Formax FD 120 User manual

FD 120
Card Cutter
MAINTENANCE MANUAL
5/2011
MyBinding.com
5500 NE Moore Court
Hillsboro, OR 97124
Toll Free: 1-800-944-4573
Local: 503-640-5920

1
SAFETYPRECAUTIONS
Alwaysobservethecautionsandwarningsgivenbelowtopreventpersonalinjuryorproperty
damage.
Thedegreeofdangeranddamagethatcouldoccurisindicatedontwolevelsbythefollowing
marks.
WARNING:Ignoringthismarkcouldresultinthepossibilityofseriousinjuryorevendeath.
CAUTION:Ignoringthismarkcouldresultinthepossibilityofinjuryorphysicaldamage
Thefollowinggraphicsymbolsindicatethevarioustypesofactiontobeperformedoravoided.
Thisgraphicsymbolindicatesaforbiddenaction.
means“Donotdisassemble.”
means“Donottouch.”
Thisgraphicsymbolindicatesactionsthatmustbeperformed.
means“Disconnectthepowerplug.”
Donotplacemetalobjectsorvesselscontainingliquidsontopoftheunit.Theentryofanymetal
objectorliquidcouldresultinafireoranelectricalshock.
Donotinsertanymetaloreasily‐combustibleobjectinsidethisunit.Thiscouldresultinafireor
anelectricalshock.
Donottouchorinsertforeignobjectsintoanyrotatingpartduringoperation.Thiscouldresultin
injury.
Donotremovethecoverorbackpanel.Thisunitcontainshigh‐voltagecomponentsthatcould
causeanelectricalshock.
Donotdisassemble,modifyorrepairthisunit.Thereisadangeroffire,electricalshockorinjury.
Contactyourdealerwhenrepairsarenecessary.

2
Useonlythepowersupplyvoltagespecifiedonthemainnameplate.Usingothervoltagescould
resultinafireoranelectricalshock.
Keepthisunitandthepowercordawayfromheatersandheatervents.Excessiveheatcould
meltthecoverorpowercordcovering,andresultinafireoranelectricalshock.
Donotusesolventinsideorneartheunit(e.g.whencleaningtheunit).Suchsolventsmay
damagetherubberrollersandresininsidetheunit,resultinginmalfunctions.
Makesurethatthecombinedpowerconsumptionoftheappliancestobeconnecteddoesnot
exceedthecapacityratingofthepoweroutletsorplugreceptacles.Exceedingthecapacityrating
couldcausethepoweroutlets,plugreceptacles,orpowerextensioncordstooverheatandcatch
afire.
Removeanydustthataccumulatesonthepowerplugprongsandthesurfaceoftheplugfrom
whichtheprongsextend.Accumulateddustcouldresultinafire.
Ifanyforeignobjectsuchasmetalorliquidshouldenterthisunit,immediatelyturntheunitoff
atthepowerswitchanddisconnectthepowerplugfromthepoweroutlet.Failuretodosocould
resultinafireoranelectricalshock.Contactyourdealerimmediately.
Donotdamagethepowercordorpowerplug.(Donotscratch,alter,bend,twist,pullorplace
heavyobjectsonthepowercordorpowerplug.)Thiscouldresultindamage,afireoran
electricalshock.
Alwaysgriptheplugwhendisconnectingthepowerplugfromthepoweroutlet.Forciblypulling
onthepowercordcouldcausedamage,resultinginafireoranelectricalshock.
Donothandlethepowerplugwithwethands.Thiscouldresultinanelectricalshock.
Beforecleaningthisunit,turntheunitoffatthepowerswitchanddisconnectthepowerplug
fromthepoweroutlet.Accidentaloperationoftheunitduringcleaningcouldresultininjury.
Donottouchthepowerswitchwithwethands.Otherwiseelectrichazardsmayoccur
Donotuseflammablespraysinsideorneartheunit(e.g.whencleaningtheunit).Such
flammablegasmayigniteandcauseafireorcombustion.
Keepawaylonghair,ties,jewelryandlooseclothing.Thiscouldresultininjury.

3
Donotputfingersinsideduringoperation.Thiscouldresultininjury.
Alwaysdisconnectthepowerplugfromthepoweroutletwhentheunitisnottobeusedforan
extendedperiod.Failuretodosocouldresultinafireduetoleakagecurrentiftheinsulation
shoulddeteriorate.
Installthisunitonalevel,stablestandorfloor,withsufficientspacearoundit.Failuretodoso
couldresultintheunitoverturningandcausinginjury.
Donotinstallthisunitinalocationwherethereisexcessivehumidityorwherecontactwith
waterispossible.Poorchoiceoflocationcouldresultindeteriorationoftheinsulation,afireor
anelectricalshock.
Disconnectthepowerplugfromthepoweroutletbeforeattemptingtomovethisunit.Failureto
dosocouldresultinpowercorddamage,afireoranelectricalshock.
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5500 NE Moore Court
Hillsboro, OR 97124
Toll Free: 1-800-944-4573
Local: 503-640-5920

4
PrecautionsinMaintenanceandHandling
1. Repairsshouldbeperformedbyqualifiedservicepersonnel.
2. WARNING:
2.1Toavoidtheriskofelectricalshock,disconnectthemachinefromtheA.C.powersource
beforeperforminganyserviceprocedure.
3. ThehardwareusedisMETRIC.Replacehardwareonlywiththesamesizeaswasoriginally
used.
4. Observecautionwhencuttingcable“tie‐wraps”soasnotto damagetheelectricalwires.
5. Notetheroutingofwiringharnesses,cablesandthepositionofpartsandassembliesbefore
disassembly.Theymustbereassembledintheoriginalconfigurationtoavoiddamagefrom
movingcomponentsduringoperation.
6. Whenusingatoolgeneratingheatsuchassolderingiron,takecarenottodamagethe
harnessesandcables.
MyBinding.com
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Hillsboro, OR 97124
Toll Free: 1-800-944-4573
Local: 503-640-5920

5
Contents
1. Introduction......................................................................................6
2. Specifications.....................................................................................6
3. ControlPanel......................................................................................6
4. KeyComponents................................................................................8
5. PartsonTopoftheFrame..................................................................10
6. PartsonOperatingSide......................................................................11
7. PartsonNon‐operatingSide.............................................................12
8. PartsunderneaththeFrame..............................................................13
9. ElectricPWBAssy...............................................................................14
10. ElectricalWiringDiagram.................................................................17
11. SensorVoltageMeasurement..........................................................18
12. ReplaceSlitter..................................................................................19
13. ReplaceCuttingKnife.......................................................................20
14. FeedingTestandPermanentCount.................................................21
15. Calibration........................................................................................22
16. FeedTrayTensionAdjustment.........................................................24
17. FeedGapAdjustment.......................................................................25
18. TopMarginParallelAdjustment.......................................................26
19. Self‐DiagnoseforMalfunction.........................................................25
20. ErrorMessageandTroubleShouting...............................................26
21. RecommendedSpareparts..............................................................27
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6
1. Introduction
TheFD 120isdesignedtosimplifybusinesscard,photoandpostcardcuttingof paper
printedbydigitalpress,colorlaserprinterorinkjetimageprinter.
2. SPECIFICATIONS
PaperSizeLT/LegalSize/9”x14”(Max)
PaperWeight120gsm~350gsm
FeederCapacity75sheets(200gsm)
ReceivingTray500businesscards
SpeedUpto130businesscardspermin
Accuracy±0.3mm
Dimension13.8”(W)x15.4”(D)x13”(H)
NetWeight60lbs(27Kgs)
Power110/220VSelectable,50/60Hz,1.2A
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7
3. CONTROLPANEL
Note:DependingonƚŚĞŽƉĞƌĂƚŝŶŐmode,theŬĞLJƐĐĂŶŚĂǀĞdifferentfunctions.
StandardControlPanelDealerControlPanel
KeysStaŶĚĂƌĚControůWĂŶĞů DealerControlPanel
StartandStopthecutterStartandStopthecutter
ChangejobChangejob
SelectbatchcountSelectbatchcount
ClearpaperjamincaseofS3error.1. ClearpaperjamincaseofS3error.
2. Incrementsettingsby0.1mmwhenpressed.
Confirmjobandbatchcountsetting.1. Confirmjobandbatchcountsetting.
2. Decrementsettingsby0.1mmwhenpressed.
Resterrorandcounter.Savesettings
N/AEnterprogrammode
N/ASettopmargin
N/ASetfinishedlength
N/ASetgutterlength
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8
4. KEYCOMPONENTS
IndexP/NPartNameQtyRemarks
4‐1‐0100S‐000‐6112Switch,PowerEntry1
4‐1‐02881‐102‐0002KeyPad1
4‐1‐03881‐103‐0000Tray,Extension1
4‐1‐04881‐104‐0000Knob,CenterAlignment1
4‐1‐05881‐105‐0000SideGuide,L1
4‐1‐0600R‐000‐1052Roller,Feed3
4‐1‐07881‐107‐0000Cover,Top1
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9
IndexP/NPartNameQtyRemarks
4‐1‐08881‐108‐0000WasteBin1
4‐1‐09881‐109‐0000Tray,Stacking1
4‐1‐10881‐110‐0000Cover,Safety,Rear1
4‐1‐11881‐111‐0000ThumbScrew,SlitterRelease1
4‐1‐12881‐112‐0000Module,Slitter,2”x3.5”1
4‐1‐13881‐113‐0000Roller,Ejection,Lower2
4‐1‐14881‐114‐0000Roller,Ejection,Upper2
4‐1‐15881‐115‐0000Belt,SlittingTransport2
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10
5. PartsonTopoftheFrame
IndexP/NPartName QtyRemarks
5‐2‐01881‐103‐0000Tray,Extension,Feed1
5‐2‐02881‐202‐0000SideGuide,L,Feed1
5‐2‐03881‐104‐0000Knob,CuttingCenterAlignment 1
5‐2‐0400R‐000‐1052Roller,Feed3
5‐2‐0500S‐000‐1514Sensor,Paper1
5‐2‐0600S‐000‐1514Sensor,Paper1
5‐2‐0700S‐000‐1515Sensor,MarkReader,White1
5‐2‐08881‐102‐0001KeyPad1
5‐2‐0900A‐000‐0207Sensor,Paper,Black1
5‐2‐1000S‐000‐1604Separator,Feed1
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11
6. PartsonOperatingSide
IndexP/NPartName QtyRemarks
6‐3‐0100A‐000‐1001Asm,PWB,Logic 1
6‐3‐0200C‐000‐0083Cable,34pin,55cm,DriverInterface1
6‐3‐0300C‐000‐0071Cable,34pin,37cm,LogicInterface1
6‐3‐0400A‐000‐1121Asm,PWB,Interface1
6‐3‐0500A‐000‐1611Asm,PWB,LCDInterface1
6‐3‐0600C‐000‐0051Cable,16pin,47cm,LCDInterface1
6‐3‐0700C‐000‐0031Cable,14pin,PanelInterface1
6‐3‐0800A‐000‐1501Asm,PWB,ControlPanel1
6‐3‐0900A‐000‐0188Switch,Interlock 1
6‐3‐1000D‐000‐0303Display,LCD1
6‐3‐1100A‐000‐0188Switch,Interlock1
6‐3‐1200S‐000‐1513Sensor,Interrupter1
6‐3‐1300B‐000‐0512Belt,0.08P,102MXL1
6‐3‐1400A‐000‐0188Switch,Interlock1
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12
7. PartsonNonOperatingSide
IndexP/NPartName QtyRemarks
7‐4‐0100A‐000‐1211Asm,PWB,Power1
7‐4‐0200B‐000‐0524Belt,0.08P,132MXL1
7‐4‐03881‐403‐0000Spring,FeedTrayTension1
7‐4‐0400M‐000‐0404Motor,RD,2.58V,3A(replacedby00M‐000‐0403)1
7‐4‐0500M‐000‐0403Motor,SQ,2.58v,3A 1
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13
8. PartsunderneaththeFrame
IndexP/NPartName Qty Remarks
8‐5‐0100F‐000‐0003Fan,DC,12V1
8‐5‐0200A‐000‐0161Asm,DriverBox1
00A‐000‐1402Asm,PWB,Driver,L2982
8‐5‐0300F‐000‐0401Filter,ACLine1
8‐5‐0400S‐000‐6101Switch,115/230VSelectable1
8‐5‐0500T‐000‐1405Transformer,115/230V 1
8‐5‐0600M‐000‐0403Motor,SQ,2.58V,3A1
8‐5‐0700M‐000‐0404Motor,RD,2.58V,3A(Replacedby00M‐000‐0403)1
8‐5‐0800M‐000‐0401Motor,SQ,2,8V,1.7A(alternative3.96V,1.2A)1
8‐5‐0900R‐000‐0301Rectifier1
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9. ElectricPWBAsm.
9.1P/N00A‐000‐1001 Assy,PWB,Logic
9.2P/N00A‐000‐1601 Asm,PWB,LCDDISPLAY
IndexP/NPartName QtyRemarks
9‐6‐0100A‐000‐1001Asm,PWB,Logic1
9‐6‐0200A‐000‐1611Asm,PWB,Display,LCD1
9‐6‐0300A‐000‐1121Asm,PWB,Interface1
9‐6‐0400A‐000‐0161Asm,DriverBox1
9‐6‐0500A‐000‐1211Asm,PWB,Power1
9‐6‐0600A‐000‐1501Asm,PWB,ControlPanel1
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9.3P/N00A‐000‐1121 ASM,PWB,INTERFACE
9. 4P/N00A‐000‐0161 ASM,DRIVERBOX
J
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9. 5P/N00A‐000‐1211ASM,PWB,POWER
9.6.P/N00A‐000‐1501ASM,PWB,CONTROLPANEL
J2
J1
J11
J3
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10. ElectricalWiringDiagram
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11. SensorVoltageMeasurement
Sensorsplayanimportantroleinmonitoringandtrackingtheflowofthemediainsideofmachine.A
majorityofstallconditionscouldbesensorrelated.Therefore,adigitalmulti‐meter(DMM)isusedfor
measuringthevoltagereadingofthesensors,andassuringproperalignment.
5.1SetDMMto20attheDVCsection.
5.2UsingthetwoprobesoftheDMMtogetvoltage,oneprobeplacedatthechassisgroundofthe
system,whiletheotheroneprobepin1ofthesensorconnectorontheinterfaceboard.
5.3Coveringthesensor,thereadingofDMMshouldbelessthan0.2V.
5.4Uncoveringthesensor,thereadingofDMMshouldbemorethan4.5V.
5.5MarkReadingSensors
。Seeingpaper0.2V
。Seeingmark1.8V
Therangeofsensor’svoltagereadingisgreaterthan4.5Vorlessthan0.2Vhasthebeststateforthe
sensortomonitoringthemediamovement.Thesensorconnectoronthesensorboardhasthreepins.
Thefirstpinisforsignalofsensorvoltagereadingmeasurement.ThesecondpinisforVCC(5V).The
thirdpinisforground.Somesensorsconnectoris4‐pin,the3rdpinisempty;the4thpinwillbe
commonground.
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12. ReplaceSlitter
Opentherearcover
RotatethethumbscrewloosentheSlitter
Laydowntheslitterandpullitouttowardexitdirection
*Note:Theslitterassemblyisreplacedasawholeunit.
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