Plockmatic SF 4000 User manual

INSTALLATION INSTRUCTION
PLOCKMATIC SF 4000 SYSTEM
This Installation Instruction is an excerpt from the Service Manual
30 March 2012
Subject to change
Doc. No. T09298
Part No. 119-107059

Introduction
This manual contains instructions on the operation and maitenance 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.
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 property.
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.
Note
• The indications like front and rear, left and right refer to the paper transport direction.
• The operator manual always has to be available at the place of use of the machine.
• In the interest of technical development the company reserves the right to make alterations to
specicationswithoutpriornotice!
WARNING:
Please read separately enclosed Doc. N0001641 Safety Instructions before using this ma-
chine. It contains information related to USER SAFETY and PREVENTING EQUIPMENT
PROBLEMS.

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
procedure.
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 wriststrap.
5. Place the adjustable wriststrap 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.
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 in the ESD
bag the replacement PCB came in.
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software 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, refer to this procedure 3.1.
- Use ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure.

1-1
Installation
30 March 2012 INSTALLATION REQUIREMENTS
TABLE OF CONTENTS
1 INSTALLATION PROCEDURE..................................................... 1-3
1.1 INSTALLATION REQUIREMENTS............................................................ 1-3
1.1.1 MINIMUM SPACE REQUIREMENTS................................................ 1-3
1.1.2 POWER REQUIREMENTS ............................................................... 1-4
1.2 SF 4000 INSTALLATION ......................................................................... 1-5
1.2.1 UNPACKING ................................................................................... 1-5
1.2.2 BASE INSTALLATION..................................................................... 1-7
1.2.3 FEEDER & LOADER INSTALLATION ............................................ 1-9
1.3 OPEN INTERFACE INSTALLATION ..................................................... 1-11
1.3.1 ACCESSORY CHECK .................................................................. 1-11
1.3.2 INSTALL POWER SUPPLY ASSY................................................. 1-12
1.3.3 INSTALL PLOCKMATIC OPEN INTERFACE................................ 1-13
1.4 DOCKING .............................................................................................. 1-15

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1-3
Installation
30 March 2012 INSTALLATION REQUIREMENTS
1 INSTALLATION PROCEDURE
1.1 INSTALLATION REQUIREMENTS
1.1.1 MINIMUM SPACE REQUIREMENTS
710 mm (28”)
~1930 mm (76”)
800 mm (31.5”)1900 mm (75”) 950 mm (37.4”) 1118 mm (44”)
A
B
C
A = 1800 mm (71”). Beltstacker inline B = 480 mm (18.9”). Beltstacker angeled C = 425 mm (16.7”). Integrated stacker, max length

1-4
30 March 2012
INSTALLATION REQUIREMENTS
1.1.2 POWER REQUIREMENTS
WARNING
• Make sure that the wall outlet is near the main machine and easily
accessible.Makesuretheplugisrmlyinsertedintheoutlet.
• Avoid multi-wiring.
• Be sure to ground the machine.
• Input voltage level: 100-240 V, 50-60 Hz.
• Permissiblevoltageuctuation:±10%
• Never place anything on the power cord.

1-5
Installation
30 March 2012 INSTALLATION REQUIREMENTS
1.2 SF 4000 INSTALLATION
1.2.1 UNPACKING
1. Remove all parts from top box in package. It is heavy so unpack before mov-
ing box.
2. Check the quantity and condition of parts in top box against below list:
Description Quantity
A. Base Frame Short 3
B. Reinforcement Plate 2
C. Base Beam 2
D. Base Top 4
E. Base Foot Cover 2
F. Wheel 4
G. Screw bag 1
H. Base Frame Long 4
[A]
[B]
[C]
[D] [E] [G] [H]
[F]

1-6
30 March 2012
INSTALLATION REQUIREMENTS
1. Remove all parts from the pallets.
WARNING
Two persons are required for the installation of SF4000.
1.2.1 UNPACKING

1-7
Installation
30 March 2012 INSTALLATION REQUIREMENTS
1. Mount 2x Base Frame Long [A] and 1x Base Frame Short [B] together with 4x
screws [C].
2. Again mount 2x Base Frame Long [A] and 1x Base Frame Short [B] together
with 4x screws [A].
3. Mount the two base half together with 4x screws [D].
4. Turn base around and mount 2x Reinforcement plate [E] with 8x screws and
nuts[F].
6. Mount 4x Wheels [G].
[A]
[B]
[C]
[D]
[E]
[F]
[G]
1.2.2 BASE INSTALLATION

1-8
30 March 2012
INSTALLATION REQUIREMENTS
1.2.2 BASE INSTALLATION
7. Set default wheel hight too 125 mm.
8. Mount 2x support screws [H].
9. Mount front [I] and rear [J] Base Beam with 2x screws [K]. Notice that front
and rear Base Beam are mounted with different rotation.
10. Mount 4x Base Top [L] with 16x screws [M]. All 4 Base Top with same rotation.
[H]
[I]
[J]
[K]
[L]
[M]

1-9
Installation
30 March 2012 INSTALLATION REQUIREMENTS
1. LiftFeederintoplace[A].NoticethatitisimportanttotfootcorrectintoBase
Beam. Otherwise foot will break.
2. Put 4x Base Foot Cover [B] on and fasten with 4x screws [C].
3. Remove 2x handle [D] and remove side covers.
5. Lift Loader into place [E].
1.2.3 FEEDER & LOADER INSTALLATION
[A]
[B] [C]
[E]
[D]

1-10
30 March 2012
INSTALLATION REQUIREMENTS
6. Fasten Loader together with feeder with 4x screws [F].
7. Connect 3x cables [G].
8. Put covers back.
9. Lock covers with 8x screws [H].
1.2.3 FEEDER & LOADER INSTALLATION
[F]
[G]
[H]

1-11
Installation
30 March 2012 INSTALLATION REQUIREMENTS
1.3 OPEN INTERFACE INSTALLATION
1.3.1 ACCESSORY CHECK
Check the quantity and condition of the accessories in the box against the following list:
Description Q’ty
A. Communication box ............................................................. 1
B. Communication cable CAN .................................................. 1
C. Communication cable RS-232 ............................................. 1
D. Power supply cable .............................................................. 1
E. Bracket ................................................................................. 1
F. DSUB screw ........................................................................ 1
G. PCB holder........................................................................... 2
H. PCB...................................................................................... 1
[A]
[B]
[C]
[D]
[E] [F] [G] [H]

1-12
30 March 2012
INSTALLATION REQUIREMENTS
1.3.2 INSTALL POWER SUPPLY ASSY.
1. Mount 2x PCB holder [A] on Bracket [B].
2. Mount PCB [C] into PCB holder.
3. Mount PCB assembly together with DSUB [D] using 2x DSUB screw [E]. No-
tice that PCB assembly should be placed between the two DSUB.
4. Mount connector P1 and P2 [F] on PCB.
6. Mount other end of Power cable into PSU [G].
[A]
[B]
[C]
[D]
[E]
[F]
[G]
[E]

1-13
Installation
30 March 2012 INSTALLATION REQUIREMENTS
1.3.3 INSTALL PLOCKMATIC OPEN INTERFACE
7. Connect Communication cable CAN [A] into MF4000.
8. Connect Communication cable CAN [A] and Communication cable RS-232 [B]
into Communication box [C].
9. Remove rear cover on SF4000.
10. Mount communication cable RS-232 [B] into SF4000. Don’t forget to mount 2x
cable ties [D] for cable relief.
11. Installation is now done.
[A]
[B]
[C]
[B]
[D]

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1-15
Installation
30 March 2012 INSTALLATION REQUIREMENTS
1. Mount docking nobs [A] on MF4000.
2. Dock SF4000 against docking nobs on MF4000. Make sure that the 2 ma-
chinesareparallell[B]±2mm.Ifnecessary,adjusthightoneitherMF4000or
SF4000.
3. Secure SF4000 by sliding docking latch [C] in.
4. Installation is now done. Turn power on system and run.
1.4 DOCKING
[A]
[C]
[B]

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