Formax FD 6100 User manual

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Formax 6100
Paper Folder/Inserter
Service Manual

ISSUE : 21/09/2003 FD 6100 - MAINTENANCE MANUAL
REVISION : 2.1
SECTION : CONTENTS PAGE
1
FD 6100

ISSUE : 21/09/2003 FD 6100 - MAINTENANCE MANUAL
REVISION : 2.1
SECTION : CONTENTS PAGE
2
CONTENTS
REVISIONS
SECTION 1: MAINTENANCE

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REVISION : 2.1
SECTION : CONTENTS PAGE
3
SECTION 2: PARTS LIST
SECTION 3: UNPACKING

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REVISION : 2.1
SECTION : CONTENTS PAGE 4
CONTENTS
MODIFICATIONS FOLLOW-UP
Main modifications
Revision Date Reference
soft. Section Page DESCRIPTION
1.4 10/07/03 1.11 ALL Launch Version
S1 FR 5, 23, 25, 31, 32, 48, 50
S1 ENG Pages 5, 6, 7, 11, 23, 25, 31, 32, 40, 48, 50 have been modified.
S2 ALL
2.0 01/09/03 1.15
S4 ALL
S1 ENG 31 Adding of US terminology
S1 ENG 46-49 Splitting of the USA and Europe specifications
2.1 21/09/03 1.15
S3 3-5 Removing of the empty chapters

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MANUAL CONTENTS
SECTION 1: MAINTENANCE
1 INTRODUCTION ..................................................................................................6
1.1 PRECAUTION............................................................................................................................. 6
1.2 TERMINOLOGY.......................................................................................................................... 7
1.3 GENERAL OVERVIEW............................................................................................................... 9
1.4 SENSORS/SWITCHES, MOTORS AND CLUTCHES.............................................................. 15
1.5 PCB INTERCONNECTION DIAGRAM..................................................................................... 17
1.6 PROTOCOL AND HARDWARE CONFIGURATION ............................................................... 20
2 SERVICE CALL CHECK LISTS.........................................................................21
2.1 START OF SERVICE CALL CHECK LIST .............................................................................. 21
2.2 END OF SERVICE CALL CHECK LIST................................................................................... 21
2.3 PREVENTIVE MAINTENANCE................................................................................................ 22
2.4 MAINTENANCE KITS DETAILS .............................................................................................. 23
3 SOFTWARE UPGRADE AND CPU BOARD REPLACEMENT.........................39
3.1 SOFTWARE UPGRADE........................................................................................................... 39
3.2 CPU BOARD REPLACEMENT ................................................................................................ 39
4 DIAGNOSTICS TOOL........................................................................................40
4.1 ERROR MESSAGE LIST.......................................................................................................... 40
4.2 FUNCTIONAL FAULTS............................................................................................................42
4.3 FUNCTIONAL TESTS............................................................................................................... 43
5 DISASSEMBLING, RE-ASSEMBLING AND ADJUSTMENTS..........................51
5.1 TOOLS ...................................................................................................................................... 51
5.2 DISASSEMBLING..................................................................................................................... 51
5.3 RE-ASSEMBLING AND ADJUSTMENTS ............................................................................... 52
5.4 DISASSEMBLING AND RE-ASSEMBLING SUMMARY......................................................... 53
6 THEORY OF OPERATION.................................................................................54
6.1 KEY CODES.............................................................................................................................. 54
6.2 USER MODE DIAGRAM........................................................................................................... 55
6.3 SETTING MODE DIAGRAM (ADVANCED USER MODE)...................................................... 56
6.4 BASE SERVICE MODE............................................................................................................57
6.5 SEQUENCES OF SOFTWARE FUNCTIONS.......................................................................... 58
7 EUROPE SPECIFICATIONS..............................................................................59
8 USA SPECIFICATIONS.....................................................................................61
9 RECOMMENDED SPARE PARTS LIST............................................................64
Click
page

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CONTENTS
1 INTRODUCTION
1.1 PRECAUTION
•Actuators : never grease or lubricate plastic parts in movement . Only use compressed air for cleaning and maintenance.
•Never grease ball bearings.
•It is strongly advised to use only the recommended grease (synthetic grease) as other types of grease may damage the
mechanisms of the machine.
•Empty the water tank before transporting the machine.
MAINTENANCE PRODUCTS
Grease: MOLYCOTE PLASTISLIP PG75 (plastic parts)
ESSO MULTIPURPOSE 4746 (bearing output roller)
.

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REVISION : 2.1
SECTION : 01 PAGE 7
CONTENTS
1.2 TERMINOLOGY
A SELECTION
CLUTCH See description in Section 1, Chapter 1.4.1 "Sensors"
A, feeder A Front manual and automatic feeder for documents
A-EMPTY See description in Section 1, Chapter 1.4.1 "Sensors"
B SELECTION
CLUTCH See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
B, feeder B Rear automatic feeder for documents
B-EMPTY See description in Section 1, Chapter 1.4.1 "Sensors"
BOTTOM FOLDER
MOTOR See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
C SELECTION
CLUTCH See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
C TRANSPORT
CLUTCH See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
C, feeder C Automatic feeder for inserts or BRE
CAM MOTOR See description in Section 1, Chapter 1.4.1 "Sensors"
CAM-ZERO See description in Section 1, Chapter 1.4.1 "Sensors"
C-CLOSED See description in Section 1, Chapter 1.4.1 "Sensors"
C-EMPTY See description in Section 1, Chapter 1.4.1 "Sensors"
DD-A See description in Section 1, Chapter 1.4.1 "Sensors"
DD-B See description in Section 1, Chapter 1.4.1 "Sensors"
DD-C See description in Section 1, Chapter 1.4.1 "Sensors"
DD-KEY See description in Section 1, Chapter 1.4.1 "Sensors"
DOC-LOADED See description in Section 1, Chapter 1.4.1 "Sensors"
DOCUMENT FEEDER
CLUTCH See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
END-SEPARATION-A See description in Section 1, Chapter 1.4.1 "Sensors"
END-SEPARATION-B See description in Section 1, Chapter 1.4.1 "Sensors"
END-SEPARATION-C See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
ENV TRANSPORT
MOTOR See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
ENV-EXIT See description in Section 1, Chapter 1.4.1 "Sensors"
ENV-REFERENCE See description in Section 1, Chapter 1.4.1 "Sensors"
Flash Memory including the software
Hopper Envelope feeder
HOPPER MOTOR See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
INSERT-SIGNAL See description in Section 1, Chapter 1.4.1 "Sensors"
INSERT-STOP See description in Section 1, Chapter 1.4.1 "Sensors"
LETTER-OUTPUT See description in Section 1, Chapter 1.4.1 "Sensors"
MACHINE-OPEN See description in Section 1, Chapter 1.4.1 "Sensors"
MAIN MOTOR See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
MANUAL FEEDING
MOTOR See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
MMI Man Machine Interface
MULTI Multimeter in ohmmeter position.
SINGLE FOLD
MOTOR See description in Section 1, Chapter 1.4.2 "Clutches and Motors"

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CONTENTS
TOP FOLDER MOTOR See description in Section 1, Chapter 1.4.2 "Clutches and Motors"
Type E sensor Electrodes
Type F sensor Flag sensor
Type H sensor Hall effect sensor
Type PP motor stepper motor
Type R sensor Reed bulb (activation of a mechanical switch under a magnet effect)
Type S switch Mechanical Switch
•Icons:
Fix: Job memorized
Blinking: Job modified Job secured (locked)
³
•Type of folds :
Single fold C fold or letter fold Double parallel fold

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CONTENTS
1.3 GENERAL OVERVIEW
1.3.1 FEEDER A-B SENSORS AND SWITCH VIEW
DD-A END SEPARATION - B END-SEPARATION-A
DD-KEY
DD-B
B-EMPTYA-EMPTY / AUTOSTART

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CONTENTS
1.3.2 BASE SENSORS AND SWITCH VIEW
MACHINE
OPEN
ENV.EXIT
ZERO.CAME
REF.ENV
LETTER.OUTP
C.CLOSED
DD.BAC.C
END AND
SEPARATION C
DOC.LOADED
C.EMPTY
INSERT.STOP
FOLDING
PLATE 2

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CONTENTS
1.3.3 BASE SENSORS AND SWITCH VIEW
MACHINE-OPEN
INSERT-STOP
ENV-REFERENCE
ENV-EXIT
LETTER-OUTPUT
DOC-LOADED
CAM-ZERO
INSERT-SIGNAL
END-
SEP R TION C
C-EMPTY
C-CLOSED
DD-C

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CONTENTS
1.3.5 CLUTCHES VIEW
C SELECTION CLUTCH DOCUMENT FEEDER
CLUTCH
C TRANSPORT CLUTCH
B SELECTION
CLUTCH
A SELECTION
CLUTCH
MANUAL
FEEDING MOTOR

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CONTENTS
1.3.6 MOTORS VIEW
HOPPER
MOTOR
ENV
TRANSPORT
MOTOR
BOTTOM
FOLDER
MOTOR
TOP FOLDER
MOTOR
MAIN MOTOR
CAM MOTOR
SINGLE FOLD
MOTOR
(EUR only)

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CONTENTS
1.3.7 PAPER PATH VIEW
DOCUMENT PATH
ENVELOPE PATH

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CONTENTS
1.4 SENSORS/SWITCHES, MOTORS AND CLUTCHES
1.4.1 SENSORS
SERVICE TEST COMPONENT NAME FUNCTION
Bin C path closed C-CLOSED Checks if feeder C path is closed
Exit env. feeder ENV-EXIT Checks if the envelope has left the envelope hopper
Machine open MACHINE-OPEN Checks if the machine is open
End separation C END-SEPARATION-C C SEPARATION CLUTCH drive
Document in feeder C C-EMPTY No inserts in the feeder C
Document loaded DOC-LOADED inserting check
Stop insert INSERT-STOP Insert (or BRE) stop position
SERVICE TEST COMPONENT NAME FUNCTION
Insert signal INSERT-SIGNAL Synchronization document / Insert (or BRE)
Envelope Exit LETTER-OUTPUT Letter output check
Envelope Ref. ENV-REFERENCE Reference for the envelope inserting position
Cam zero CAM-ZERO Cam home position
SERVICE TEST COMPONENT NAME FUNCTION
Document in feeder A A-EMPTY / AUTOSTART No document in feeder A / AUTOISTART
Document in feeder B B-EMPTY No document in feeder B
End separation A END-SEPARATION-A A SEPARATION CLUTCH drive
End separation B END-SEPARATION-B B SEPARATION CLUTCH drive
Double detection key DD-KEY Enable or disable DD-A and DD-B
SERVICE TEST COMPONENT NAME FUNCTION
Entry doc A sensor DD-A Voltage delivered by the feeder A duplicate detector
Entry doc B sensor DD-B Voltage delivered by the feeder B duplicate detector
Entry doc C sensor DD-C Voltage delivered by the feeder C duplicate detector
DOUBLE DETECTION (Thickness detection)
MACHINE SENSORS (PART 1)
MACHINE SENSORS (PART 2)
FEEDER A-B SENSORS

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CONTENTS
1.4.2 MOTORS AND CLUTCHES
SERVICE TEST COMPONENT NAME FUNCTION
Not available A SELECTION CLUTCH Activate feeder A selection rollers
Not available B SELECTION CLUTCH Activate feeder B selection rollers
Not available C SELECTION CLUTCH Activate feeder C selection rollers
SERVICE TEST COMPONENT NAME FUNCTION
Not available C TRANSPORT CLUTCH Activate the transport C rollers.
Not available DOCUMENT FEEDER CLUTCH - Transfer mechanical power to document feeders
- Activate document transportation until folding rollers.
SERVICE TEST COMPONENT NAME FUNCTION
Not available TOP FOLDER MOTOR Drives Top folder adjustment
Not available BOTTOM FOLDER MOTOR Drives Bottom folder adjustment
Not available MAIN MOTOR - Drives the folding rollers. - Documents feeding.
- Insert/BRE feeding
Not available CAM MOTOR Drives the cam (inserting area)
Not available ENV TRANSPORT MOTOR Drives envelope from the hopper exit until the exit of
the machine
Not available HOPPER MOTOR Drives the envelope until the hopper exit.
Not available SINGLE FOLD MOTOR Drives the pocket A closing bar (Europe only)
Not available MANUAL FEEDING MOTOR Opens the feeder A path in order to perform daily mail
FEEDERS CLUTCHES
MACHINE CLUTCHES
MOTORS

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SECTION : 01 PAGE 17
CONTENTS
1.5 PCB INTERCONNECTION DIAGRAM
1.5.1 MAIN PCB (PART 1)
1.5.2

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CONTENTS
1.5.3 MAIN PCB (PART 2)
1.5.4

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CONTENTS
1.5.5 FEEDER PCB
1.5.6