Plockmatic SQF-200 SquareFolder User manual

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Plockmatic SQF200
Squarefolder
Service Manual

SQUAREFOLDER SQF 200
SERVICE MANUAL
12 February 2007
Subject to change

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V
29 November 2006
TABLE OF CONTENTS
1 INSTALLATION PROCEDURE
1.1 INSTALLATION PROCEDURE........................................................SQF-1-1
2 PREVENTIVE MAINTENANCE SCHEDULE
2.1 PREVENTIVE MAINTENANCE SCHEDULE..................................SQF-2-1
3 REPLACEMENT AND ADJUSTMENT
3.1 COVERS..........................................................................................SQF-3-1
3.1.1 FRONT COVER......................................................................SQF-3-1
3.1.2 REAR COVER ........................................................................SQF-3-2
3.1.3 INFEED COVER.....................................................................SQF-3-3
3.1.4 OUTFEED COVER.................................................................SQF-3-4
3.1.5 TOP COVER...........................................................................SQF-3-6
3.1.6 TILT THE MACHINE ...............................................................SQF-3-7
3.2 MOTORS.........................................................................................SQF-3-9
3.2.1 TRANSPORT BELT MOTOR (M1)..........................................SQF-3-9
3.2.2 STOP GATE MOTOR (M2) ...................................................SQF-3-10
3.2.3 CLAMP MOTOR (M3)...........................................................SQF-3-11
3.2.4 ROLLER MOTOR (M4)AND PRESSURE ROLLER.............SQF-3-12
3.3 SENSORS AND SWITCHES.........................................................SQF-3-15
3.3.1 STOP GATE SENSOR (Q1)..................................................SQF-3-15
3.3.2 ROLLER MOTOR FRONT/REAR SENSORS (Q2AND Q3)SQF-3-16
3.3.3 CLAMP MOTOR HOME POSITON SENSOR (Q4) ..............SQF-3-17
3.3.4 INFEED / OUTFEED SENSORS (Q5 AND Q7)....................SQF-3-18
3.3.5 CLAMP SENSOR (Q6)..........................................................SQF-3-20
3.3.6 MOTOR M4 ENCODER SENSOR (Q8)................................SQF-3-21
3.3.7 TOP COVER INTERLOCK SWITCHES (S2 & S4)...............SQF-3-22
3.3.8 UPPER TRANSPORT BELT CLUTCHES (SOL1 & SOL3)...SQF-3-23
3.3.9 LOWER TRANSPORT BELT CLUTCHES (SOL2 & SOL4)..SQF-3-24
3.4 BELTS............................................................................................SQF-3-25
3.4.1 UPPER TRANSPORT BELT.................................................SQF-3-25
3.4.2 LOWER TRANSPORT BELT ................................................SQF-3-26
3.4.3 TEFLON TAPE LOWER TRANSPORT BELT ....................SQF-3-29
3.5 MECHANICS.................................................................................SQF-3-31
3.5.1 SET CLAMPS........................................................................SQF-3-31
3.5.2 STOP GATE..........................................................................SQF-3-34
3.6 PCB ...............................................................................................SQF-3-37
3.6.1 PCB MD6DC “D”...................................................................SQF-3-37
3.7 POWER REQUIREMENTS...........................................................SQF-3-39
3.7.1 TAPPING THE TRANSFORMER..........................................SQF-3-39
4. TROUBLESHOOTING
4.1 FAULT CODE DESCRIPTIONS.......................................................SQF-4-1
4.2 BLOWN FUSE CONDITION..........................................................SQF-4-13
4.3 LED’S.............................................................................................SQF-4-15
4.4 TEST POINTS...............................................................................SQF-4-17

VI
29 November 2006
5 SERVICE TABLES
5.1 SERVICE TABLES...........................................................................SQF-5-1
6. DETAILED SECTION DESCRIPTION
6.1 ELECTRICAL COMPONENT LIST..................................................SQF-6-1
6.1.1 COMPONENT LAYOUT..........................................................SQF-6-2
6.2 BOARD STRUCTURE .....................................................SQF-6-5
6.2.1 CONTROLLER MD6DC “D”....................................................SQF-6-5
6.3 PRINCIPLE OF OPERATION..........................................................SQF-6-7
SPECIFICATIONS
SPECIFICATIONS..............................................................................SQF-Spc-1
WIRING
Squarefolder........................................................................................SQF-Wir-1

SQF-1-1
29 November 2006
Installation
1 INSTALLATION PROCEDURE
1.1 INSTALLATION PROCEDURE
Squarefolder installation procedure is located in the Booklet Maker BM 200
Service Manual ( 1.6)

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SQF-2-1
29 November 2006
Preventive
Maintenance
2 PREVENTIVE MAINTENANCE SCHEDULE
2.1 PREVENTIVE MAINTENANCE SCHEDULE
Squarefolder preventive maintenace schedule is located in the Booklet Maker BM
200 Service Manual ( 2)

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SQF-3-1
Replacement
Adjustment
29 November 2006
3 REPLACEMENT AND ADJUSTMENT
3.1 COVERS
3.1.1 FRONT COVER
COVERS
[A]
Removal
1. Open top cover.
2. Remove screws [A] ( x 3 ).
3. Remove screws [B] ( x 2 )
[A]
[B]

SQF-3-2
29 November 2006
3.1.2 REAR COVER
[A] [A]
Removal
1. Loosen screws [A] ( x 2 ).
NOTE: Lift out lower part and unhook the Rear cover.
COVERS

SQF-3-3
Replacement
Adjustment
29 November 2006
3.1.3 INFEED COVER
[A]
Removal
1. Open Top cover.
2. Remove nuts [A] ( x 4 ).
3. Remove nuts [B] and remove locking bracket ( x 2 ).
4. Tilt machine ( 3.1.6 ).
5. Remove nuts [C] ( x 2 ).
Replacement
4. Reverse the removal procedure.
NOTE: Make sure that the springs to the Upper Transport Belts are in correct
position.
[A]
[C]
COVERS
[B]
Bottom view

SQF-3-4
29 November 2006
3.1.4 OUTFEED COVER
COVERS
[A]
Removal
1. Remove Top cover gas spring lower end from joint [A].
NOTE: Press plastic stud from pivot point.
2. Remove screws [B] ( x 2).
3. Remove Front and Rear cover ( 3.1.1, 3.1.2 ).
4. Remove screws [C] ( x 2).
5. Remove Belt Stacker hangers [E] ( x 2).
6. Remove screws [F] ( x 4).
7. Lift Out feed cover carefully and disconnect wiring to sensor Q7 Phototransistor
[G] ( x 1).
[C]
[B]
Front view
Rear view
[D]

SQF-3-5
Replacement
Adjustment
29 November 2006
[E]
[F]
[G]
Top view, Outfeed
cover slightly tilted

SQF-3-6
29 November 2006
3.1.5 TOP COVER
Removal
1. Open Top cover.
2. Remove Top cover gas spring lower end from joint [A].
NOTE: Press plastic stud from pivot point.
3. Remove screws [B] ( x 4).
[B]
[A]
COVERS
Bad
Top cover too low Good Bad
Top cover too high

SQF-3-7
Replacement
Adjustment
29 November 2006
3.1.6 TILT THE MACHINE
Removal
1. Remove Belt stacker ( Service manual BM 200 3.8.1).
2. Remove the Trim bin.
3. Remove the Service bracket [A] by removing two nuts ( x 2 ).
4. Remove the foot screw [C] and mount it in the oposite hole up-side-down.
5. Place the Service bracket [B] in the Squarefolder base.
6. Turnfootscrew[C]ontheServicebracket,untiltheServicebracketrmly
contactstheoor.
7. Remove the screw [D] securing the machine with the base.
8. Remove Front cover ( 3.1.1).
9. Remove Rear cover ( 3.1.2).
10.Loosen screws [E] half a turn. One on each side ( x 2).
COVERS
[A]
[B]
[C]
[D]
WARNING
Squarefolder may Tip. Install Service bracket before separating the Square-
folder from the Trimmer.
WARNING
Before tilting make sure pivot screws [E] are NOT tightened.
Infeed view Infeed view
from below

SQF-3-8
29 November 2006
11.Remove screws [F]. One on each side ( x 2).
NOTE: Keep the screws. They will be used later in this procedure.
[F]
COVERS
Front view Rear view
Front view,
machine tilted Rear view, machine tilted
CAUTION
When lowering or raising the machine, lift in infeed area only.
[G]
[E]
12.Tilt machine by lifting infeed cover.
13.Secure machine with both the screws [G]. One on each side. Use the screws
previously removed from [F]. ( x2).
WARNING
When tilting SQF 200, make sure to tighten BOTH screws [G],
one on each side.

SQF-3-9
Replacement
Adjustment
29 November 2006
Removal
1. Tilt machine ( 3.1.6).
2. Remove R-pin [A] ( x 1).
3. Remove sprocket [B].
4. Disconnect the motor connectors ( x 2) .
5. Remove screws [C] ( x 4).
6. Remove Motor.
Replacement
1. Reinstall the motor, and secure it by tighten screws [C] ( x 4).
2. Connect the motor connectors ( x 2) .
NOTE: The Orange wire on ”+”, and the Violet wire on ”-”.
3. Reverse the rest of the removal procedure.
3.2 MOTORS
3.2.1 TRANSPORT BELT MOTOR (M1)
MOTORS
M1
[C]
[A] [B]

SQF-3-10
29 November 2006
3.2.2 STOP GATE MOTOR (M2)
MOTORS
M2
Removal
1. Tilt machine ( 3.1.6).
3. Remove cam by loosening allen screw [A] ( x 1).
4. Remove screws [B] ( x4).
5. Disconnect the Motor ( x 2).
6. Remove Motor.
Replacement
1. Reinstall the motor, but do not tighten screws [B] ( x 4).
2. Connect the motor connectors ( x 2) .
NOTE: The Orange wire on ”+”, and the Violet wire on ”-”.
3. Reverse the rest of the removal procedure.
4. Perform Stop Gate adjustment B ( 3.5.2).
[A] [B]

SQF-3-11
Replacement
Adjustment
29 November 2006
3.2.3 CLAMP MOTOR (M3)
Removal
1. Remove Outfeed Cover ( 3.1.4 ).
2. Remove the E-Clips and Washers [A] ( x 2, x 2).
3. Remove the driving disc [B] by loosening allen screw ( x 1).
4. Disconnect the motor connectors ( x 2).
5. Remove screws [C] holding Motor bracket ( x 4).
6. Remove screws holding Motor bracket ( x 3).
Replacement
1. Mount Motor to Motor bracket ( x 3).
2. Reinstall motor, by tighten screw [C] ( x 4).
3. Connect the motor connectors ( x 2) .
NOTE: The Orange wire on ”1”, and the Violet wire on ”2”.
4. Reverse the rest of the removal procedure.
MOTORS
M3
[A][C] [C][B]
[C]
CAUTION
Be careful not to damage sensor SQF-Q4
[SQF-Q4]