-008.
1=On The angle is defined as linear displacement
Default value: 0 at the lead screw.

12 CT Antistatic On/Off switch for Antistatic device in Waste channel. 7 Counter 0 Counter for Creased sheets
Waste 0=Off
1=On
Default value: 0

Plockmatic BM500 system 20 May 2019 5. Service tables (GP)

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GP 10 NVM Values, continued

NVM Values (Accessed via AF602) NVM Values (Accessed via VF602)

Index Default Function Index Default Function

0 Total counter (set) 0 Counter for sets 0 Beltspeed 1 720 Self calibrated

1 Total counter (sheet) 0 Counter for sheets 1 Beltspeed 2 1500 Self calibrated

2 Beltspeed 1 720 Self calibrated 2 Min ClutchLen 103

3 Beltspeed 2 1500 Self calibrated 3 Substract ClutchLen 160

4 Min ClutchLen 80 4 Dead Cycling SPH 15000

5 Substract ClutchLen 140 5 Debug value 0 Service function

6 Dead Cycling SPH 15000 6 Optic DSD LED PWM BIN A 60

7 Debug value 0 Service function 7 Optic DSD LED PWM BIN B 60

8 Optic DSD LED PWM BIN A 60 8 Optic DSD Pullup BIN A 0

9 Optic DSD LED PWM BIN B 60 9 Optic DSD Pullup BIN B 0

10 Optic DSD Pullup BIN A 0 10 Ultra sound DSD PWM BIN A 20

11 Optic DSD Pullup BIN B 0 11 Ultra sound DSD PWM BIN B 20

12 Ultra sound DSD PWM BIN A 20 12 US Dist meter compensation A 100

13 Ultra sound DSD PWM BIN B 20 13 US Dist meter compensation B 100

14 US Dist meter compensation A 100 14 Total counter 0

15 US Dist meter compensation B 100 15 Fan Malfunction PWM 10(%) (max Limit for function
100%) detection
16 Fan malfunction PWM 10 (%) (max Limit for function detection
100%) 16 US Distance Process Position 62
Vacuum A

17 US Distance Process Position 62

Vacuum B

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GP 11 BM Fold Delay GP 12 BM Paper Size Reset
WARNING:
Purpose
This procedure requires that the machine is operated with Top Cover open and
If fold delay is set to On and the sheet length is 400mm or less, the Top Cover Interlock cheated.
the booklet stays between the second pair of fold rollers up to about 15 seconds
depending on the number of sheets per set. Always use extreme caution when operating the machine with the Top Cover open.

The set stays between the fold rollers until the last sheet of the next set Purpose
enters the infeed area, but never longer than 15 seconds.
To restore booklet quality fabric settings for NVM values.
Reasons for this could be:
If the sheet length is more than 400 mm, fold delay is not used.
• NVM reset was performed but NVM values could not be retrieved.
• Bad booklet quality (Booklet Maker related).
• Bad Crease / Trim performance in spite of correct NVM (CST related).

NOTE:
If booklet quality is not acceptable, go to section Booklet Quality to adjust mechanical
parameters.

CST Module
Procedure
Perform BQ2 , BQ3, BQ4, BQ5, BQ6, BQ7 and BQ8.

Continued on next page.

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Booklet Maker only (Square Folder and Trimmer on next page)
this edge towards side guide
Initial Actions
• Perform BQ9 - BQ17 [A]
this end upwards
this end downwards
Procedure
1. Remove Rear Cover (REP 1.1) to access Paper size reset tool (GP 40)
2. Open the Top Cover and insert an Interlock Cheater.
3. Enter Service Mode (GP 1).
4. Select target (module) BM.
5. Select item [Paper size reset].
6. The text “Ready” will be shown on the LCD display. Press [Start] to start procedure.
7. Side guides, staple stop gate, [B] [A]
fold stop gate and staple position will now automatically be adjusted.
8. When prompted “Insert tool!”, lift up infeed motor [B] and insert Paper reset tool [A]
NOTE: Make sure that the tab of the Paper size reset tool enters the slot in the clincher
[C]
9. Press green check mark when Paper size reset tool is in place.
10. The Booklet maker will continue adjusting staple position.
Stop gate moves upwards until it reaches the tool and then the text “Adjust back jogger!”
will be shown.
NOTE: If this fails, repeat procedure from step 1.

NOTE: If the purpose of performing the paper size reset procedure is strictly a result of
an electronical or logical operation, such as replacement of PCB Controller ARM7 PCB
“A”,
the procedure can be ended here by by jumping to step 14.

If any changes has been made that effects the geometry regarding the paper size,
such as mechanically adjusted stop gate, back jogger or replaced/moved home position
sensor,
the procedure must be continued to the end.

[C]
Continued on next page.
Correctly positioned tool Not correctly positioned tool
Plockmatic BM500 system 20 May 2019 5. Service tables (GP)
5-23
GP 12 BM Paper Size Reset, continued

Book Fold Module

Procedure [E]
Perform BQ 14 Fold Skew and BQ 9 Transport Feed Force.

Trimmer Module
Procedure
Perform:
BQ 7 Crease position in Process Direction (Mismatch) and
BQ 8 Crease Insufficient Quality (Spine Cracking despite Crease)
[F]
[D]

Incorrect, play between tool

and Back Jogger Fingers. [G]

[H]

Correct, no play/no tension

between tool and Back Jogger
Fingers.

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GP 13 Trimmer Service (Trimmer Module) GP 14 Enabling CF (Cover Feeder Module)
Purpose Purpose
This procedure allows you to change the Trimmer Blow Type.
This procedure is requested after installing a Cover Feeder Module in the Booklet Maker or after
an NVM Reset (GP 20) has been carried out.
Procedure

Note: Blow Type should be set to Fans. The Air blast is a kit currently not available. Procedure

1. Enter Service Mode (GP 1). Enabling the Cover Feeder and the code CF-501 Paper Low Sensor

2. Select Trimmer module. Press the OK button.

1. Enter Service Mode (GP 1).
3. UI screen will display Blow Type.
2. Select target (module) BM.
4. Ensure Blow Type is set to Fans. To change, press the OK button.
3. Select item “Cover Feeder installed:NO”.
5. With the Arrow button, select Fans. Press the OK button.
4. Press [Change] and confirm by pressing [Yes].
6. Press Cancel to exit Trimmer Service.
5. Select item “Enable Cover Low warning: NO”.
6. Press the [Change] and confirm by pressing [Yes].
7. Exit the Service mode by switching off the main power or
press the [Exit] button once to go back to the “Service menu, select target” screen. Press the
[Exit] button once more to leave Service menu and enter the operator mode.

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GP 15 SQF Service Adjust stop gate (Square Folder Module) GP 16 Counters
Purpose The counter function is currently not available for
Booklet maker, Square Folder and Trimmer.
This procedure is used when performing BQ 12 Square Fold Stop Gate Adjustment A.

NOTE:
Rotator Creaser Trimmer
Adjust Mode should only be set to YES when
performing BQ 10 Square Fold Stop Gate Adjustment A. 1. Enter Service Mode (GP 1).
2. Select target (module) CST.
Procedure 3. Select item “NVM”.
4. Select items “Rotated (Cnt)”, “Creased (Cnt)”, “Bleed Trimmed (Cnt)” and “Hardware
1. Enter Service Mode (GP 1). (Cnt)” to display readings.
2. Select target (module) SQF. 5. Press [Go back] to return to CST Service Components.
3. Select item “Adjust mode:NO”. 6. Press [Home] to reach Target selection menu.
4. Press [Change] and confirm by pressing [Yes]. 7. Press [Exit service] when ready to exit service mode.
5. Press [Home] to reach Target selection menu.
6. Press [Exit service] when ready to exit service mode.
Explanation:
Rotated (Cnt), Creased (Cnt) and Bleed Trimmed (Cnt) shows the actual numbers.
NOTE: Hardware (Cnt) shows the number of sheets passed since the last thousand.
After adjustment, make sure to set adjust mode back to “Adjust mode: NO”.
It counts up to 1000 and then resets to 0.

To get the actual hardware count, check the hardware counter in the CST.
Multiply by 1000 and add the number shown according to the procedure described above.

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GP 17 Fault code Structure GP 18 Checking Versions of Installed Software
Purpose Purpose
This procedure provides information to assist the Service Representative in
This procedure is to identify the software version installed on the modules.
understanding the Fault code Prefix and Range.

Procedure
Fault code Prefix
1. On the UI, select Tools.
Prefix Machine Module 2. On the UI, select Software version.
CT - xxx Rotator Creaser Trimmer 3. Software version of the installed modules are displayed
BM - xxx Booklet Maker (including Stacker)
4. Press Exit to leave the Software version screen.
TR - xxx Trimmer
ST - xxx Stacker
SQF - xxx Square Folder
ST - xxx Stacker
CF - xxx Cover Feeder
CR-xxx Creaser module
AF - xxx AF602
VF - xxx VF602

Fault code Range

Range Fault Type

0xx- Components not homed, component posi-
tioning errors, Timing items, etc.
1xx
2xx Paper Jams
4xx Operator messages (low staples, Trimmer
basket full)
5xx
6xx User Interface

Example: CF-202 indicates a jam at the CF-Q3 (M4) Front Sensor in the Cover Feeder.

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GP 19 Update Software
Booklet maker
Purpose BM500 CPU v x.xx Win02 (Controller PCB “A”) - See REP 7.3
The purpose of this procedure is to provide the instructions needed to Note:
install software to the Booklet Maker. If loading CPU software you must follow the Software Release Document.

Note: Before starting the software installation, BM500 MD6DC upper v x.xx Win05 (upper PCB “H”) - See REP 7.0
check the attached document that came with the software for special instructions. BM500 MD6DC middle v x.xx Win05 (middle PCB “B”) - See REP 7.1

Initial Actions BM500 MD6DC lower v x.xx Win05 (lower PCB “C”) - See REP 7.2

Note: Ensure that all changes implemented are saved in the Tools Tab / “Stored Jobs”,
also are record into the document. Trimmer
When NVM Reset is performed, the settings will revert to the default settings established by BM Trimmer MD6DC v x.xx Win05 (PCB “A”) - REP 10.28
the manufacturer.

Square Folder
Procedure BM Book Fold MD6DC v x.xx Win05 (PCB “D”) - REP 11.24

CAUTION! CST
ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, CST CPU v x.xx Win02 (Controller PCB “A”) - See
data and/or communications problems. Failure to use proper ESD procedures will cause Note:
damage to electronic components (example: PCBs). If loading CPU software you must follow the Software Release Document.
ESD problems can be minimized by maintaining all machine ground connections,
CST MD3DC v x.xx Win05 (PCB “B”) - See GP42
ensuring the proper handling of circuit boards and sensors.
CST MD1SM v x.xx Win05 (PCB “C”) - See GP43
Use ESD protection when working near PCBs. CST MD1SM v x.xx Win05 (PCB “D”) - See
Failure to use ESD protection is likely to result in a PCB failure.
CST MD1SM v x.xx Win05 (PCB “E”) - See
CST MD1SM v x.xx Win05 (PCB “H”) - See
Go to Plockmatic Website, log into the Customer Center, and download the latest software
file(s) that you need to load. CST MD1SM v x.xx Win05 (PCB “J”) - See

Booklet maker
CR
Procedure for BM-xxx (User Interface):
1. Copy the file “bM500-1.00.rman” to the root folder of an USB stick. PCB CPU APP 32 “A” CR500 - See GP55
2. Power off the Booklet maker. PCB M21 “E” (Motor M1) CR500 - See GP56
3. Insert the USB stick in the USB port on the back side of the user interface.
4. Power on the Booklet maker. Available files will be shown. PCB M21 “G” (Motor M2) CR500 - See GP57
5. Select the file BM-xxx and press the Install button. PCB M21 “H” (Motor M3) CR500 - See GP58
6. Press Yes in the dialog box that comes up.
7. Follow instructions on screen.
8. Perform an NVM Reset (GP 20 NVM Reset in the Service Manual). AF602/VF602
PCB CPU APP 32 (PCB “A”) - See GP 49
Procedure for PCB’s:
1. Run the software file PCB CPU APP 32 (PCB “H”) - See GP 50
2. Refer to software file release documentation PCB CPU APP 32 (PCB “L”) - See GP 51
3. Follow the procedure in the file release documentation to update software
Note: Ensure all software versions are updated to the latest version. If replac- PCB M21 (PCB “K”) - See GP 52
ing PCB’s, refer to DIP switch settings in GP’s or REP’s for respective PCBs PCB M21 (PCB “O”) - See GP 53

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GP 19 Update Software (Continued)

PCB M21 (PCB “G”) - See GP 54

Use the provided tools located inside the back cover of the Booklet maker

SW Loading cable RS232 4+2P for loading

--MD6DC PCB’s on Booklet maker
--MD3DC PCB on CST
--MD1SM PCB’s on CST

SW Download cable DB9M to DB9F

--CPU PCB on Booklet maker
--MD6DC PCB on Square Folder
--MD6DC PCB on Trimmer

USB to RS232 Converter

--For connection to lap top missing serial port (RS232)

USB memory stick

--For Booklet maker User Interface

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GP 20 NVM Reset 20. Press [Go back] to reach BM Service components menu.

Purpose 21. Select [Printer] (GP 8).

The NVM Reset procedure is used to recover booklet quality base NVM values for side 22. If present, enable Cover Feeder Module (GP 14).
guides, staple stop gate, fold stop gate, staple position, back jogger and trim knife zero. 23. Press [Home] to reach Target selection menu.
The NVM Reset procedure is used after updating software, replacing the PCB Control- 24. Press [Exit service] when ready to exit service mode.
ler, PCB A, PCB E (BM) or F (CST), or when a part affecting the booklet quality has been
replaced.
The NVM reset procedure can also be initiated to resolve minor logic problems. Flowcharts

Procedure Need to update

General procedure to perform NVM reset is described below. Depending on circumstances, software
exact procedure to retieve NVM values may vary, see flowcharts further below.
NOTE: All data in the EEPROM will be cleared including jobs, jam history etc.
The only data not cleared are the Staple, Fold, Trim, Cover Feed, Rotator, Crease and Bleed
Trimmer counters.
Possible
Yes No
1. Enter Service Mode (GP 1). to retrieve NVM
values?
2. Select target (module) BM.
3. Select item [NVM].
NVM tag NVM tag
4. Record NVM values: BM: Index 2-7 and 11. available? available?
Yes No Yes No
5. Press [Home] to reach Target selection menu.
6. Select target (module) [CST].
7. Select item [NVM]. Compare values Record critical Download soft-
with NVM tag and NVM values (see ware GP 19.
8. Record NVM values: CST: Index 2-4. if different note GP 20) on a piece
9. Press [Go back] to reach CST Service Components menu. the new values of paper and
on the tag. store in machine
10. Select item [Reset NVM]. Follow on screen instruction. for reference. Perform NVM
reset GP 20.
11. Press [Reset]. Read/follow on screen instructions. Press [Go back] to reach CST Ser-
vice Components menu.
Update software
12. Select item [NVM]. GP 19. Perform Paper
size reset GP 12.
13. Re-enter NVM values CST: Index 2-4 recorded in step 8.
14. Press [Home] to reach Target selection menu. Perform NVM
reset GP 20. Record critical
15. Select target (module) [BM]. NVM values (see
16. Select item [Reset NVM]. Follow on screen instruction. GP 12 & 20) on
a piece of paper
17. Press [Reset]. Read/follow on screen instructions. Press [Go back] to reach BM Service and store in ma-
Components menu. chine for future
18. Select item [NVM]. reference

19. Re-enter NVM values BM: Index 2-7 and 11 recorded in step 4.
continued on next page

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GP 20 NVM Reset, continued

Need to replace
PCB Controller,
PCB A

Possible
Yes No
to retrieve NVM
values?
Replaced a part
affecting booklet
NVM tag NVM tag quality
Yes available? No Yes available? No

Perform Paper
size reset GP 12.
Compare values Record critical
NVM values (see Replace PCB.
with NVM tag and
if different note GP 20) on a piece
of paper and Record critical
the new values
store in machine NVM values (see
on the tag.
for reference. Download soft- GP 12) on NVM
ware GP 19. tag or a piece of
paper and store
in machine for
Replace PCB. Perform NVM future reference.
reset GP 20.

Download soft-
ware GP 19. Perform Paper
size reset GP 12.

Perform NVM
reset GP 20. Record critical
NVM values (see
GP 12 & 20) on
a piece of paper
and store in ma-
chine for future
reference

continued on next page

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GP 21 BM Calibrate Transport Pressure GP 23 BM and CST Printer Interface Check

Purpose Purpose
This procedure will explain how to calibrate the BM Transport Pressure. This PCB is not in use for Off-line systems.

Procedure
Perform, BQ 11 Transport Feed Force

GP 22 Cheat Trimmer cover 15min

Purpose
This procedure will explain how to bypass the Trimmer Safety feature.

Procedure
Go to GP 4, section How to use the software cheater.

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GP 24 SQF Adjust Mode GP 25 Trimmer. Adjustment, compressor air stream trim
waste kit
Purpose
This procedure will explain how to use the Square Folder Adjust Mode. Condition
You need to have a compressor air stream trim waste kit (optional) installed
to be able to take advantage of this adjustment.
Procedure
Go to Section 3, BQ 10 Fold Skew
Purpose

This procedure explains how set the delay (NVM 23) and the duration (NVM 24) of the air blast
to avoid trim strips from causing jams by not entering the trim bin.
Normally the default settings will be quite sufficient.
However, under certain circumstances these settings might need to be adjusted to
help the trim strips to enter the trim bin.

Unfortunately there are no specific guidelines that can clearly tell you in which direction you
need to alter the settings.

Try increasing/decreasing the values and see what works for the actual job.

Note: Adjustment of air blast duration is in milliseconds.

Procedure

1. Enter Service Mode (GP 1)

2. Select target (module) BM
3. Select [NVM]
4. Scroll down to NVM 23 and/or 24.
5. Enter a new value by pressing the [+] or [-] buttons and
confirm by pressing the [OK] button.
6. Press [Exit]

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GP 26 30Vdc PSU (Power Supply SP-750-27) LED
GP 27 12 VDC PSU (Power Supply RS-35-12) LED
Purpose
Purpose
This procedure provides an explanation of the LED indication on the PSU.
This procedure provides an explanation of the LED indication on the Power supply.
Procedure --LED will be illuminated when 12 Vdc is present.
WARNING! --LED flashes when there is a short circuit related to 12V
Turn off the BM Main Power Switch and disconnect the Main Power Cord before
disconnecting, removing or replacing any electrical components
LED will be illuminated when 30 Vdc is present and system is in Ready state [A].
This LED will not be illuminated when:

--System has an in-complete Interlock circuit (such as Cover/s open).

--System has a missing / disconnected Power and / or Communication Cable/s.
--System is in Power Saver Mode.

[A]

[A]

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GP 28 PCB Printer Interface PCB ”E” LEDs GP 29 MD6DC PCB LEDs
Purpose Purpose
This PCB is not in use for In-line systems. Provides an explanation of the LED indications on the PCB.
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 is missing, LED would be OFF.

D2: Red LED flashes whenever information is sent or received on the Internal CAN.
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.

NOTE: The description above applies to all MD6DC PCB’s in the system:

• MD6DC “H” - BM
• MD6DC “B” - BM
• MD6DC “C” - BM
• MD6DC “A” - TR
• MD6DC “D” - SQF

D15 D1 D2

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 GP 30 Controller PCB ”A” LEDs and Test Points GP 31 MD6DC PCB Test points
Purpose Purpose
Provides an explanation of the LED indications on the PCB. Provides test points on the PCB.
VCC: Ground is the minus when measuring 5V (VCC).
WARNING!
GND/PGND: Ground /Power Ground is the minus when measuring either ESD Hazard! ESD (Electrostatic Discharge) can cause hardware crashes, data and/or communica-
unregulated tions problems. Failure to use proper ESD procedures will cause damage to electronic components
30V or 5V (VCC) (eg: PCBs).

GND / PGND ESD problems can be minimized by maintaining all machine ground connections,
ensuring the proper handling of circuit boards and sensors. Use ESD protection when working near
PCBs. Failure to use ESD protection is likely to result in a PCB failure
NOTE: The description above applies to all MD6DC PCB’s in the system:
• MD6DC “H” - BM
• MD6DC “B” - BM
• MD6DC “C” - BM
VCC • MD6DC “A” - TR
• MD6DC “D” - SQF

+UNREG: Outgoing 30V PSU.

VCC: Stabilized and rectified 5V made from incoming 12V PSU.

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 30V or 5V
LED (Flashes) (VCC).

GND/PGND
GND/
PGND
VCC

VCC

30V

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GP 32 4IN 4OUT PCB ”J” LEDs
Purpose
Provides an explanation of the LED indications on the PCB.

D1 = Yellow LED Lit when

Interlockswitch SW1(SW17 Soft Signal)
activated.

D1

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GP 33 Addon PCB ”F” Testpoints

Purpose
Provides testpoints on the PCB.

J1
J2
J3
J4

GND

GND / PGND: Ground /Power Ground is the minus

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GP 34 Set Size Guide
Note:
The following tables are guidelines designed to give an indication on how many sheet a
specific application can have for a given media weight.
Exact number of sheets is depending on media type and image.

BM500 BM350
Paper Size Paper Size
A3 or 11x17" A4 or 8.5x11" A3 or 11 x 17" A4 or 8,5 x 11"
Paper weight Area Coverage Area Coverage Area Coverage Area Coverage
Bond Offset Cover Tag Index Gsm Low Full Low Full Low Full Low Full
20 50 28 46 42 80 50 32 50 32 35 25 35 25
24 60 33 56 50 90 45 32 44 32 30 20 30 20
31 81 45 73 66 120 25 24 26 25 22 19 22 19
36 90 50 82 75 140 17 19 20 22 20 15 20 15
53 135 74 122 110 200 15 14 15 15 13 10 13 10
58 146 80 134 120 220 13 12 14 12 11 9 11 9
76 192 105 175 158 280 12 10 10 10 9 7 9 7
82 208 114 189 170 300 9 9 9 9 8 6 8 6

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GP 35 Tag Matrix and Serial Plate Location BM

The Tag Matrix for the BM is located on the inside of the exit cover [A].

[A]

The Serial Plate is located at the Rear

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GP 36 Tag Matrix and Serial Plate Location Trimmer GP 37 Tag Matrix and Serial Plate Location Square Folder
The tag matrix is located on the inside of the infeed frame [A].
The tag matrix is located on on the inside of the infeed frame [A].
The serial plate is located at the Rear [B].

[A]
[A]

The serial plate is located at the Rear [B].

[B]

[B]

Plockmatic BM500 system 20 May 2019 5. Service tables (GP)

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GP 38 Tag Matrix and Serial Plate Location CT GP 39 Tool location
The Tag Matrix is located on the inside of the rear frame [A]. The caster wrench [A], the paper size reset tool [B] and the Torx screwdriver [C] are
located inside the Rear Cover of the Booklet Maker
The Serial Plate is located at the rear [B].

[A]
[A]

[B]

[C]

[B]

Plockmatic BM500 system 20 May 2019 5. Service tables (GP)

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GP 40 Interlock cheater location
The interlock cheaters for BM, TR and SQF are located inside the Booklet Maker [A].

[B]

WARNING!
Always use extreme caution when operating the machine with any interlock switch cheated.

Plockmatic BM500 system 20 May 2019 5. Service tables (GP)

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GP 41 CST CPU / Controller PCB “A“ LEDs GP 42 CST Solenoid Driver PCB “B“ LEDs
Purpose Purpose
The purpose is to provide an explanation of the LED indications on the PCB. The purpose is to provide an explanation of the LED indications on the PCB.

LED Description
LED Description
D1, D2 Red LED flashes when power is on. The flashing indicates
D5 Yellow LED flashes when power is on. The flashing indicates that a program is present and functioning. Should a download
that a program is present and functioning. Should a download fail or the 5V is missing, the Red LED would be OFF.
fail or the 5V is missin, Yellow LED would be OFF.
D26 Red LED is ON when the software activates 5V to J6 pins 1-6
and J13 pins 1, 4, 7, 10, 14, 17, 20, 23

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GP 43 CST Stepper Motor Driver GP 44 CST PCB Printer Interface, PCB “F“ LEDs
(M7) PCB “C“, (M4) PCB “D“, (M1) PCB “E“, (M6) PCB Purpose
“H“, (M3) PCB “J“ LEDs This PCB is not in use for Off-line systems.

Purpose
The purpose is to provide an explanation of the LED indications on the PCB.

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

Note: Red LED is permanently ON after the first system initiation for PCB’s
Stepper Motor Driver (M1) PCB “E”, “H” and Stepper Motor Driver (M3)
PCB “J”, before the first system initiation the Red LED is flashing.
D2 Red LED is ON when hold current is active.

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GP 45 CST I/O 4IN4OUT PCB “G“ GP 46 CST CPU / Controller PCB “A“ Test points
Purpose Purpose
The purpose is to provide an explanation of the LED indications on the PCB. The purpose is to provide test points on the PCB.

LED Description
D1 SW2 (Q8) activated, slide inner position
Test points Description
D2 SW3 (Q9) activated, to cover closed VCC +5VDC measured from GND/PGND
D3 Q11 activated GND/ Ground / Power Ground is the minus when measuring voltage
D4 Q12 activated, optional PGND in the machine such as, VCC (+5VDC), +24VDC and +48VDC

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GP 47 CST MD3DC Solenoid Driver PCB “B“ Test points GP 48 CST Stepper Motor Driver
Purpose
The purpose is to provide test points on the PCB. Purpose
The purpose is to provide test points on the PCB.

Test points Description

VCC +5VDC measured from GND/PGND

GND/ Ground / Power Ground is the minus when measuring voltage

PGND in the machine such as, VCC (+5VDC), +24VDC and +48VDC
+UNREG +24VDC measured from GND/PGND. The +24VDC is not
Test points Description present when interlock relay is inactivated; the voltage will be
0VDC in this state.
VCC +5VDC measured from GND/PGND

GND/ Ground / Power Ground is the minus when measuring voltage

PGND in the machine such as, VCC (+5VDC), +24VDC and +48VDC
+UNREG +24VDC measured from GND/PGND. The +24VDC is not
present when interlock relay is inactivated; the voltage will be
0VDC in this state.

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GP 49 CST Controller PCB CPU “A“
4. Make sure DIP-switches 1, 2 and 3 is set to ON (up) position.
CAUTION Make sure DIP-switches 4 is set to OFF (down) position.

ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, 5. Run the CST MD1SM lower v1.00.exe* file (* v1.00 is an example - use
data and/or communications problems. Failure to use proper ESD proce- latest version) and follow the instruction in the program, or according to the
dures will cause damage to electronic components (example: PCBs). ESD latest bulletin.
problems can be minimized by maintaining all machine ground connec-
tions, ensuring the proper handling of circuit boards and sensors. Use ESD
protection when working near PCBs. Failure to use ESD protection is likely
to result in a PCB failure.
ON
1. Switch Off the Main Power Switch.

2. Remove Rear Cover. 1 2 3 4

3. Remove screw ( x 1) and fold out PCB [A].

[A]

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GP 50 CST PCB MD3DC “B“ GP 51 CST PCB MD1SM “C“

CAUTION CAUTION

ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD proce- data and/or communications problems. Failure to use proper ESD proce-
dures will cause damage to electronic components (example: PCBs). ESD dures will cause damage to electronic components (example: PCBs). ESD
problems can be minimized by maintaining all machine ground connec- problems can be minimized by maintaining all machine ground connec-
tions, ensuring the proper handling of circuit boards and sensors. Use ESD tions, ensuring the proper handling of circuit boards and sensors. Use ESD
protection when working near PCBs. Failure to use ESD protection is likely protection when working near PCBs. Failure to use ESD protection is likely
to result in a PCB failure. to result in a PCB failure.

1. Switch Off the Main Power Switch. 1. Switch Off the Main Power Switch.

2. Remove Rear Cover. 2. Remove Rear Cover.

3. Make sure DIP-switches 1 & 4 is set to ON (up) position. 3. Make sure DIP-switches 1, 2 and 4 is set to OFF (down) position.
Make sure DIP-switches 2 & 3 is set to OFF (down) position. Make sure DIP-switches 3 is set to ON (up) position.

4. Run the CST MD3DC v1.00.exe* file 4. Run the CST MD1SM v1.00.exe* file
(* v1.00 is an example - use latest version) and follow the instruction in the program, or (* v1.00 is an example - use latest version) and follow the instruction in the program, or
according to the latest bulletin. according to the latest bulletin.

ON
ON
1 2 3 4
1 2 3 4

Plockmatic BM500 system 20 May 2019 5. Service tables (GP)

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GP 52 CST PCB MD1SM “D“ GP 53 CST PCB MD1SM “H“

CAUTION CAUTION

ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD proce- data and/or communications problems. Failure to use proper ESD proce-
dures will cause damage to electronic components (example: PCBs). ESD dures will cause damage to electronic components (example: PCBs). ESD
problems can be minimized by maintaining all machine ground connec- problems can be minimized by maintaining all machine ground connec-
tions, ensuring the proper handling of circuit boards and sensors. Use ESD tions, ensuring the proper handling of circuit boards and sensors. Use ESD
protection when working near PCBs. Failure to use ESD protection is likely protection when working near PCBs. Failure to use ESD protection is likely
to result in a PCB failure. to result in a PCB failure.

1. Switch Off the Main Power Switch. 1. Switch Off the Main Power Switch.

2. Remove Rear Cover. 2. Remove Rear Cover.

3. Make sure DIP-switches 2, 3 and 4 is set to OFF (down) position. 3. Make sure DIP-switches 1 and 4 is set to OFF (down) position.
Make sure DIP-switches 1 is set to ON (up) position. Make sure DIP-switches 2 and 3 is set to ON (up) position.

4. Run the CST MD1SM v1.00.exe* file 4. Run the CST MD1SM v1.00.exe* file
(* v1.00 is an example - use latest version) and follow the instruction in the program, or (* v1.00 is an example - use latest version) and follow the instruction in the program, or
according to the latest bulletin. according to the latest bulletin.

ON ON

1 2 3 4 1 2 3 4

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GP 54 CST PCB MD1SM “J“

CAUTION

ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,

data and/or communications problems. Failure to use proper ESD proce-
dures will cause damage to electronic components (example: PCBs). ESD
problems can be minimized by maintaining all machine ground connec- [B]
tions, ensuring the proper handling of circuit boards and sensors. Use ESD
protection when working near PCBs. Failure to use ESD protection is likely
to result in a PCB failure.

1. Switch off the Main Power Switch and disconnect the Power Cord.

2. Remove the Rear Cover.

3. Remove Upper Slide Guide (REP 13.9). ON

4. Disconnect connectors (x3) [A].
1 2 3 4
5 Remove nuts (x3) [B].

6. Remove Protective Cover.

7. Re-connect connectors

8. Make sure DIP-switches 1 and 2 is set to ON (up) position

and DIP-switches 3 and 4 is set to OFF (down) position

9. Run the CST MD1SM v1.00.exe* file

(* v1.00 is an example - use latest version) and follow the instruction in the program, or
according to the latest bulletin.

[A]

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GP 55 PCB CPU APP 32 “A” AF602/VF602 GP 56 PCB CPU APP 32 “H” (Upper Bin) AF602/VF602

CAUTION CAUTION

ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD proce- data and/or communications problems. Failure to use proper ESD proce-
dures will cause damage to electronic components (example: PCBs). ESD dures will cause damage to electronic components (example: PCBs). ESD
problems can be minimized by maintaining all machine ground connec- problems can be minimized by maintaining all machine ground connec-
tions, ensuring the proper handling of circuit boards and sensors. Use ESD tions, ensuring the proper handling of circuit boards and sensors. Use ESD
protection when working near PCBs. Failure to use ESD protection is likely protection when working near PCBs. Failure to use ESD protection is likely
to result in a PCB failure. to result in a PCB failure.

1. Switch off the Main Power Switch and disconnect the Power Cord. 1. Switch off the Main Power Switch and disconnect the Power Cord.
2. Remove the Rear Cover. 2. Remove the Rear Cover.
Make sure DIP-switches are in correct position. Make sure DIP-switches are in correct position.

3. Run the AF602/VF602 CPU v1.00.exe* file 3. Run the AF602/VF602 CPU v1.00.exe* file
(* v1.00 is an example - use latest version according to the latest bulletin) (* v1.00 is an example - use latest version according to the latest bulletin)
and follow the instruction in the program. and follow the instruction in the program.

2 3 4 5 6 1
OFF
ON
ON
OFF
1 2 3 4 5 6

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GP 57 PCB CPU APP 32 “L” AF602/VF602 GP 58 PCB M21 “K” (Upper Bin M101) AF602/VF602
CAUTION CAUTION

ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD proce- data and/or communications problems. Failure to use proper ESD proce-
dures will cause damage to electronic components (example: PCBs). ESD dures will cause damage to electronic components (example: PCBs). ESD
problems can be minimized by maintaining all machine ground connec- problems can be minimized by maintaining all machine ground connec-
tions, ensuring the proper handling of circuit boards and sensors. Use ESD tions, ensuring the proper handling of circuit boards and sensors. Use ESD
protection when working near PCBs. Failure to use ESD protection is likely protection when working near PCBs. Failure to use ESD protection is likely
to result in a PCB failure. to result in a PCB failure.

1. Switch off the Main Power Switch and disconnect the Power Cord. 1. Switch off the Main Power Switch and disconnect the Power Cord.
2. Remove the Rear Cover. 2. Remove the Rear Cover.
Make sure DIP-switches are in correct position. Make sure DIP-switches are in correct position.

3. Run the AF602/VF602 CPU v1.00.exe* file 3. Run the AF602/VF602 M21 H v1.00.exe* file
(* v1.00 is an example - use latest version according to the latest bulletin) (* v1.00 is an example - use latest version according to the latest bulletin)
and follow the instruction in the program. and follow the instruction in the program.

2 3 4 5 6 1
OFF
ON

2 3 4 5 6
1
ON OFF

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GP 59 PCB M21 “O” (Lower Bin) AF602/VF602 GP 60 PCB M21 “G” (Feed Motor M301) AF602/VF602
CAUTION CAUTION

ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD proce- data and/or communications problems. Failure to use proper ESD proce-
dures will cause damage to electronic components (example: PCBs). ESD dures will cause damage to electronic components (example: PCBs). ESD
problems can be minimized by maintaining all machine ground connec- problems can be minimized by maintaining all machine ground connec-
tions, ensuring the proper handling of circuit boards and sensors. Use ESD tions, ensuring the proper handling of circuit boards and sensors. Use ESD
protection when working near PCBs. Failure to use ESD protection is likely protection when working near PCBs. Failure to use ESD protection is likely
to result in a PCB failure. to result in a PCB failure.

1. Switch off the Main Power Switch and disconnect the Power Cord. 1. Switch off the Main Power Switch and disconnect the Power Cord.
2. Remove the Rear Cover. 2. Remove the Rear Cover.
Make sure DIP-switches are in correct position. Make sure DIP-switches are in correct position.

3. Run the AF602/VF602 M21 H v1.00.exe* file 3. Run the AF602/VF602 BIN CPU v1.00.exe* file
(* v1.00 is an example - use latest version according to the latest bulletin) (* v1.00 is an example - use latest version according to the latest bulletin)
and follow the instruction in the program. and follow the instruction in the program.

ON
OFF
1 2 3 4 5 6

2 3 4 5 6
1

ON OFF

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GP 61 SP Sensor PCB “CC” (Upper Bin) VF602 GP 62 SP Sensor PCB “Y” (Lower Bin) VF602
CAUTION CAUTION

ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD proce- data and/or communications problems. Failure to use proper ESD proce-
dures will cause damage to electronic components (example: PCBs). ESD dures will cause damage to electronic components (example: PCBs). ESD
problems can be minimized by maintaining all machine ground connec- problems can be minimized by maintaining all machine ground connec-
tions, ensuring the proper handling of circuit boards and sensors. Use ESD tions, ensuring the proper handling of circuit boards and sensors. Use ESD
protection when working near PCBs. Failure to use ESD protection is likely protection when working near PCBs. Failure to use ESD protection is likely
to result in a PCB failure. to result in a PCB failure.

1. Switch off the Main Power Switch and disconnect the Power Cord. 1. Switch off the Main Power Switch and disconnect the Power Cord.
2. Remove the Rear Cover to open the Upper Bin. 2. Remove the Rear Cover to open the Lower Bin.
3. Remove the Upper Bin’s Cover. 3. Remove the Lower Bin’s Cover.
Make sure DIP-switches are in correct position. Make sure DIP-switches are in correct position.

4. Run the VF602 SP Sensor v1.00.exe* file 4. Run the VF602 SP Sensor v1.00.exe* file
(* v1.00 is an example - use latest version according to the latest bulletin) (* v1.00 is an example - use latest version according to the latest bulletin)
and follow the instruction in the program. and follow the instruction in the program.

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GP 63 PCB CPU APP 32 “A” CR500 GP 64 PCB M21 “E” (Motor M1) CR500

CAUTION CAUTION

ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or
communications problems. Failure to use proper ESD procedures will cause damage communications problems. Failure to use proper ESD procedures will cause damage
to electronic components (example: PCBs). ESD problems can be minimized by to electronic components (example: PCBs). ESD problems can be minimized by
maintaining all machine ground connections, ensuring the proper handling of circuit maintaining all machine ground connections, ensuring the proper handling of circuit
boards and sensors. Use ESD protection when working near PCBs. Failure to use boards and sensors. Use ESD protection when working near PCBs. Failure to use
ESD protection is likely to result in a PCB failure. ESD protection is likely to result in a PCB failure.

1. Switch off the Main Power Switch and disconnect the Power Cord. 1. Switch off the Main Power Switch and disconnect the Power Cord.

2. Remove the Creaser Front Cover. 2. Remove the Rear Cover.

Make sure DIP-switches are in correct position. Make sure DIP-switches are in correct position.

3. Run the CR2000 CPU v1.00.exe* file 3. Run the CR2000 M21E v1.00.exe* file
(* v1.00 is an example - use latest version according to the latest bulletin) and follow (* v1.00 is an example - use latest version according to the latest bulletin) and follow
the instruction in the program. the instruction in the program.

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GP 65 PCB M21 “G” (Motor M2) CR500 GP 66 PCB M21 “H” (Motor M3) CR500

CAUTION CAUTION

ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or
communications problems. Failure to use proper ESD procedures will cause damage communications problems. Failure to use proper ESD procedures will cause damage
to electronic components (example: PCBs). ESD problems can be minimized by to electronic components (example: PCBs). ESD problems can be minimized by
maintaining all machine ground connections, ensuring the proper handling of circuit maintaining all machine ground connections, ensuring the proper handling of circuit
boards and sensors. Use ESD protection when working near PCBs. Failure to use boards and sensors. Use ESD protection when working near PCBs. Failure to use
ESD protection is likely to result in a PCB failure. ESD protection is likely to result in a PCB failure.

1. Switch off the Main Power Switch and disconnect the Power Cord. 1. Switch off the Main Power Switch and disconnect the Power Cord.

2. Remove the Front Cover. 2. Remove the Rear Cover.

Make sure DIP-switches are in correct position. Make sure DIP-switches are in correct position.

3. Run the CR2000 M21G v1.00.exe* file 3. Run the CR2000 M21H v1.00.exe* file
(* v1.00 is an example - use latest version according to the latest bulletin) and follow (* v1.00 is an example - use latest version according to the latest bulletin) and follow
the instruction in the program. the instruction in the program.

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6 DETAILED DESCRIPTION
Content
6.1 Parts component list 6-2

6.2 BM500 Principle of Operation 6-2

6.2.1 Paper Infeed to Bookletmaker.............................................................................. 6-2
6.2.2 Infeed/handfeed unit.............................................................................................. 6-2
6.2.3 Infeeder................................................................................................................... 6-2
6.2.4 Stapler and Staple Stop Gate Modules................................................................ 6-3
6.2.5 Pre-fold Transport Module.................................................................................... 6-4
6.2.6 Folding Module...................................................................................................... 6-5
6.2.7 Belt Stacker Module.............................................................................................. 6-6
6.2.8 Square Folder (Squareforming Module).............................................................. 6-7
6.2.9 Trimmer (Face Trimmer Module) ......................................................................... 6-8
6.2.10 AF602...................................................................................................................... 6-9
6.2.11 VF602.................................................................................................................... 6-10
6.2.12 CR500.................................................................................................................... 6-11
6.2.13 CST........................................................................................................................ 6-11

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6-1
6.1 PARTS COMPONENT LIST

Please refer to section Component Locator in relevant Spare Part Catalog(s).

6.2 BM500 PRINCIPLE OF OPERATION

Purpose
This procedure is intended to provide the Principles of Operation for the BM system.

6.2.1 PAPER INFEED TO BOOKLETMAKER

Paper is fed to the Booklet Maker by the CST, CR or a Feeder.

6.2.2 INFEED/HANDFEED UNIT

Sheets entering the Infeed unit will actuate the Infeeder paper path sensor Q53. Motor M19 Sensor Q53
Motor M19 in the Infeed unit will feed the sheets through the to the Infeeder Compiler area. (including Q34)

6.2.3 INFEEDER
Motor M1 Sensor Q1
The Infeeder receives sheet from the CST module, CR or a Feeder. (including Q2)

Sheet will be registered over Q1 as it enters the Booklet Maker.

Motor M1 will cycle up and feed sheets down against the Staple Stop Gate.
After each sheet in a set is fed down against the Staple Stop, the M2 Motor will cycle up and jog
the sheet/s.

The M2 Motor will keep the joggers on top of the sheet/s, and act as a upper guide for next coming
sheet.

As soon as another sheet has arrived against the Staple Stop, the M2 Motor will cycle down and up
again,
jogging the last sheet and again staying on top, to act as a paper guide for next upcoming sheet.

The M3 Motor will jog the side guides when it can (no sheets coming in), and always on the last
sheet to ensure a properly tamped set.
Back Joggers (x4) Sensor Q13 Motor M3 (in-
(driven by Motor M2 (M3 home) cluding Q12)
After final sheet has been tamped, staple cycle will start.
and Sensor Q44)

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6.2.4 STAPLER AND STAPLE STOP GATE MODULES M20 (including M23 and Sensor M21 (including
Q49, Q50 and Q36 (M23 home) Q46, Q47 and
With the set jogged, The stapler motors M20 and M21 cycles, Q51) Q48)
putting staples through the set.

When the staples are driven through the set, a trig signal,
Sensor Q48 and Q51, from the stapler, starts the corresponding clincher solenoid,
which bends the staple legs to be flat.

When the staples contact the clinchers,

a closed circuit is established through Q19 and Q20,
by current running from stapler head through staple contacting the clincher.

The closed circuit created, indicates that staples are present.

If no staple is present the paper will insulate the stapler head from the clincher,
which will result in an open circuit.

The open circuit at this time will indicate, staple miss.

The stapler motors M20 and M21 will complete its cycle and stop in upper BK-clinch left BK-clinch right
position as the stapler home position sensors Q47 and Q50 activates. solenoid solenoid
(including Q19) (including Q20)
Each staple head also has a Low Staple Sensor, Q46 and Q49.

The BM is also equipped with Thick Set Sensing device located between the staplers M20 (including
M21 (including M23 and Sensor
(motors M20 and M21). Q49, Q50 and
Q46, Q47 and Q36 (M23 home)
Q51)
Q48)
Throughout the compiling sequence the Booklet Maker will
measure the set thickness to prevent too thick sets to pass through the system.

This is done by motor M23 and sensor Q36 that senses thickness of set.

This sensor also provides info to adjust staple-line,

trim length as well as square fold mode.

BK-clinch right
BK-clinch left
solenoid
solenoid
(including Q20)
(including Q19)

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6.2.5 PRE-FOLD TRANSPORT MODULE
When the stapling is done, the side guides motor M3 moves out.
The staple stop gate motor M22, moves the transport rollers upwards,
gripping the set between the transport roller below and idler roller on top of the set.

The staple stop gate is pulled down by the same motor and latched below the paper path.

The set transport motor M5 starts and transports the set down to the fold stop.
Fold stop sensor Q7 (see Folding Module) near the fold stop, activates.

Side guides M3 move out to their initial position.

In case the sheet length is shorter than the distance between staple stop and fold stop (i.e. A4),
the staple stop will unlatch as soon as the set has cleared the Start Sensor Saddle Stapling Q4.

The staple stop is unlatched by the staple stop gate motor M22.
In case the sheet length is longer than the distance between staple stop and fold stop (i.e. A3),
the staple stop gate motor M22 will release the transport wheel pressure as soon as the set has reached
the fold stop gate.
Motor M5 Sensor Q42 Sensor Q4 Motor M22
When the set is folded and leaves the Start Sensor Saddle Stapling Q4, (including Q40) (M22 home) (including Q41)
the staple stop gate moves up, preparing to receive new sheets.

By stopping in variable positions, different staple positions can be obtained.

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6.2.6 FOLDING MODULE
Fold roller motor M6 that drives the first and second pair of fold rollers
starts when stapling is complete.

The fold stop gate motor M8 moves the fold stop down about 15 mm,
and the sheets transported by the pre fold transport reaches
the fold stop sensor Q7 and stops at the fold stop.

The fold stop motor now starts to move upwards to jog the set into position.
By stopping in a variable position, different fold positions can be obtained.
Motor M6
Slightly after that the fold knife motor M7 cycles. Sensor Q8 (including Q9)
The fold knife pushes the center of the set up through the first pair of fold rollers.

The fold knife motor will complete its cycle and stop in the
lower position when the fold knife home position sensor Q15 activates.

A booklet is now formed. When the booklets leading edge (the spine) is
about to enter the second pair of fold rollers,
the fold roller motor M6 stops for a short time* and then starts again.

The time the booklet sits between the second pair of fold rollers
depends on the number of sheets per set.
The longer it sits the more compressed the spine becomes, resulting in a flatter booklet.

When the set is exiting the second pair of fold rollers the Exit sensor Q8 activates.
When the trail edge of the set exits the Booklet Maker the Exit sensor Q8 becomes clear.

* If fold delay is set to On and the sheet length is 400mm or less,

the booklet sits between the second pair of fold rollers up to about 15 seconds,
Sensor Q7 Motor M8
depending on the number of sheets per set.
(including Q43)
The set stays between the fold rollers until the
last sheet of the next set enters the infeed area,
but never longer than 15 seconds.
If the sheet length is more than 400mm, fold delay is not used.

Motor M7 and
Q15

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6.2.7 BELT STACKER MODULE
If the Belt Stacker is installed directly on the Booklet Maker
(no Square Folder / Trimmer installed),
the stacker motor ST-M1 starts when the Exit sensor or Q8 activates
and runs ST-M1 for a short while to separate the booklets on the stacker period.

Principle of Operation is same if it is mounted to the TR or the SQF,

Exit sensor activates ST-M1.

ST-M1

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 6.2.8 SQUARE FOLDER (SQUAREFORMING MODULE) Motor M2
(including Q10)
In BM500 the Squareforming Module is installed in front of the Trimmer Module.
Booklet Maker sends a start signal.
The transport belt motor M1 starts and transports the booklet into the machine.

The infeed sensor Q5 is activated by the booklet.

The booklet passes and deactivates the infeed sensor Q5.

The Stop gate motor M2 actuates and stops the booklet,

leaving a certain amount of spine outside the clamp
(determined by operator or Auto setting on the UI).

The booklet is then compressed by the Set clamp motor M3 driving the upper clamp down,
holding the booklet in place.

Next the Stop gate motor M2 moves the gate downward and
the Roller motor M4 moves (rolling) over the spine of the Booklet, Motor M1
pressing it up against the Set clamps, producing the Square fold look.

When the Square folding sequence is completed,

the Set clamp motor M3 moves the upper clamp up
and releases its grip on the booklet.

The booklet is transported passed the Exit sensor Q7,

and out into the Trimmer Module. For some modes, multiple cycles are used.
Motor M3

Motor M3

Motor M4
(including Q8)

Sensor Q7 (2
pieces, 1 pcs
underneath
paperpath

Sensor Q5 (2
pieces)

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6.2.9 TRIMMER (FACE TRIMMER MODULE) Sensor Q13

Booklet Maker (or Square Folder) sends a start signal. Motor M8

The transport motor M1 starts and transports the booklet into the machine.
The infeed sensor Q13 is activated by the booklet.

The booklet passes and deactivates the infeed sensor Q13.

When the booklet hits the stop gate, the transport motor M1 stops.
The timing is controlled by transport motor sensor Q4 and set by the paper size.

To accommodate various booklet thicknesses,

motor M8 has been added to lift up the Exit belt assy.
Motor M1
Trim length is determined by settings on the operator UI or the thickness sensor (Auto
mode) and controlled by motor M4 that moves stop gate assy back and forth.

Trim knife motor M2 starts moving the knife down.

After a while when the knife is about to cut the sheets,
transport motor M1 is triggered by knife position sensor Q5
to reverse and helps knife motor M2 during the cutting stroke.

About the time when the knife has cut through the sheets,
the stop gate motor M3 moves the stop gate down and Motor M2
Sensor Q6
the transport motor 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 sensor Q5.
The stacker motor (ST-M1 - see Belt Stacker Module) starts
when the Exit sensor Q6 activates and
runs for a short while to separate the booklets on the stacker belt. Sensor Q5

When Exit sensor Q6 activates, stop gate motor M3 moves

the stop gate to up position and is stopped when
the stop gate home position sensor Q7 activates.

Sensor Q4

Motor M4
(including Q12)

Motor M3

Sensor Q7

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6.2.10 AF602

Function After Calibrate is Selected Function After Start is Selected

• Presence of programmed feed sequence is verified • Presence of programmed feed sequence is Verified
• Bin empty sensor (Q105/205) checks that there is paper in bin • Bin empty sensor (Q105/205) checks that there is paper in bin
• Lift motor (M101/M201) runs to operating height. • Lift motor (M101/M201) runs to operating height.
• This is given by Upper home position sensor (Q104/204). • This is given by Upper home position sensor (Q104/204).
• The stack of paper lifts drive roller until sensor de-activates. • The stack of paper lifts drive roller until sensor de-activates.
• Lift height is after that adjusted continuously during run, • Lift height is after that adjusted continuously during run,
• Feed motor (M301) starts • Feed motor (M301) starts
• Bin fans (FAN101-104/FAN201-204) blows 100% for one second and • Bin fans (FAN101-104/FAN201-204) blows 100% for one second and
is after that (in auto mode) regulated by the top sheet height position is after that (in auto mode) regulated by the top sheet height position
measured by USDS meter sensor (Q301/302) measured by USDS meter sensor (Q301/302)
• Feed roller clutch/solenoid (SOL101/201) activates Feed roller and • Feed roller clutch/solenoid (SOL101/201) activates Feed roller and
feeds sheet feeds sheet
• Feed roller clutch/solenoid (SOL101/201) de-activates when sheet has • Feed roller clutch/solenoid (SOL101/201) de-activates when sheet has
reached grip in exit rollers (calculated time from when DSD sensor is reached grip in exit rollers (calculated time from when DSD sensor is
activated). activated).
• US DSD sensor (Q102/Q202) verifies that there always is single sheet • US DSD sensor (Q102/Q202) / Optical DSD sensor verifies that there
feed always is single sheet feed
• Optical DSD sensor calibrates to sheet density for each sheet and for • Exit sensor verifies that sheet arrives in time
whole set • Exit sensor verifies that sheet exits in time
• Exit sensor verifies that sheet arrives in time • Machine continues running until programmed job ends or bin is empty
• Exit sensor verifies that sheet exits in time
• Machine stops after last sheet in set and waits for “go” signal

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6.2.11 VF602

Function After Calibrate is Selected Function After Start is Selected

• Presence of programmed feed sequence is verified • Presence of programmed feed sequence is verified
• Bin empty sensor (Q105/205) checks that there is paper in bin • Bin empty sensor (Q105/205) checks that there is paper in bin
• Lift motor (M101/M201) runs to operating height • Lift motor (M101/M201) runs to operating height.
• Feed motor (M301) starts • Feed motor (M301) starts
• Bin fans (FAN101-104/FAN201-204) blows 100% for one second and is after that (in • Bin fans (FAN101-104/FAN201-204) blows 100% for one second and is after that (in
auto mode) regulated by the top sheet height position measured by USDS meter sensor auto mode) regulated by the top sheet height position measured by USDS meter sensor
(Q301/302) (Q301/302)
• Vacuum fan and separation fan initiate simultaneously with bin fans • Vacuum fan and separation fan initiate simultaneously with bin fans
• Vacuum Assembly clutch/solenoid activates vacuum and feeds sheet • Vacuum Assembly clutch/solenoid activates vacuum and feeds sheet
• Vacuum Assembly clutch/solenoid de-activates when sheet has reached the exit rollers • Vacuum Assembly clutch/solenoid de-activates when sheet has reached the exit rollers
(calculated distance from when DSD sensor is activated) (calculated time from when DSD sensor is activated)
• Stop clutch activates to stop rollers • Stop clutch activates to stop rollers
• US DSD sensor (Q102/Q202) verifies that only one sheet is fed at a time • US DSD sensor (Q102/Q202) / Optical DSD sensor verifies that only one sheet is fed at
a time and that paper length is the same for all sheets
• Optical DSD sensor calibrates to sheet density for each sheet and for whole set
• Exit sensor verifies that sheet arrives in time
• Exit sensor verifies that sheet arrives in time
• Exit sensor verifies that sheet exits in time
• Exit sensor verifies that sheet exits in time
• Machine continues running until programmed job ends or bin is empty
• Machine stops after last sheet in set and waits for “go” signal

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 6.2.12 CR500 6.2.13 CST

• Sheets are fed into the unit from a feeder.

Initialization cycle
• The sheets are then transported through the paper path with their skew maintained by
long rubber rollers and spring loaded metal surfaced idler rollers, to ensure a firm grip.
By turning on the main power, following three systems :
• The transportation system is driven by stepper motor (M1) via a timing belt. Registration width adjustment motor ( M4), creaser motor ( M6) and bleed trimmer width adjust-
• The angular deviation of the crease tool sub frame relative the lead edge of the sheet ment motor ( M7) will initiate.
is measured by 2 pairs of sensors positioned on the sub frame.
• Media wider than 300mm use the outer sensors Q1 and Q4 (C-C 260mm). The initiation of the motors M4 and M7 requires that M1 is running properly.

• Media narrower than 300mm use the inner sensors Q2 and Q3 (C-C 80mm).
Input of operator settings and/ or activation of interlock switches will initiate these systems totally or
• The skew is then adjusted accordingly by stepper motor (M2) via a lead screw mecha- partly.
nism.
• The lead screw is indexed by the home sensor Q7 at init.
• The position of the lead edge is also determined by the same pair of sensors (Q1-Q4).
CST-Q6
• The position of the crease is then determined by dead reckoning from the lead edge
knowing the length of the paper, the line speed and compensated for the amount of
skew compensation needed individually for each sheet to be creased. CST-M7
• The Crease tools are driven by stepper motor (M3) via a timing belt that also synchro-
nizes the crease tools.
• The crease tools are indexed by the home sensor (Q6) and a 180° cam.
• When the sheets exit the unit, they pass an exit sensor (Q5) to ensure set integrity.
• The crease unit is controlled from the Booklet Makers user interface.

CST-M1

CST-M4

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 Initialization cycle

By turning on the main power, following three systems :

CST-M6 Registration width adjustment motor ( M4), creaser motor ( M6) and bleed trimmer width adjust-
ment motor ( M7) will initiate.

The initiation of the motors M4 and M7 requires that M1 is running properly.

Input of operator settings and/ or activation of interlock switches will initiate these systems totally or
partly.

PCB communication
CST-Q3 PCB communications are checked upon power on.
If communication failures occur, one or more of folllowing faultcodes will be triggered and displayed.

• CST-111 Stepper Motor Driver ( M1) PCB “E”, had no CAN communication.
• CST-113 Stepper Motor Driver ( M3) PCB “J”, had no CAN communication.
• CST-114 Stepper Motor Driver ( M4) PCB “D”, had no CAN communication.
• CST-116 Stepper Motor Driver ( M6) PCB “H”, had no CAN communication.
• CST-117 Stepper Motor Driver ( M7) PCB “C”, had no CAN communication.
• CST-120 Solenoid Driver PCB “B”, had no CAN communication.
PCB communication
CST-M3
PCB communications are checked upon power on.
If communication failures occur, one or more of folllowing faultcodes will be triggered and displayed.

• CST-111 Stepper Motor Driver ( M1) PCB “E”, had no CAN communication.
• CST-113 Stepper Motor Driver ( M3) PCB “J”, had no CAN communication.
• CST-114 Stepper Motor Driver ( M4) PCB “D”, had no CAN communication.
• CST-116 Stepper Motor Driver ( M6) PCB “H”, had no CAN communication.
• CST-117 Stepper Motor Driver ( M7) PCB “C”, had no CAN communication.
• CST-120 Solenoid Driver PCB “B”, had no CAN communication.

PCB Voltage levels

PCB voltages are measured upon power on.
If measeured values are not within voltage range, one or more of folllowing faultcodes will be trig-
gered and displayed.

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PCB Voltage levels MOTOR SYSTEMS DURING INITIATION CYCLE
PCB voltages are measured upon power on.
If measeured values are not within voltage range, one or more of folllowing faultcodes will be trig- M4 REGISTRATION MOTOR SYSTEM
gered and displayed. The motor M4 control the registration system using the width of the incoming sheet and image
• CST-121 Stepper Motor Driver ( M1) PCB “E” , had too low voltage. offset as input parameters. Whenever the width or the offset value are changed and at power on,
the motor system returns to the position of the home position sensor (Q3), and initiate a linear
• CST-123 Stepper Motor Driver ( M3) PCB “J”, had too low voltage. movement to the position corresponding to the input parameters.
• CST-124 Stepper Motor Driver ( M4) PCB “D” ( M4), had too low voltage
• CST-126 Stepper Motor Driver ( M6) PCB “H”, had too low voltage. If the sensor Q3 is not activated within reasonable time after initiation of M4, following faultcode will
be triggered. CST-101 Registration Home Sensor not activated in time after start of M4.
• CST-127 Stepper Motor Driver ( M7) PCB “C”, had too low voltage.
• CST-130 Solenoid Driver PCB “B”, had too low voltage. If the sensor is not deactivated within a reasonable time after the motor M4 has initiated the linear
The power on also trigger a check of any mismatch between the supply voltages and the state of movement towards the calibrated and final position, following faultcode will be triggered:
the interlock switches. Following fault code will be triggered if mismatch is deteced: CST-102 Registration Home Sensor not deactivated in time after start of M4.
CST-140 Interlock circuit Mismatch Q8, Q9 state with Voltage
To avoid mechanical binding M1 needs to be running while running M4 systems.

M6 CREASER SYSTEM
The purpose of the motor M6 is to perform the Creaser Tool Action.

The Creaser tool is basically two metallic cylinder, one is equipped with a vertical groove whereas
the other is equipped with a vertical metalic strip. The strip fit well into the groove in order to crease
sheets.
Dependent of the thickness of the sheets, there is two possible choice of groove width, either nar-
row or wide width, the later suitable for thicker media.

CST-Q7 CST-Q9
For accurate position of the Crease on the sheet, the tools will locate the start position at initiation.
After position the tool in start position (strike position) the crease is ready to carry out a strike in
order to crease a sheet.

After the crease stroke is carried out, the tools will be re-positioned to strike position for creasing
additional sheets, by performing a empty stroke just behind the trail edge of the creased sheet.

The Creaser tool home sensor (Q5) is used for positioning purposes at initiation.
If the home sensor signal dont change state, after a reasonable amount of time after initiation of M6
during run, following faultcode will be triggered:

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CST-011 Creaser Tools M6 Home Sensor not activated in time M7 BLEED TRIMMER WIDTH SETTING SYSTEM
During run the position of the tools is checked with respect to Q5, in each crease operation. If the The purpose of the motor M7 is to control the Bleed Trimmer cutting width using the outgoing (cut)
Tools loose their position, following fault condition is triggered. sheet width (cross process direction) as the input parameter.

CST-105 Creaser Tools Home Sensor not activated in time after start of M6. At Power On and when the input parameter is changed, the M7 system first locates the home posi-
tion sensor (Q6), and then traverses out to the final position corresponding to the input parameter.

If the sensor is not activated within a reasonable time after that M7 has started to traverse towards
Q6, following fault condition will be triggered and displayed:
44-2003 Sensor Q6 Not activated in time after start of M7.

If the sensor is not deactivated within a reasonable time after start of M7 towards final position (out
from home position), following fault condition will be triggered and displayed:
44-2004 Sensor Q6 Not deactivated in time after start of M7.

To avoid mechanical binding, the M1 system must be running and SOL3 deactivated when M7
initiation is done.

CST-Q5
CST-SOL3

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SOLENOID SYSTEMS DURING INITIATION CYCLE Cycle Up signal (C2)
All Solenoid Systems are deactivated during the Initiation Cycle. Start M1
Start M3 (in half of normal Transport velocity if rotating).
PROCESS CYCLE
UPSTREAM SIGNALS PAPER PATH SENSORS
Paper Path Sensor Q1
Off Line signal (S0) Faultcode CST-001 (Q1 not activated in time) is triggered:
Active when the CST is powered on. If Q1 not activated within 1000 [ms] after receiving the Sheet Exit signal.
Faultcode CST-002 (Q1 activated too long) is triggered if:
Faulted signal (S1) If the deactivation time [ms] of Q1 is not within:
(paper length [mm] ) / (transport speed [m/s] ) ± 20%
Jam and fault states will activate the “Faulted” signal.
Reset by activating both Top Cover and Slide Door Interlocks.
At Power On or Initiation.

Full signal (S2)

Paper Path Sensor Q2
The “Full” signal is activated when the waste bin sensor (Q11) has been activated too long (503).
Faultcode CST-003 (Q2 not activated in time) is triggered:
Reset by activating either Top Cover and/or Slide Door Interlocks.
If Q2 (after receiving the sheet present signal from sensor (Q1) is not activated within:
(195 [mm]) / (transport speed [m/s] ) ±20%
Sheet Delivered signal (S3) Faultcode CST-004 (Q2 activated too long) is triggered:
The CST sends “Sheet Delivered” to the feeder after a sheet has passed the Exit Sensor Q7. If the deactivation time [ms] of Q2 is not within:
(paper length [mm]) / (transport speed [m/s] ) ±20% (No rotation)
Set Delivered signal (S4)
(paper length [mm]) / (transport speed [m/s] ) ±20% + t r (Rotation)
The CST sends “Set Delivered” to the upstream device after a set has been delivered to the Book-
let Maker Systems Belt Stacker.
t r = sheets rotation time.
Sheet Exit signal (C0)
Q1 At Power On or Initiation.
Sheet must arrive at Q1 within 1.000 msec from receiving the Sheet Exit Signal.
Else the 201 jam condition is triggered. Remarks: Q2 triggers SOL1 and Q2 triggers SOL2.

SOL3 Paper Path Sensor Q10

SOL3 activated state, disengage the Bleed Trimmer knives is triggered a specified time after the
latest Sheet Exit signal. Faultcode CST-005 (Q10 not activated in time) is triggered:
SOL3 deactivated state is also triggered from the first incoming Sheet Exit signal. If Q10 (after receiving the sheet present signal from sensor (Q2 ) is not activated within:

(609 [mm]) / (transport speed [m/s]) ± 20% ( No rotation)

End of Set signal (C1)
Only the last sheet in the set will be Creased.
(609 [mm]) / (transport speed [m/s]) ± 20% + t r (Rotation)
And only if Creasing is selected.
The last sheet will also trigger the Stapling action in the Booklet Maker. t r = sheets rotation time.

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 If Q7 is not deactivated within:
Faultcode CST-006 (Q10 activated too long) is triggered:
(paper length [mm] ) / [transport speed [ms ]) ±20%

If the deactivation time [ms] of Q10 is not within:

(paper length [mm] ) / (transport speed [m/s] ) ±20% If activated after Power On or Initiation.

If activated after Power On or Initiation. Creaser Tool Home position Sensor Q5

Remarks: Q10 triggers SOL4 and SOL5 release cycle In each crease operation the position of the tools is checked with respect to the position of sensor
Q5.

Faultcode CST-011 (Q5 not activated in time) is triggered:

Paper Path Sensor Q4

If the Tools loose their position at the check.

Faultcode CST-007 (Q4 not activated in time) is triggered:

If Q4 (after receiving the sheet present signal from sensor (Q10 ) is not activated within: Waste Bin Full Sensor Q11
(347 [mm] ) / (transport speed [m/s]) ±20% Faultcode “Waste Bin Full” (Q11 activated too long) is triggered:
If Q11 is blocked longer then 1 [s]
Faultcode CST-008 (Q4 activated too long) is triggered: Reset is done by interrupting either of the interlock switches.

If Q4 is not deactivated within: Waste Bin Full Sensor Q14

Faultcode CST-012 (Q14 activated too long) is triggered:
(paper length [mm]) / (transport speed [ms]) ±20%
If Q14 is blocked longer then 1 [s]
Reset is done by interrupting the Slide Door Interlock Switch.
If activated after Power On or Initiation.

Remarks: Q4 registers the lead edge of the Cover Sheet and triggers the Crease Tool action (M6
system)
MOTOR SYSTEMS IN PROCESS MODE
M1, Main Drive Motor
The purpose of this motor is to power the general transportation of paper through the paper path
Paper Path Sensor Q7 via multiple timing belts, drivshafts and idler rollers.
After receiving the “Cycle Up signal” the motor M1 starts and maintains a steady and predictable
Faultcode CST-009 (Q7 not activated in time) is triggered: speed needed for the Crease operation.

If Q7 (after receiving the signal sheet present from sensor (Q4) is not activated within: M3, Rotator Motor
The purpose of this motor is to transport sheets straight through the rotator section or enable
(501 [mm] ) / (transport speed [ms] ) ±20% sheets to rotate 90° to facilitate enhanced Printer Productivity for small sizes, if selected to do so.
If straight transport is selected, M3 will run at 100% of the Transport Speed.
Faultcode CST-010 (Q7 activated too long) is triggered: If Rotation is selected, M3 will run at about 50% of the Transport Speed.

Plockmatic BM500 system 20 May 2019 6. Detailed Description

6-16
M6, Creaser Motor from each other. Wear and noise is thereby considerably reduced.
The purpose of the M6 motor is to perform the Creaser Tool Action.
The Creaser tool is basically two metallic cylinder, one is equipped with a vertical groove whereas The SOL3 action is triggered when a 5.000 msec. delay from last “Sheet Exit signal” is elapsed. A
the other is equipped with a vertical metalic strip. The strip fit well into the groove in order to crease new “Sheet Exit signal” will reset the delay again.
sheets.
Dependent of the thickness of the sheets, there is two possible choice of groove width, either nar- SOL4, Slide Disengage Solenoid
row or wide width, the later suitable for thicker media.
The purpose of this solenoid is to enable the idler rollers of the lowes slide nip to disengage in
order to.
For accurate position of the Crease on the sheet, the tools will locate the start position at initiation.
After position the tool in start position (strike position) the crease is ready to carry out a strike in
order to crease a sheet. To avoid long sheets to reach the first fine registration rollers (when still are held in the trail edge)
and thereby prevent sheets from parallel alignment with the alignment rail.

After the crease stroke is carried out, the tools will be re-positioned to strike position for creasing
additional sheets, by performing a empty stroke just behind the trail edge of the creased sheet. The SOL4 action is triggered from Q4

The Creaser tool home sensor (Q5) is only used for positioning purposes at initiation. However, In SOL5, Registration Disengage Solenoid
each crease operation the position of the tools is checked with respect to the position of sensor Q5. The purpose of this solenoid is to enable the registration rollers of the fine registration rail to disen-
If the Tools loose their position at the check, faultcode CST-011 is triggered. gage in order to:

SOLENOID SYSTEMS IN PROCESS MODE

Avoid long sheets that reach the first fixing roller, to be disturbed by the fine alignment registration
system.
SOL1, Rotator Disengage Solenoid
The purpose of this solenoid is to enable the idler rollers of the first rotator nip to disengage in order
to: SOL5 action is triggered from sensor Q4

Allow sheets be rotated.

Avoid long sheets (not rotated) to reach the first coarse registration rollers (when still are held in the
trail edge) and thereby prevent sheets from parallel alignment with the alignment rail.

The SOL1 action is triggered from sensor Q2.

SOL2, Rotator Disengage Solenoid

The purpose of this solenoid is to enable the idler rollers of the second rotator nip to disengage in
order to:

Avoid long sheets (not rotated) to reach the first coarse registration rollers (when still are held in the
trail edge) and thereby prevent sheets from parallel alignment with the alignment rail.

SOL2 action is triggered from sensor Q2.

SOL2 is deactivated (nip is actived) when sheets are rotating.

SOL3, Bleed Trimmer Disengage Solenoid

The purpose of this solenoid is to enable the Upper and Lower Bleed Trimmer Blades to disengage
Plockmatic BM500 system 20 May 2019 6. Detailed Description
6-17
7 SPECIFICATIONS

Content
Booklet Maker ..................................................................................................................... 7-2
Trimmer................................................................................................................................ 7-3
Square Folder...................................................................................................................... 7-3
CST....................................................................................................................................... 7-4
CR......................................................................................................................................... 7-4
AF602 Air Feeder / VF602 Vacuum Feeder........................................................................ 7-5
Booklet quality specification ............................................................................................. 7-6
Set Size Guide..................................................................................................................... 7-7

Plockmatic BM500 system 20 May 2019 7. Specifications

7-1
 BOOKLET MAKER Power consumption 200 W or less Continuous operation
complete system with
Property Specification Remarks SQF and TR

Speed Maintain engine speed. Actual speed in number of Power consumption

(Online usage) booklets (per min / hour) (Stand by)
depends on number of
sheets per booklet. Target shut down* 1 / 600 booklets or less 1 / 4800 Copies
*Shut down: Finisher
stops by paper jam, staple
Maximum Speed 1800 booklets / hour jam.
(A4 / 8.5x11”)
1800 booklets / hour Physical Connection Attached after Finisher (detachable) Docking Bracket is stan-
(A3 / 11x17”) Attached by bracket (docking unit) dard accessory
Released by foot release
Standard Paper A4, SRA4, A3, SRA3, B4, 8.5x11”, Custom sizes are avail-
Sizes 8.5x14”, 9x12”, 11x17”, 12x18” able Electrical Connec- Jam signal to stop Printer (Soft stop) Seven types of paper size
tion Jam signal to stop Printer (Har stop) information:
Paper Size Width 206 mm / 8.1” Start signal from Printer to start
(Minimum) Length 275 mm / 10.8” Booklet Maker A3SEF / A4SEF / DLT-
Paper size information from Printer SEF /
Paper Size Width 320 mm / 12.6” Connection detect BM350 LTSEF / LGSEF / B4SEF
(Maximum) Length 457.2mm / 18” Sheet exit / SRA3 or 18 x 12”
Paper detect
Paper Weight 64 gsm / 16 lb. Bond, uncoated Ready
(Minimum) 105 gsm / coated Processing
Paper Weight 300 gsm / 172 lb. Index/ 115 lb. 350 gsm for some media Plockmatic uses QT open source license (LGPL) to develop the software used in this
(Maximum) Cover machine (https://www.qt.io/qt-licensing-terms).

Input / Output 2 – 50 sheets or 2 – 35 sheets Stapled

Sheets (80 gsm / 20 lb. Bond or equivalent)
(Stapled)

Input / Output 1 – 2 sheets Non stapled folding

Sheets
(Non stapled)

Off-line Use Possible Staple/fold (2 staples)

Weight 145 kg / 320 lb

Dimensions 1420 x 970 x 700 mm / Incl. Stacker

(L x H x D) 56” x 39” x 28”

Power Source 100-230 V ±10 % 50-60 Hz

Plockmatic BM500 system 20 May 2019 7. Specifications

7-2
 TRIMMER SQUARE FOLDER
Property Specification Remarks Area Specifications Remarks

Speed Same as Booklet Maker Speed Same as Booklet Maker

Standard Paper Sizes Same as Booklet Maker Custom sizes are available Standard Paper Sizes Same as Booklet Maker Custom sizes are available

Default trim length 4,5 mm / (11/64”) Adjustable in 0.5mm (0.004”) Paper Weight (Minimum) Same as Booklet Maker
steps
Paper Weight (Maximum) Same as Booklet Maker
Minimum trimming 1 mm / (0.0394 in)* Recommended minimum is
2.5mm (0.098”). Input / Output Sheets Same as Booklet Maker

Maximum trimming 16 mm (5/8”) per cut Trim larger than 16mm (5/8”) Input / Output Sheets Same as Booklet Maker
will cause trimmer to make
Off-line Use Possible (Together with Booklet
multiple cycles. This reduces
Maker & Trimmer)
system speed in some ap-
plications. Multiple cuts also Weight 45 kg / 99 lb
affect lifetime.
Dimensions (L x H x D) 360 x 900 x 620 mm /
Paper Weight (Minimum) Same as Booklet Maker 14.2 x 35.4 x 24.4”
Paper Weight (Maximum) Same as Booklet Maker Power Source Powered from Booklet
Maker
Input / Output Sheets Same as Booklet Maker

Input / Output Sheets Same as Booklet Maker

Off-line Use Possible Together with Booklet Maker

Weight 68 kg / 150 lb or less

Dimensions (L x H x D) 360 x 900 x 620mm /

14”x 35.5” x 24.5”

Power Source Powered from Booklet

Maker

* When trimming SRA3 (450mm): Booklets minimum trimming is 5mm.

When trimming 18” : Booklets minimum trimming is 9mm.

Continued on next page.

Plockmatic BM500 system 20 May 2019 7. Specifications

7-3
 CST Weight 200 kg/441 lb

Area Specifications Remarks Dimensions (L x H x D) 720 x 1115 x 755

(incl. 100 mm. waste
Speed Same as Booklet Maker transport)
38,4” x 43.9” x 29.7”
Standard Paper Sizes Same as Booklet Maker
Power Source 100-230V ± 10% 50-60 Hz
Paper Size Minimum (Out) Same as Booklet Maker
Power Consumption 400W Max
Paper Size Maximum (Out) Same as Booklet Maker
300W Continuos operation
Paper Width Maximum (In) 330 mm

Paper Weight (Minimum) Same as Booklet Maker

Paper Weight (Maximum) Same as Booklet Maker* *media with weight over CR
300gsm may cause limited Area Specifications Remarks
performance

Rotator Width (cross process Speed Same as BM

direction) min. 275 mm.
(10.9”). Standard Paper Sizes Same as BM

Paper Size Minimum (Out) Same as BM

Width (cross process
direction) max. 325 mm. Paper Size Maximum (Out) Same as BM
(12.7”).
Paper Width Maximum (In) Same as BM
Length (cross process
direction) min. 205 mm. Paper Weight (Minimum) 64gsm / 16lb Bond un-
(8.1”). coated

Paper Weight (Maximum) Same as BM

Length (cross process
direction) max. 232 mm. Creaser
(9.1”). Fine tool Stock < 120gsm / 80lb
Creaser Tools Stock < 120 gsm Coarse tool Book/Text/Offset
Fine tool Stock > 120 gsm Stock > 120gsm / 80lb
Coarse tool gsm = grams per sq. Book/Text/Offset
meter
Input / Output Sheets Same as BM
Bleed Trimmer
Off-line Use Not possible
Minimum bleed trimming 5 mm Weight 130kg / 286lb
Maximum bleed trimming 30 mm
Max assymetric bleed trim- ±5 mm Dimensions (L x H x D) 350 x 1240 x 705mm /
ming 13.8” x 49” x 27.7”
Input / Output Sheets Same as Booklet Maker Power Source 100- 230V / 50-60Hz ±10%
Input / Output Sheets Same as Booklet Maker Power Consumption 400W or less Continuous operation
Off-line Use Not possible

Plockmatic BM500 system 20 May 2019 7. Specifications

7-4
 AF602 AIR FEEDER / VF602 VACUUM FEEDER
Specifications Remarks

Minimum paper size, W&L 120 x 210 mm

Maximum paper size 356 x 660 mm

Minimum paper weight 64 gsm

Maximum paper weight Same as Booklet Maker

Maximum loading capacity, 270 mm

each bin 10.6”

Maximum loading weight, 92 kg

each bin 202 Lbs

Off-line Use Possible with Service UI

Weight 250 kg
550 Lbs

Dimensions (L x H x D) 1050 x 1250 x 705 mm

42” x 50” x 28”

Power Source 100-240 V / 50-60 Hz +6%, -10%

Power Consumption 4A @ 230V, 8A @ 100V Continuous operation

Operating temperature 10-30°C

Plockmatic BM500 system 20 May 2019 7. Specifications

7-5
 BOOKLET QUALITY SPECIFICATION

Conditions:

• Four sheet booklet

• 80 gsm premium paper
• Paper corners are assumed to be perfect 90°
• Tolerances are referring to deviations within one job
• For a given paper format, the machine settings must be according to the formula with 0.1 mm precision.

Definition Formula Tolerance for A4 / 8.5 x 11 “ Tolerance for A3 / 11 x 17 “

Fold Position Variation (L1+L2) / 2 (fig 1) 0,6 mm 0,6 mm

Fold skew L1 - L2 (fig 1) ± 0,5 mm ± 0,7 mm

Staple precision Staple position relative to the fold line. ± 0,5 mm ± 0,5 mm

Side registration Offset between sheets within one booklet, 0,7 mm 0,7 mm
perpendicular to the transport direction

Face Trim skew L1 - L2 ( for trimmed booklets, fig 1) 1.0 mm 1.0 mm

Face Trim position variation (L1+L2) / 2 (fig 1) 1,0 mm 1,0 mm

Side trim skew a-b (fig 2) Measure on operator side ±0,5 mm ±0,5 mm

Side trim position* (a + b) /2 (fig 2) ±0,5 mm ±0,5 mm

Crease skew* L1 - L2 (fig 1) Measure on operator side ±0,5 mm ±0,5 mm

Crease position paper size / 2 compared with (L1+L2) /2 ±0,5 mm ±0,5 mm

* Last 15 mm of side trim is allowed to deviate ± 1 mm.

Booklet outside specification are less than 0.5 %.
Measurements on folded sets are taken from the inside of the booklet.
L1

Transport
direction

a b

L2
Fig 1. Fig 2.

Plockmatic BM500 system 20 May 2019 7. Specifications

7-6
SET SIZE GUIDE
Note:
The following tables are guidelines designed to give an indication on how many sheet a spe-
cific application can have for a given mediaweight.
Exact number of sheets depends on mediatype and image.

BM500 BM350
Paper Size Paper Size
A3 or 11x17" A4 or 8.5x11" A3 or 11 x 17" A4 or 8,5 x 11"
Paper weight Area Coverage Area Coverage Area Coverage Area Coverage
Bond Offset Cover Tag Index Gsm Low Full Low Full Low Full Low Full
20 50 28 46 42 80 50 32 50 32 35 25 35 25
24 60 33 56 50 90 45 32 44 32 30 20 30 20
31 81 45 73 66 120 25 24 25 24 22 19 22 19
36 90 50 82 75 140 22 20 22 20 20 15 20 15
43 110 60 100 90 160 20 18 20 18 18 17 18 17
53 135 74 122 110 200 15 14 15 14 13 10 13 10
58 146 80 134 120 220 13 12 13 12 11 9 11 9
67 170 93 156 140 250 12 11 12 11 10 9 10 9
76 192 105 175 158 280 11 10 11 10 9 7 9 7
82 208 114 189 170 300 9 9 9 9 8 6 8 6
94 236 130 215 200 350 7 7 7 7 6 5 6 5

Plockmatic BM500 system 20 May 2019 7. Specifications

7-7
8 WIRING
Contents
8.1 BM500 Booklet Maker including Cover Feeder....................................................... 8-2
8.2 BM-SQF Square Folder.............................................................................................. 8-3
8.3 BM-TR Trimmer.......................................................................................................... 8-4
8.4 BM-CST Rotator Creaser Trimmer............................................................................ 8-5
8.4 BM-CR......................................................................................................................... 8-6
8.5 BST4000-1 High Capacity Stacker............................................................................ 8-7
8.6 AF602 Feeder............................................................................................................. 8-8
8.7 VF602 Feeder.............................................................................................................. 8-9

Plockmatic BM500 system 20 May 2019 8. Wiring

8-1
8.1 BM500 Booklet Maker including Cover Feeder

Plockmatic BM500 system 20 May 2019 8. Wiring

8-2
8.2 BM-SQF Square Folder

Plockmatic BM500 system 20 May 2019 8. Wiring

8-3
8.3 BM-TR Trimmer

Plockmatic BM500 system 20 May 2019 8. Wiring

8-4
8.4 BM-CST Rotator Creaser Trimmer

Plockmatic BM500 system 20 May 2019 8. Wiring

8-5
8.4 BM-CR

Plockmatic BM500 system 20 May 2019 8. Wiring

8-6
8.5 BST4000-1 High Capacity Stacker

Plockmatic BM500 system 20 May 2019 8. Wiring

8-7
8.6 AF602 Feeder

Plockmatic BM500 system 20 May 2019 8. Wiring

8-8
8.7 VF602 Feeder

Plockmatic BM500 system 20 May 2019 8. Wiring

8-9
8.7 VF602 Feeder (continued)

Plockmatic BM500 system 20 May 2019 8. Wiring

8-10
 9 Booklet Quality (BQ)

Contents
BQ 1 Entry RAP................................................................................................................ 9-2
BQ 2 Bleed Trimmer not Parallel to Registration edge (Skew cut).............................. 9-8
BQ 3 Bleed Trimmer Sheet Width (Mismatch)............................................................. 9-12
BQ 4 Bleed Trimmer Image Offset (Mismatch)............................................................ 9-12
BQ 5 Bleed Trimmer Cutting Quality (Dull, damaged or misaligned Knives)........... 9-13
BQ 6 Crease not Perpendicular to Registration Edge (Skew Crease)...................... 9-15
BQ 7 Crease position in Process Direction (Mismatch)............................................. 9-16
BQ 8 Crease Insufficient Quality (Spine Cracking, despite Crease)......................... 9-16
BQ 9 Transport Feed Force........................................................................................... 9-19
BQ 10 Side Guide Parallelism......................................................................................... 9-20
BQ 11 Side Guide Position (Side registration quality)................................................. 9-21
BQ 12 Staple form (Staple quality)................................................................................. 9-21
BQ 13 Staples parallel to lead edge.............................................................................. 9-23
BQ 14 Fold Skew.............................................................................................................. 9-25
BQ 15 Fold Position on Staples...................................................................................... 9-26
BQ 16 Staple and Fold Position...................................................................................... 9-27
BQ 17 Back Jogger Parallel and Aligned to Sheet........................................................ 9-28
BQ 18 BookFold Module, Square form quality.............................................................. 9-29
BQ 19 Face Trim skew..................................................................................................... 9-30
BQ 20 Face Trim length................................................................................................... 9-30

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

9-1
 BQ 1 Entry RAP
Purpose Initial Actions
The purpose of this procedure is to provide a good methodology to perform
• Check / perform the cleaning described in the operator manual for all process modules.
the Booklet Quality settings for the whole Booklet Maker system.
• Ensure that there is no obstruction in the paper path in any of the process modules.
• Depending on the system configuration at hand, some sections may not be applicable.
• Ensure that all baffles open and close properly.
• Some of the described adjustments are possible to perform at the same time, but for clarity,
they are described separately. • Ensure that the covers and slides close and lock properly.
• Ensure that all waste containers are emptied.
Figures below, from section 7, are here presented slightly differently for clarity. • Ensure that the paper is entering the system aligned to entry position label in CT and cen-
The last column is the tolerance recommended when using perfect 90° paper of good tered into Booklet maker *
quality at medium weight and gloss. Perform complete BQ section from beginning to end in described
order
Definition A4 / 8.5 x 11 “ A3 / 11 x 17 “ Recommended
There are adjustments that can affect other parts of booklet quality than the specific
adjustment tolerance
function and especially give a varied result causing confusion at troubleshooting.
Side trim skew 1 mm 1 mm 0.2mm
Side trim position ±0.5 mm ±0.5 mm 0.2mm
Crease skew 1 mm 1 mm 0.2mm *) See Section 1.15
Crease position ±0.5 mm ±0.5 mm ±0.2mm
Staple precision ± 0.5 mm ± 0.5 mm 0.2mm
Side registration 0.7 mm 0.7 mm 0.2mm
Fold skew 1 mm 1 mm 0.2mm
Fold Position ±0.3 mm ±0.3 mm 0.2mm
Face Trim skew 1.0 mm 1.0 mm 0.2mm
Face Trim position ±0.5 mm ±0.5 mm ±0.2mm

Continued on next page

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)
9-2
 BQ 1 Entry RAP, continued
Below table is a help to understand the dependencies of Symptom and Cause
Symptom possible causes Explanation Priority how to verify Action
Fold skew Skew paper Skew paper will always be folded skew 1 Measure paper or compare two Replace paper
sheets after flipping one over on
long edge
Side trim, skew Same as skew paper 2 Check per BQ2 Perform per BQ2
Staple stop, skew Skew staples might occasionally guide the fold to skew 3 Check per BQ14 Perform per BQ14
Transport feed force, If too loose, set might not reach fold stop. 4 Check per BQ10 Perform per BQ10
wrong If uneven force, set will be fed skew and might bounce in fold stop
Fold stop, skew No explanation needed 5 Turn off trim and test run Perform BQ15
Staple Skew Skew paper Skew paper will always cause staples to look skew but are parallel to 1 Turn off trim and test run Replace paper
lead edge
Fold stop skew Actual fault might be fold skew, but looks, (is interpreted) as staple 2 Check per BQ15 Perform BQ15
skew
Side guides, skew Skew side guides holds paper in skew position when being stapled 3 Check per BQ11 Perform BQ11
Staple stop, skew Will produce skew staples 4 Check per BQ14 Perform BQ14
Fold off center Paper, too long or too Paper do not match loaded sheet size and if no trim, staple and fold 1 Measure paper Replace paper
short will be off center
Paper too wide Paper do not match loaded sheet size and set is prevented from 2 Measure paper Replace paper
reaching fold stop by side guides too tight
Side guides too tight Set is prevented from reaching fold stop by side guides too tight 3 Select larger paper width in UI and Adjust NVM 2
test run
Staple off center Staples out of position might occasionally guide the fold position 4 Turn off trim and test run Perform BQ16
Transport feed force, If too loose, set might not reach fold stop 5 Check per BQ10 Perform BQ10
wrong
Fold stop position Wrong position will cause offset fold 6 Check per BQ17 Perform BQ17
Staple off Fold off center Actual fault might be fold off center, but looks, (is interpreted) as 1 Turn off trim and test run Perform BQ17
center staples off center
Transport feed force, If too loose, set might not reach fold stop 2 Check per BQ10 Perform BQ10
wrong
Staple & fold NVM-value wrong Position of Staple stop assy, together with Fold stop assy is wrong 1 Check per BQ16 Perform BQ16
off center
Transport feed force, If too loose, set might not reach fold stop 2 Check per BQ10 Perform BQ10
wrong
Side guides too tight Set is prevented from reaching fold stop by side guides too tight 3 Select larger paper width and test Adjust NVM 2
run

Continued on next page

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

9-3
 BQ 1 Entry RAP, continued
Symptom possible causes Explanation Priority how to verify Action
Wavy side Dull knives Dull rotating knives has a problem cutting straight 1 Inspect knifes T Replace knifes per
trim REP13.1 - 13.2

Not enough angle be- At too low angle, knifes can behave the same as when dull 2 Inspect knifes Perform 2nd part of BQ5
tween upper and lower
knife (“toe in”)
Cover not Cover smaller than in- Covers are originally smaller than inlays and job is run without side 1 Measure Shift to correct size covers
aligned to lays (most likely width) trim. or inlays
inlays
Covers are shrinking covers are same size as inlays but shrink less than inlays through 2 Measure directly out of printer Use feature cover adjust
less than inlays printer.
Covers are still shrunken when being side trimmed in CT,
as covers have shrunken less they will grow less than inlays.
Covers or inlays not Difference in angle cut can appear as misalignment 3 Physically compare cover to inlays. Replace bad stock.
originally cut to same To check which is bad take two of
90° same sheet and flip one around and
compare.
Wrinkles in Setting of parallel trim If alignment rail is adjusted so it’s more than 90° against the nip roll- 1 Check per BQ3 Adjust per BQ3
process direc- strip in CT is over ers just before the crease rollers.
tion on any adjusted When these nip rollers starts pulling the sheet, it will increasingly
sheet in the press it against the alignment rail so the sheet will move into the nip
book and on rollers buckled and there be pressed into wrinkles.
both front and
rear end of Loose fastener some- Not the same speed on fold rollers causing book to skew between 1 Check all fasteners tighten fasteners
sheet where in fold roller fold rollers and thereby causing wrinkles
transmission.
Fold knife not parallel to Fold rollers grabs set one side first and skews the set creating 2 Inspect Adjust height
fold rollers in height. wrinkles.
Fold knife not centered Friction between knife and book is higher in some area causing inner 3 Not described in service manual. Adjust position.
between fold rollers sheet to skew and wrinkle. Move knife up by rotating cam. Use
a feeler gauge 0.5mm and check
that knife has equal distance to fold
roller on each tooth of the knife.
Crease off- Wrong NVM value 1 Check NVM value Adjust NVM2
center
Too high tension on tim- Motor doesn’t have enough power to run rollers at correct speed 2 Check timing belt tension Loosen tension
ing belt
Loose set screw on tim- Timing pulley slips on shaft 3 Check fasteners tighten fasteners
ing pulley
Bad motor if none of above helps it must be the motor 4 Replace motor Replace motor
Crease skew Crease rollers are 1 First make sure that trim strip is Perform BQ7
mechanically not 90° to parallel then check per BQ7
alignment rail
Side trim not parallel Sheet is skew side trimmed and appear as skew crease 2 Check per BQ2 Perform per BQ2
Continued on next page

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

9-4
 Symptom possible causes Explanation Priority how to verify Action
Skew side Skew paper Skew paper will always be folded skew 1 Measure paper or compare two Replace paper
trim sheets after flipping one over on
long edge
Side trim, skew Same as skew paper 2 Check per BQ2 Perform per BQ2

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

9-5
 BQ 1 Entry RAP, continued
Inspect bleed trim cutting quality.
Below flowchart is describing the work order, in short
Sheet edges are clean cut, free from fraying and burrs

Select a job with side trim and run with door open. Catch a couple Yes No
of trim strip on operator side. Keep track of lead edge
Bleed trim cutting quality
Discard the last 50mm of the strip and compare front and trail end
Perform BQ5
of strip. The front and trail end is less than 1mm different

Yes No Disable side trim and enable Crease.

Run some books and check position of crease to lead edge.
Bleed trim parallel to registration edge Crease skew is within 0.2mm*
Perform BQ2
Yes No
Take recent run books and measure width of sheets. Crease perpendicular to registration
* Note!
Sheet width is exactly the same as selected width. edge
Sheets must be
perfect 90° Perform BQ6
Yes No

Bleed trim sheet width Run more books. Crease position is centered on book
Perform BQ3
Yes No
Run some more sheets, catch trim strips on operator side and mea- Crease position in process direction
sure width. Compare to calculated width ±0,5mm Perform BQ7

Selected sheet width in, mi-

Run fresh printed coated stock 150 – 250 gsm on selection Course.
nus measured sheet width
Crease quality is good (No cracks in spine)
out divided by two.
Wi-Wo = Strip width
Yes No
2

Yes No Crease Insufficient Quality

Perform BQ8
Bleed trim Image Offset
Perform BQ4
Continued on next page
Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)
9-6
 BQ 1 Entry RAP, continued
Yes No
Disable creasing
Adjust staples parallel to lead edge
Before checking booklet quality,
Perform BQ13
perform BQ9 Transport feed force

Measure the exact size of paper and enter as custom paper size. Fold is parallel to lead edge
Hand feed, 3 sheet A3/11”x17” sets with face trim & SQF OFF.
Staple position Manual, 0 pos. Fold position Manual, 0 pos. Yes No
Check booklet quality per specification.
Booklet quality is good
Adjust fold skew
Perform BQ14
Yes No

Side guides aligned to paper path Fold is on staples

Perform BQ10
Yes No
During run,
side guides do not buckle paper and that books are perfectly Adjust fold at staple position
jogged. Perform BQ15
Yes No
Staple and fold is at correct distance to lead edge
Adjust side guides position
Perform BQ11 Yes No

Staple form is within specification Adjust staple and fold position

Perform BQ16
Yes No

Adjust staple form Back joggers are parallel and aligned to paper
Perform BQ12
Adjust back jogger position
The staples have the same distance to lead edge Perform BQ17

Continued on next page

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)
9-7
 BQ 1 Entry RAP, continued

Enable on Square fold, Run 6 sheet books and check square fold
quality. Trim quality is good
Square fold quality is good, even and square at mode 1
Yes No
Yes No
Square fold quality Replace upper and lower knife
Perform BQ18 Perform REP 10.18 and 10.19

Disable Square fold and enable face trim.

Congratulations
Run some books and check trim skew and position.
Booklet quality is now good
Trim skew is within ±0.2mm

Yes No
Adjust trim skew
Perform BQ19

Run more books, check trim length compared to selected length

Trim length is within 0.2mm

Yes No

Adjust trim length

Perform BQ20

Run A3/11”x17” 2, 20 and 35/50 sheet booklets.

Check trim quality.
Sheet edges are clean cut, free from fraying and burrs

Yes No
Check that upper knife is correctly tight-
ened REP 10.18 Check adjustment of
lower knife REP 10.19

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

9-8
 BQ 2 Bleed Trimmer not Parallel to Registration edge (Skew cut)

Purpose
To ensure that the sheet is cut parallel to the registration (Operator side) edge.
[A]
Initial Actions
• Ensure that the Registration Cross Rollers are clean, not damaged or worn.
• Ensure that the nip rollers are clean, not damaged and in good working order.
• Ensure that there is no obstruction in the paper path (particularly in the knife area).
• Ensure that all baffles open and close properly.
• Ensure that the slide locks properly in closed position. viewed from sec-
ondary alignment
[B] rail side
Procedure
1. Using a sheet of paper (dashed line) [A], align the Support Bracket [B] to the Secondary
Alignment Rail [C] and tighten nuts [D] (x2).
2. Process a SRA3 or ”12 x 18” 120-160gsm (32-43 lb Bond) sheet and measure the Regis-
tration (operator side) waste strip width, discard the last 15mm of strip:
The Lead Edge Width and the Trail Edge Width should be equal within 0.2 mm.
3. Turn the knurled set screw [F], and adjust the Registration Secondary Alignment Rails
angle so that the Registration (operator side) waste strip width is within 0.2 mm. Start
from having lead edge wider and step by step adjust to required alignment. Do not over
adjust.
That can cause jam on thicker stock and wrinkles on thinner stock. [C] [D]
[F]

Continued on next page.

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

9-9
 BQ 2 Bleed Trimmer not Parallel to Registration edge
(Skew cut) Continued
Procedure
Disable the Crease function
Run 3 sheets and check that the waste strip from the sheets edge (on operator side) is
parallel within 0.2mm from Lead Edge to Trail Edge
The Registration Waste Strip (on operator side) is not within ±0.2mm
Perform adjustment.
1. Check that the plastic Registration Cross Rollers Idler Rollers are centred over the rubber
wheel. If not, reposition the Registration Cross Rollers Idler Rollers.
2. Check/adjust height of Idler Rollers.
For adjustment, use a 0,5mm (0.020”) feeler gauge
Turn these screws counterclock- Turn these screws counterclock-
3. Turn adjustment screw clockwise until feeler gauge moves freely. wise 2 turns when adjusting wise 3 turns when adjusting
4. Turn screw counterclockwise until the two white plastic wheels move, when the feeler
gauge is moved according.
5. Remove feeler gauge. 1. Position a 4 mm spacer in-between the Solenoid plungers E-clip and rubber washer to
define the length of the stroke.
6. Turn screw counterclockwise 2 turns on primary side.
Turn screw counterclockwise 2 turns on secondary inner rollers. 2. Loosen screws [A] (x2) and position solenoid linkage in contact with ball bearings.
Turn screw counterclockwise 3 turns on secondary outer rollers. Tighten screws.

7. Tighten lock nuts. 3. Loosen screws [B] (x2) and position the Home Position Bracket so that there is 1±0.5 mm
play

Perform BQ 6 Bleed Trimmer Cutting Quality (Dull or damaged Knives)

[B]

[C]

[B]

[A]
[E]
[D]

[A]
Turn these screws coun-
[F] terclockwise 2 turns when
adjusting
Continued on next page.
Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)
9-10
 BQ 2 Bleed Trimmer not Parallel to Registration edge 7. Check / adjust Bleed trim disengage shaft. The positions of the ball bearings so that the
(Skew cut) Continued Upper Knife moves 0.6±0.3mm (0.0236±0.0118”) from the Lower Knife when actuated.

4. Enter the service mode, see section 5.

5. Activate transportation disengage solenoid CT-SOL4
6. Loosen screws [A] (x2). Position solenoid CT-SOL4 and tighten the screws to achieve
the play according to below figure (when activated).
0,5±0,5mm

[A]

Transportation Disengage Solenoid (CT-SOL4) position, activated

Continued on next page.

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)
9-11
 BQ 2 Bleed Trimmer not Parallel to Registration edge
(Skew cut) Continued
8. Position a 4mm (5/32”) spacer in-between the Solenoid plungers E-clip and
rubber washer to define the length of the stroke [A].
Ensure that Solenoid lever is in contact with the stop when screws (x4) are tightened [A].
9. Loosen screw and position solenoid linkage to achieve 2±0.5mm (5/64±1/64”)
when solenoid is closed [B]. Tighten screw.

[A]

[B]

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

9-12
 BQ 3 Bleed Trimmer Sheet Width (Mismatch) BQ 4 Bleed Trimmer Image Offset (Mismatch)
Purpose Purpose
To ensure that the Sheet Width entered on the UI corresponds within ±0.2mm to the actual To ensure that the Image Offset entered on the UI corresponds within
cut width. 0.2mm to the actual measured offset.

Procedure Procedure
• Disable the Crease function • Disable the Creaser function
• Run 3 sheets and check that the actual sheet width is within • Run 3 sheets and check that the actual Image Offset entered on the UI corresponds
±0.2mm from the Sheet Width entered on the UI. within ±0.2mm to the actual measured offset.
• Adjust RCT [NVM 4 RCT M7 Offset] • Adjust RCT [NVM 3 RCT M4 Offset]

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

9-13
 BQ 5 Bleed Trimmer Cutting Quality (Dull, damaged or
misaligned Knives)
Purpose
To ensure that the quality of the Bleed Trimmers cutting edges is good.

Initial Actions [L]

• Check function of SOL3 in Service Mode.
• Check that the SOL3 action fully disengages the upper knives on both operator and non- 2-3m
m (49
operator side /64”-5
3/64”
when activated.
• Check that the SOL3 mechanism fully releases the knives when deactivated.

Procedure
1. Disable the Creaser function
[K]
2. Run 3 sheets and check that the edges are clean cut and free from fraying and burrs.
3. Check adjustment of trim strip guide:
- The distance between Waste Guide and Lower Knife is 2-3mm [L].
- The Waste Guide is positioned above the cutting point [M].
- The curved part of the Waste Guide is inside the circumference of the lower knife [N]
- Loosen screws [J] to adjust Waste guide position.
4. Replace the Bleed Trimmer Knives per REP 13.1 and REP 13.2
[J]

[M]
[N]

Rear side (non operator side)

knives viewed from rear side
Paper travelling
direction
[K]
Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)
9-14
 BQ5 Bleed Trimmer Cutting Quality (Dull, damaged or
misaligned Knives) Continued

Purpose
This adjustment can be performed if replacing knifes do not help.

1. Loosen the counter nu [A] and check that tap screw is touching the aluminum block.
2. loosen the four screws [B] holding the block.
3. tighten the tap screw [A] ½ turn clockwise.
4. Lock the tap screw with the nut and tighten the four screws [B].
5. Run sheets through and check the trim quality.
6. If not good enough, repeat procedure.

[B]

[A]

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

9-15
 BQ 6 Crease not Perpendicular to Registration Edge
(Skew Crease)
Purpose
To ensure that the sheet is creased perpendicular to the registration edge (on operator side).
[C]

Initial Actions
• Ensure that the Registration Cross Rollers are clean, not damaged or worn.
• Ensure that the nip rollers are clean, not damaged and in good working order.
• Ensure that there is no obstruction in the paper path (particularly in the knife area).
• Ensure that all baffles open and close properly.
• Ensure that the slide locks properly in closed position.
[D]
Procedure
• Check / perform BQ 2 Bleed Trimmer not Parallel to Registration edge (Skew cut).
• Disable the Bleed Trimmer and the Face Trimmer functions.
• Run 3 sheets cut to perfect 90° SRA3 or 12”x18” and check that the Crease is perpendicu-
lar to the Registration Edge (operator side) within ±0.2mm.
• Hold the Creaser Space Unit [C] and loosen screws [D] (x2). Position the Creaser Assembly
so that the Crease is perpendicular within 0.2 mm.

[A]

[B]

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

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 BQ 7 Crease position in Process Direction (Mismatch) BQ 8 Crease Insufficient Quality (Spine Cracking, despite
Purpose Crease)
To ensure that the Cover Sheet is creased in the middle and at a consistent distance Purpose
from the Lead Edge within ±0.2 mm. To ensure that the Cover Sheet is sufficiently creased to minimize Toner and Media cracking.

Initial Actions Initial Actions

• Ensure that the Registration Cross Rollers are clean, not damaged or worn.
• Ensure that the fine and coarse grooves in the crease tool (PL 12.14) are clean,
• Ensure that the nip rollers are clean, not damaged and in good working order. not damaged or worn.

• Ensure that there is no obstruction in the paper path (particularly in the knife area). • Ensure that the fine and coarse rulers in the crease tool (PL 12.14) are clean,
not damaged or worn.
• Ensure that all baffles open and close properly.
• Ensure that there is no obstruction in the paper path (particularly in the creaser area).
• Ensure that the slide locks properly in closed position.
• Ensure that all baffles open and close properly.
• Ensure that the Crease Position Operator Adjustment Factors are set 0.0 mm for both
Crease Tools in the UI. • Ensure that the slide locks properly in closed position.
• Ensure that the Crease Position Operator Adjustment Factors are set 0.0 mm for
Procedure both Crease Tools in the UI.

• Check / perform BQ 7 Crease not Perpendicular to Registration edge (Skew crease). • Relieve Timing Belt Tension by loosening screw [A].

• Set Units to metric.

• Set the Coarse Tool correction to 0 and.
• Select Creasing Coarse.
• Select SRA3T or 12”x18” format.
• Ensure that the Face Trimmer is set to off.
• Process one sheet of SRA3 or 12”x18”. [A]
Measure the distance from the Lead Edge to the center of the Crease.
Calculate the difference in 0.1mm units.
Difference = Measured distance from Lead Edge minus (-) Theoretical distance from Lead
Edge.
• Adjust NVM value if the difference is bigger than ±0.2mm.
• Add the Difference calculated to the current value in NVM2 CT Creasing Offset.

Continued on next page

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)
9-17
 BQ 8 Crease Insufficient Quality, Continued

• Align the tool ruler into the fine tool groove [B].
• On front and rear side, loosen screws [C] (x6) and position the Creaser Tools Anvils with the
eccentrics [D] (x2) so that the tools barely touch each other.
• Tighten screws [C].
• Loosen the locknuts [E] and turn the set screw (x2) [F] so that the Limiting plunger gets in
contact with the ball bearing and then back out 1/8 turn
• Tighten the locknuts [E] (x2)

[D] [C]

[F]
[B]
[E]

NOTE:
Viewed from front side of module.

Continued on next page

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)
9-18
 BQ 8 Crease Insufficient Quality, Continued • Keep pulleys [C] and [D] in position and align the creaser tools so that one of creaser tool
[H] rulers mates with the fine tool groove (the narrower one) of creaser tool [ I ].
• Turn the eccentric [A] counter to tension the Timing belt [B] firmly so that there is no slack.
Hold eccentric [A]. • Tighten screw [E].

• Check position of pulleys [C] and [D] so that the screws [E] and [F] are pointing to the right • Hold the creaser tool [ I ] steady and turn pulley [C] to position the lower side of the fine tool
for good access. If not, relax belt tension and reposition pulleys [C] and [D]. groove towards the ruler of the creaser tool [ I ] as illustrated [J].

• Tighten screw [G]. • Tighten screw [F].

• Loosen the screws [E] and [F]. • Check that tools not interfere on any side by turning them in process direction with CT-M6
pulley. [H] [I]

[A]

[G]

[B]

Groove is
leading

[F]

[E]

Process
direction
[D] [C]
Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)
9-19
 BQ 9 Transport Feed Force
Do NOT turn these screws [D] Do NOT turn these screws
Purpose
To get a correct transportation from stapler area to fold area.
The feed rollers are therefore important and can be adjusted in two ways:
• By pivoting (to get equal feed force between them)
• By adjusting their position up and down (to determine the magnitude of the feed force).

The pivoting is adjusted mechanically and the magnitude of the feed force is adjusted from UI
(by setting a NVM value). [C]
[C]
1. Set the machine to A4 / 8.5x11”. Enter Service Mode (GP 1).
2. Select [Calibrate transport pressure].
3. Insert one strip of paper (1 sheet) between transport drive rollers [E].
4. Adjust the drive force by pressing [+] or [-] until the force is just enough
to move the paper inwards.

Move the strip to the other rollers, and check that the drive force is equal.
If force is equal, go to step 9 [B]
If force not is equal, proceed to next step.
5. Disconnect connectors (x3) [A] and connector [x1] [B].
6. Remove screws (x4) [C]. Remove staple bracket assembly [D].
7. Adjust by loosen the screws / nuts (x2) [F] and move the pivoting roller bracket,
repeat until the feed force is equal between the grey rollers.
8. Tighten screws / nuts (x2) [F] and make sure the feed force is equal.
9. As a second adjustment the feed force magnitude shall be adjusted for these rollers.
Increase the feed force step by step (starting at no feed force) until just having a slight
drag, then increase the value by adding 6 digits (steps).
The adjustment is now completed.
10. Re-assemble the staple bracket assembly [D].
11. Run some books and check booklet quality
[F]
12. Enter new NVM value to NVM tag in BM top cover

[A]

[E]

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

9-20
 BQ 10 Side Guide Parallelism Adjustment
Purpose
The purpose of this adjustment is to ensure that the Paper / Side Guides (on operator and 1. Align the side guide [A] to the two holes [B] in the paper path.
non-operator side) are parallel to each other and paper path. 2. Check the distance between the two holes and the side guide.
The distance should be as close to equal as possible between the lower hole and
the side guide and the upper hole and the side guide. If not, go to step 3.
Procedure
3. Loosen screw [C], also loosen screw [D] just a little.
• Check / adjust the Paper / Side Guide Parallelism (Below figure)
Adjust the paper / side guide [A] per step 2 ( x2 ).
• Tighten screws [C] and [D], recheck alignment.
4. Perform the same check on the rear side guide, adjust if needed.

[D]

[C]

[A]

[B]

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

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 BQ 11 Side Guide Position (Side registration quality) Purpose
Purpose The purpose of this adjustment is to ensure that the staples are correctly formed.
The purpose of this adjustment is to ensure that the Side Guides jogs the set to perfect
alignment. Procedure, Check staple quality
If the Paper size reset function does not position the side guides good enough you can fine
tune the settings with this procedure.
• Enter Service mode.
• Select [Motors] Select motor M20 (Left stapler)
Procedure • Place two sheet of 80 gsm papers or similar under the stapler heads.
• Run sets of 5-10 sheet A3 or 11”x17”. • Press [Cycle both staplers] a couple of times while moving the paper for each cycle.
• Measure sheets out from printer and select custom paper size accordingly. • Inspect Staple form.
• During run check that sets do not buckle when side guides jog.
• Inspect side registration on booklets.
Staple legs should align Staple shall be properly clinched.
• Adjust side guide position by changing NVM 2 Side jogger offset (±). to each other and to the Legs parallel to paper and
• Increase value to move position in. Decrease to move out. “back” of the staple. pressed against paper.
• When registration is good, note new NVM value on NVM tag.

BQ 12 Staple form (Staple quality)

Explanation
Staples are 0.5mm thick.
CAUTION! Slot in clincher is 1mm wide.
Alignment of the stapler head is carried out at factory. If staple is too close to the edge of the clincher slot it might occasionally deform one or
Screws are sealed with red paint to ensure that alignment is maintained and both of the legs.
also to indicate if it has been moved.
Alignment will not change over time and will therefore not need further adjustment.
Alignment of stapler heads to clinchers.
However, if the adjustment has been tampered with (i.e. if red seal is broken) it is very
important to strictly follow the described procedure below. • Remove the staple cartridges.
• Use permanent marker pen to color the edges round clincher slot [A]
The alignment of the stapler head to anvil is crucial and will
• Replace the staple cartridges
determine the staple result as well as the lifetime of the stapler head.
• Place 10 - 20 sheet of 80 gsm / 20lb bond papers or similar under the stapler heads.
(It will be harder to see the ink marks if the paper is too glossy)
Ensure that staple position is set to 0.0 and fold position is set to 0.0 • Enter Service mode.
before adjusting machine.
• Select [Motors] Select motor M20 (Left stapler)
Begin with adjusting the staple position before adjusting the fold position.
• Press [Cycle both staplers]
The Stapler heads must be adjusted precisely in order to achieve proper staple result.
• Inspect position of staples in relation to the ink marks.
If system is equipped with CT and TR, • Adjust staple position if needed, as described in next section
make sure to turn off trimming before testing booklet quality.
Continued on next page
Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)
9-22
 BQ 12 Staple form (Staple quality), continued Adjusting Staplers
• If staple is too close to the side of the slot, stapler needs to be adjusted in direction [C]
• If staple is too much off center in cross process direction, stapler needs to be adjusted in
direction [B]
• Adjust in C direction:
• Loosen screws [D] (before loosening, make sure that adjustment screws [E] not are
loose.
• Adjust position of stapler bracket by turning screws [E]
• Fasten screws [D]
• Adjust in B direction
• There is a small play for screws [D] so if needed adjustment is small, try to loosen
screws [D] and push assy in desired direction.
• If above adjustment isn’t enough, loosen screw [F] (red painted)
• Move stapler bracket in desired direction.
• Tighten screws [F]
[F]

[E]

[A]

Staple legs with marks

from surrounding slot

[D]

[B]

[C]

[F]

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

9-23
 BQ 13 Staples parallel to lead edge
Purpose
To ensure that the staples are parallel to lead edge

Procedure
1. Make sure that BQ10 - BQ13 have been performed
2. Select paper size A3 / 11”x17” [A]
[A]
3. Enter Service mode.
4. Select [Motors] Select motor [M20] (Left stapler)
5. Place 2 sheet A3 / 11”x17” carefully against staple stop gate
6. Press [Cycle both staplers]
7. Measure distance between staples and lead edge.
[B] [C]
8. If difference is more than 0,2mm, adjust angle of staple stop gate.
Adjustment staple stop gate
9. Remove screws (x4) [A] for the stapler bracket.
10. Disconnect connector P49 (x1) [B].
11. Disconnect connectors P43, P44 and P47(x3) [C] for the stapler.
12. Remove stapler bracket assembly.
13. Remove nuts (x4) [D] and bracket [E].
14. Enter service mode, select [Motors].
[D]

Continued on next page.

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)
9-24
 BQ 13 Staples parallel to lead edge, continued [F]

15. Select [M22 Stop gate stapler].

16. Press [Cycle 1] until the stop gate is at its uppermost position.
17. Insert a perfect A4 or 8.5 x 11“ paper, landscape.
18. Edge of the sheet should be touching each finger on the stop gate assembly [F]
if not reform the stop gate fingers.
19. Select [M9 Staple fold position].
20. Press [Out] until the edge of the paper is just beneath the clinchers [G].
21. Press [Up] until the paper aligns with the clinchers [G].
22. The difference between distance X and distance Y should be less 0.2 mm.
It’s recommended to adjust to as perfect as possible.
23. Remove the inserted sheet or cut holes in sheet above screws [H]. X Y
24. Loosen screws (x3) [H] until the stop gate can rotate around the middle screw.
25. Adjust position of stop gate.
26. Tighten screws (x3) [H]
27. Remount removed parts. [G]

[D]

[D]

[E]

[H]

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

9-25
 BQ 14 Fold Skew [A]

This adjustment could be performed at the same time as BQ16 - 17

Purpose
To ensure that the fold is parallel to the lead edge of the sets.

Procedure
1. Hand feed 5 x 2-sheet sets, using A3 / 11 x 17” paper.
If applicable ensure that Trim and Squarefold is disabled.
2. Measure top and bottom distance from lead edge to fold.
If difference is more than 0.2mm, adjust fold stop.
Note: If the system is equipped with a TR and/or BF
they must be un-docked (REP 1.0) to gain access to the adjustment screws.
3. Select a large paper size. SRA3 / 12”x18”, for easier access to the screws.
Loosen the locking screws (x2) [A].
4. Adjust the fold pocket, by turning the left and right adjustment screws [B].
Note! If screws needs to be turned counter clockwise, ensure that the springs pushes the
fold pocket against the adjustment screws.
5. Tighten the adjustment screws (x2) [A].
[B] Left Adjustment Screw [B] Right Adjustment Screw
6. If a TR and / or BF was removed during adjustment, re-install them (REP 1.0).
7. Repeat from item 1. Sets presented as exiting system

If booklet is skewed as in figure

rotate to adjust the fold pocket (x2) in following way :

Left adjustment screw clockwise,

Right adjustment screw counterclockwise.

If booklet is skewed as in figure

rotate to adjust the fold pocket (x2) in following way :

Left adjustment screw counterclockwise,

Right adjustment screw clockwise.

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

9-26
 BQ 15 Fold Position on Staples [A]
This adjustment could be performed at the same time as BQ15
Purpose
To ensure that the fold is placed perfectly on the staples.

NOTE:
Make sure that [Staple position] and [Fold position] is set to [Auto] before adjusting machine.

Initial actions
Make sure that BQ 14 Staple parallel to lead edge and BQ15 Fold skew is performed before
adjusting the fold position.

Procedure
1. Hand feed 5 x 2-sheet sets, using A3 / 11 x 17” paper.
2. If the fold position is not aligned with the staples the fold stop must be adjusted,
otherwise skip remaining steps.
(Tip: make fold sharper by pressing it between your fingers. Check position on inside
of book. Fold line should minimum touch both Staples and be on the same side of the
staples).
3. Set the machine to SRA3 / 12x18“ or easier access to the screws [A].
4. Loosen screws [A], one on each side. Adjust screws [B ]per figure below. [B]

Note: One full turn of the adjustment screws [B] will move the fold stop 0.7 mm. Note: One full turn of the adjustment screws [B]
will move the fold stop 0.7 mm
5. Repeat from item 1.

Sets presented as exiting system

Clockwise counter-clockwise

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

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 BQ 16 Staple and Fold Position
Purpose
To ensure that the fold in the center and staples are positioned in the center of the set.

Procedure
1. Make sure that the previous BQ10 - BQ16 is verified.

Note: In the next step, do NOT use the preset A3 or 11 x 17” paper sizes.
2. Take an A3 or 11x17” paper, and measure the physical size of the paper with a ruler
(Measure with 0.1 mm precision).
3. Enter the measured size as custom size.
4. Verify that Staple and Fold position is set to [Auto].
5. Hand feed 5 x 2-sheet sets, from measured sheets.
If applicable ensure trim and squarefold are disabled
Check that the staples are aligned with fold, and that the fold is in the center of the set.
If not, adjust.

Adjustment
6. Enter [Service]
7. Enter [NVM values]
8. Adjust NVM 3 Rear jogger offset
Increase value (+) to make lead edge side of booklet shorter, (move foldstop and staple
stop up).
Decrease value (-) to make lead edge side of booklet longer, (move foldstop and staple
stop up)
Sets presented as exiting system
Lead edge too short Lead edge too long
Decrease value Increase value
Press (-) to lengthen Press (+) to shorten

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

9-28
 BQ 17 Back Jogger Parallel and Aligned to Sheet
Purpose Edge of the paper Edge of the paper
To adjust the Back Jogger to correct position and aligned to sheet.

Procedure
1. Un-dock BM from upstream device to gain access to adjustment screws.
2. Take an A3 or 11x17” paper, and measure the physical size of the paper with a ruler
(Measure with 0.1 mm precision).
3. Enter the measured size as custom size.
4. Insert the sheet into the compiler.
Ensure that the sheet is aligned against the staple stop,
and that the side guides are not interfering with the sheets.
5. In service mode, select motor PBM-M2 and move the back Jogger to its uppermost
position. Ensure that the jogger is in “locked” position otherwise rotate the crank until the
jogger is in “locked” position.
6. Ensure that the Jogger Fingers just touches the edge of the paper.
If not: Adjust the jogger position with screw [A] until they reach the edge.
7. Check that all four fingers simultaneously reach the paper edges.
If not: Loosen screws (x2) [B] and adjust the angle.

[B]

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

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 BQ 18 BookFold Module, Square form quality
Purpose
To adjust the appearance of the square formed spine.

Procedure
1. Set up the BookFold Module to Mode 1.
2. In BF Service Components (GP 15) change ”Adjust mode: NO” to “Adjust mode: YES”.
By this the stop gate will move to upper position after cycling, so adjustment nuts are
reachable.
3. Handfeed 6 sheet booklets A3 / 11x17”, 80 gsm / 20lb bond
4. Check the appearance of the square formed spine of the booklet per table [A].
5. If appearance is not good, adjust BookFold Module Stop Gate position,
by turning the adjustment nuts (x2) [B].
NOTE: Adjustment Nuts can be reached through holes in exit cover [C].
6. Repeat step 3 to 5 until result is good.
7. In BF Service Components (GP 15),
change ”Adjust mode: YES” back to “Adjust mode: NO”.
NOTE: It is very important to set adjust mode to OFF after adjustment is done.
If left in ”Adjust mode: YES”, a customer will not be able to change BF settings.

[A] Not good Good Not good

Case 1 Case 2 Case 3

Turn adjustment nuts (2) CW No adjustment needed. Turn adjustment nuts (2)
equally in operator and non- CCW equally in operator
operator side. side and non-operator side.

[B]

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9-30
 BQ 19 Face Trim skew BQ 20 Face Trim length
Purpose Purpose
To set trim skew within tolerance. To ensure that the dimension of the trimmed booklet is the same as those entered in the UI.

Procedure
Adjustment
1. Set Size A3 / 11 x 17”
1. Check that Trim zero value written on inside sticker of Trimmer module is noted as NVM
2. Select Trim auto #11
3. Run 3 Sets of 4 Sheets (A3 / 11 x 17”, 80 gsm or similar) and 2. Set Size A3 / 11 x 17”
check that the Booklets skew are within 0.2 mm. If not, adjust
3. Select a finished book length.
4. Insert a screwdriver per figure 1.
4. Run 3 Sets of 4 Sheets (A3 / 11 x 17” 80 gsm or similar) and
5. Turn the screw [A], until alignment is obtained (see figure 2). check that the Booklet is per selected finished size within 0.2 mm.
5. Enter Service Mode and change NVM Value #11 so that the Booklet Width corresponds
with the selected finished size.
6. Enter new trim zero value on sticker inside Trimmer module.

Fig 1.

[A]

Fig 2.

Plockmatic BM500 system 20 May 2019 9. Booklet Quality (BQ)

9-31