EF-35 - Service Manual

SERVICE MANUAL

Kyoto,Japan

510 Kuze Ooyabu-cho, Minami-ku, Kyoto, 601-8206, JapanPhone:+81-(0)75-934-6700, Fax:+81-(0)75-934-6708, www.horizon.co.jp

EF-35 Paper Folder

US503008-00 030904/EF35/00E/NT

I

Important Information

- This service manual is designed to help you to repair and maintain the EF-35 in order to keep it in good operating condition.Please read and understand the instructions in this service manual before performing any repair or maintenance.

- Horizon International Inc. shall not be liable for incidental or consequential damages resulting from: improper or inadequatemaintenance by the customer; unauthorized modification or misuse; or operation outside of the environmental specificationsfor the product.

- Horizon International Inc. follows a policy of continuing improvement in design and performance of the product. Therefore,the product design and specifications are subject to change without prior notice and without our legal obligation.

- All rights are reserved. No part of the manual may be photocopied, reproduced or translated to another language without theprior written consent of Horizon International Inc.

FOREWORD

Paper Folder

Model EF-35

II

Safety Precautions- Please read and understand all safety instructions with include the terms WARNING, and CAUTION. If these safety

instructions are ignored, personal injury may result.

- The repair, maintenance and safety instructions in this manual are valid only when the repair or maintenance work is performedaccording to the procedures described in this manual.

- The term WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

- The term CAUTION indicates a potentially hazardous situation which, if not avoided, may result in damage on machines. It mayalso be used to alert against unsafe practices.

- Horizon International Inc. cannot anticipate every possible situation that might involve a potential hazard. The instructions in thismanual and the warning labels on the machine are therefore not all-inclusive.

- All equipment shall be locked out or tagged out to protect against accidental or inadvertent operation when such operation, repairor maintenance could cause injury to personnel. Do not attempt to operate any switch, valve, or other energy isolating devicewhen it has been locked or tagged out.

- Some of the drawings in this manual show the machine uncovered for explanations of details inside the machine.

III

1. Turn off power switch and pull out the plug for precautionexcept in case of neccesity before parts replacement or othermaintenance operations.

2. Mind rotating parts such as belt and pulley or electric cableswhen operating with covers removed.

3. A single operator must operate yourself only. This manualsupposes operations by a single operator.

4. Caution that other persons do not touch the machine duringyour service operations.

5. When turning on power switch again, wait for a dozen ofseconds after turning off.

6. When replacing parts, use parts shown in parts book exceptwhen the same functions can be found among commercialparts.

Service Operation Precaution

IV

Handling Precautions for P.C.Board and ROM

P.C.Board and ROM can be damaged by humanly imperceptible static electricity.Handle P.C.Board and ROM with following care.

Keep P.C.Board in a shield bag.

P.C.BoardShield Bag

Put the ROM on a conductive sponge and keep in a shield bag.

Shield Bag

Conductive Sponge

Do not put P.C.Board and ROM on the machine, especially on the acrylic cover. (No problem on the conductive plate.)

And keep the P.C.Board and ROM away from the insulators.Insulators: Plastic, form polystyrene,

chemical fiber fabric, dry paper, etc.

Acrylic Cover

When replacing the P.C.Board and ROM, or setting the dip switches and volumes on the P.C.Board, wear a wrist strap, and connect the clip to the machine frame (not painted surface).

Wrist Strap

ClipMachine Frame

V

BLKBlack

ORNOrange

YELYellow

Description of Abbreviations in This Manual

Abbr.AxxBxxCxxFxxGxxKxx

DescriptionInverterSensorCapacitorFusePower SupplyContactor

Abbr.LxxMxxHxxQxxQPMxxQPWxx

Description Lamp, LED Motor Heater Circuit Protector/ Breaker Multi-layer circuit board Single-layer circuit board

DescriptionSwitchTransformerDriver/ InverterTerminal Board, ConnectorValveNoise FilterPower Plug

Abbr.Color

BRNBrown

REDRed

GRNGreen

BLUBlue

VIOViolet

GRYGray

WHTWhite

2. Electrical Symbols

1. Cable Colors

BRN-g=The description "g" in cable color means the gray band tying the connector.RED-BLU=The description means that the wire is blue matrix with red stripe.

Abbr.ACBKCLCONCWCCWDC

DescriptionAlternating CurrentBrakeClutchConnectorClockwiseCounterclockwiseDirect Current

Abbr.DSWF.GJSWMSPBRYSSR

DescriptionDip SwitchFrame GroundJumper SwitchMicroswitchParts BookRelaySolid State Relay

Abbr.VRSigS/N

DescriptionVolumeSignalSerial Number (of machines)

3. Other Symbols

Abbr.SxxTxxUxxXxxYxxZxxWxx

VI

CONTENTSFOREWORD ........................................................................ I

Important Information ........................................................ I

Service Operation Precaution ............................................. III

Handling Precautions for P.C.Board and ROM ............... IV

Description of Abbreviations in This Manual ................... V

1. Before You Begin

1-1 Machine Description ...................................................... 1-2

1-1-1 Overview .................................................................... 1-2

1-1-2 Control Panel (1) ........................................................ 1-3

1-1-2 Control Panel (2) ........................................................ 1-4

1-2 Other Information ........................................................ 1-5

2. Troubleshooting

2-1 The Sheet is not Fed (Although Feed Rotor Rotates) 2-2

2-1 The Sheet is not Fed

(Because Feed Rotor does not Rotate) ........ 2-4

2-2 A Sheet Jam Occurs Frequently ................................... 2-6

2-3 The Total Counter does not Count Up......................... 2-7

2-4 The Counter Sensor Keeps Lighting Up ...................... 2-7

2-5 The Circuit Breaker (Q01) is Tripped ......................... 2-8

2-6 The Folding Speed Reduces .......................................... 2-8

2-7 The Delivery Conveyor does not Operate .................... 2-9

3. Troubleshooting for Folding Quality

3-1 The Sheets are Folded Diagonally ................................ 3-2

3-2 The Fold Line Moves Gradually ................................... 3-3

3-3 The Fold Lines are not Even ......................................... 3-3

3-4 The Thick (Hard) Sheets Delivered

are not Arranged Straight ............. 3-4

3-5 Either or both sides of the sheet edge are bent ............ 3-5

3-6 Double Step Folding Occurs ......................................... 3-6

3-7 The Sheet is Wrinkled Crossing the Fold Line ........... 3-6

4. Replacement and Adjustment

4-1 Removing Feed Table .................................................... 4-2

4-2 Replacing the Fold Roller .............................................. 4-4

4-3 Adjusting the Fold Roller Gap ..................................... 4-6

4-4 Adjusting the Tension of Drive Belt ............................. 4-8

4-5 Replacing the Delivery Conveyor Belt

and Adjusting the Belt Tension ................... 4-9

4-6 Replacing the Feed Rotor Belt

and Adjusting the Belt Tension ................... 4-10

4-7 Replacing the Motor Driver .......................................... 4-12

4-8 Installing Standard for Other Parts ............................. 4-13

VII

5. Electrical Parts Layout and Description

5. Electrical Parts Layout and Description ........................ 5-2

6. P.C.B and Wiring Diagram

6-1 QPW-589 Control P.C.B ............................................... 6-2

6-2 100VAC Power Circuit Diagram.................................. 6-4

6-3 24VDC Wiring Diagram ............................................... 6-5

VIII

This page is intentionally left blank.

1. Before You Begin1-1

1. Before You Begin


1-1 Machine Description

1-1-1 Overview

0

12

3

First Roller

Third Roller

Second Roller

Fixed Fold Roller

First NutThe gap between the first rollerand the fixed fold roller can beadjusted using this nut.

Feed Rotor

Feed Table

Tension Pulley ShaftThe tension of the feed rotor belt canbe adjusted by this shaft position.

Feed Rotor Drive Shaft

Drive Motor M01

Drive Belt Tension SpringThe drive belt is tensed up withthis spring.

Tension Adjusting NutThe tension of the drive belt can beadjusted using this nut.

Idle Pulley BracketThe tension of the con-veyor belt can be adjustedby moving this bracket.

Conveyor Motor M02

Conveyor MotorTiming Belt

Conveyor Belt

Drive Belt

Second Buckle Plate

First Buckle Plate

Second NutThe gap between the secondroller and the first roller can beadjusted using this nut.

Third NutThe gap between the third rollerand the second roller can beadjusted using this nut.



1-1-2 Control Panel (1)

34

34


Pause LEDThis LED lights while the machine ispaused, and also after a preset stop.

Feed Rotor Vacuum LEDThis LED lights while the feed rotor isproviding vacuum to sheet, and blinks whenthe continuous folding mode is selected.

Feed Sensor LEDThis LED lights each time a sheet passesthrough the feed section.

Feed Interval KnobThis knob is used to adjust the feed interval.

Vacuum Time KnobThis knob is used to adjust the vacuum time forthe feed rotor. When the knob is turned all theway to the right, the LED blinks and the feedrotor provides vacuum continuously.

Pause Time KnobThis knob is used to adjust the pause timebetween one batch of sheets and the nextbatch when the preset pause mode is selected.

Test Feed ButtonWhen this button is pressed while the motor isrunning, one sheet will be fed.

Roller/ Feed Start ButtonThis button is used to start feeding the sheets.Press this button once to start the motor, theroller, delivery conveyor, and the pump. Pressthis button again to start the feeding operation.

Roller/Feed Stop ButtonWhen this button is pressed once, the ma-chine stops feeding the sheets. Press thisbutton again to stop the motor, the roller,delivery conveyor and the pump.

Pump SwitchWhen switched on in motor running, theair blow into feed table.

Fold Speed KnobThis knob is used to adjust the rotatingspeed of the fold rollers.When the knob is turned all the way tothe left, the fold rollers might stoprotating.

Conveyor Speed Adjusting KnobThis knob is used to adjust the conveyorbelt speed. When the knob is turned allthe way to the left, the delivery conveyorbelts might stop rotating.

Conveyor SwitchThis switch is used to change the operat-ing mode of the conveyor.When is selected, the conveyoroperates continuously.When is selected, the conveyoroperates only after a sheet has passedthrough the feed sensor, and during thepause time.



1-1-2 Control Panel (2)

34

34

When the continuous folding mode is selected, the presetstop lamp and the pause mode lamp are turned off.

Total CounterThis indicates the total number of foldedsheets.

Total Counter Clear ButtonThe total counter can be reset using this button.

Preset CounterThis indicates the number of sheets to be foldedin preset stop mode or preset pause mode.

Preset Number Save ButtonThis button is used to save the preset number. The presetnumber can be viewed again by pressing this button even ifthe machine has stopped during the folding operationbecause it reached the preset stop number.

Preset /Number Set ButtonThese button are used to set the preset number. Thebuttons set the units, tens, hundreds, and thousandsdigit from the right respectively.Each number can be changed by pressing thecorrect button.

Mode Select ButtonThis button is used to change the mode forcontinuous folding, preset stop, and the presetpause counter.


1-2 Other Information

The angle of the feed table

Up to S/N008899Installed by inclining about 10 degrees upward to

the sheet feeding direction.

S/N009001-014899Installed on the level.

10

~S/N008899

S/N009001-014899

1-2 Other Information

The angle of the feed table is changed tothe level to feed the thin sheets stably.



2. Troubleshooting2-1

2. Troubleshooting


2-1 The Sheet is not Fed (Although Feed Rotor Rotates)

First Check

- The gap between the gate plate and thefeed rotor is too narrow.

- The vacuum time is too short.

- Too many sheets are loaded.

- The feed guides are set too tight.

- The vacuum position of the feed rotor is notcorrect.

- The sheets are not separated correctly.

- The blower air is too weak.

If the pump filter is clean, make the air pressurestronger using the regulator on the blower. Even ifthe blower air is still weak after adjusting the airpressure, check that the blower air hose isconnected tightly using the hose clamp.

- The vacuum of the feed rotor is too weak.

If the pump filter is clean, make the vacuumstronger using the regulator on the vacuum pump.Even if the vacuum is still weak after adjusting thevacuum, check that the vacuum hose is connectedtightly using the hose clamp.

The blower and vacuum pump do notoperate.

- Check if the pump switch is turned on.

- Check if the pump connector X01 is

plugged in the machine. (Fig.1)

- Check if the pump circuit breaker Q20 is

tripped. (Fig.1)If the circuit breaker is tripped again, check if the

filter element of the blower and vacuum pump is

clogged, or the blower and vacuum pump is

overloaded.

If all of the outlets (five cocks) are closedcompletely, or closed almost, the blowerand the vacuum pump is overloaded.Release the air from the unused outlet.

Also, check if the electrical leak occurs on the

wiring between the Q20 and M03 (Fig.1)

- Check if the wiring between the power

switch S01 and the pump M03 is correct.

(Fig.2)

- When the start button is pressed, check if

the pump contactor K20 is turned on.

(Fig.1)When K20 is not turned on, if there is no defect

in the wiring between the pump contactor K20,

terminal A1, A2 and the Control P.C.B, CON 3,

Pin 9, 10, replace the contactor and the control

P.C.B in order.

- Check if the wiring between the pump

switch S14 and the Control P.C.B, CON 3

is correct. (Fig.2)

- When the pump switch is turned on, the

circuit is closed.



Fig.1

EF-35

PAPER FOLDER

PAPER FOLDERQ20

K20

X01

- After pressing the start button and rotating

the feed rotor, press the start button or

the test button again. The sheet starts

being fed and the feed rotor vacuum LED

lights up.

If the suction air valve does not work, check

the followings.

- When the suction air valve works, check if

the feed rotor vacuum LED on the control

panel lights up. (L2 in section 6-2)If it lights up, check the wiring between the

Control P.C.B, CON 3 and the feed rotor Y01.

( 6-3 24VDC Wiring Diagram)

If there is no defect in the wiring, replace the

suction air valve and the control P.C.B in order.

If it does not light up, check if the input signal of

the start button is input into the P.C.B (L4 in

section 6-2). If there is no problem in the input

signal of the start button, replace the P.C.B.



Fig.2

First Check

- The roller speed setting is too slow.

Adjust the roller speed using the fold speed knob.

The circuit breaker Q10 is tripped.

- If it is tripped again, check if the roller

motor is overloaded. And check if the

electrical leak occurs in the wirings from

the circuit breaker Q10 to the followed

wiring.

The motor driver (U01) is normal. (Fig.2)

- Check if the alarm LED (red) of the main

motor driver (U01) lights up.If it lights up, check the followings.

1. The motor is overloaded.

2. The input wiring is connected with the driver.

And the input voltage is 100V+/-10V.

3. The wiring to the main motor (M01) is OK.

- Check if the power LED (green) of the

main motor driver (U01) lights up.If it does not light up, check if the input wiring is

connected with the driver.

2-1 The Sheet is not Fed (Because Feed Rotor does not Rotate)

BLK

BLK

WHT

WHTRED

GRNREDBLKWHT

RED

GR

N

GR

N

BLK

BLK

BLK

BLK

WH

TW

HT

BLK

WH

T

BLKFG FG

BLK

WHT

WH

T

WH

T

WHT

BLK

GRN

AC100-115V~

SPEED POWER

ALARM

EXT-INT

S.S.

S.D.

BRUSHLESS DC MOTORDRIVER FBLD120AW

MO

TOR

I/O

VEXTA

S01Power Switch

X01Connector

Q20Pump Breaker

K20Pump Contactor

X03Terminal Board

Pump

Main Motor

Power Lamp

Alarm Lamp

M03

2

29

32

2 4 6 14

1 2 3

A1

A2

7643E

7643E

S14Pump Switch

CON3

BR

NR

ED

RE

DW

HT

9 10 11 12

1 3 5

2 4 6

QPW-589Control P.C. Board

L

N

NC

FG

1

2

3

4

5

6

7

8

9

10

11

12

M01

U01Main Motor Driver



Belt

Tension Roller

Feed Rotor Belt

Reduction Pulley

M01

Feed Rotor Section

Pulley


The drive mechanism of the feed rotor isnormal. Check the followings. (Fig.3)

- Check if the belts slip on the pulley.Even If the belts are cleaned up and they still

slip, replace them.

- Check if the reduction pulley rotates

smoothly.

- Check if the pulley of the feed table is

fixed with the shaft tightly.

- Check if the feed rotor belts slip on the

feed rotor.Even If the belts are cleaned up and they still

slip, adjust the belt tension. ( “4-6

Replacing the Feed Rotor Belt and Adjusting the

Belt Tension”)

- Check if the feed rotor rotates smoothly.Remove the feed rotor belt and check the feed

rotor.

Fig.3


First Check

- The sheets are curled.

- The buckle plate is not set correctly.

- If the sheet does not enter the first buckle,the gap between the buckle plate and thefold roller is too wide. (Fig.1)

- If the sheet is thick and it does not enterthe first buckle, widen the gap between thebuckle plate and the fold roller. (Fig.1)

- Actually, the double feeding occurs.

If the double feeding occurs, check the followings.

1. Fan the sheets.

2. Turn the rear blower air nozzle away fromthe sheets to reduce the blower air.

3. Narrow the gap between the gate plate andthe feed rotor.

4. Shorten the vacuum time.

5. Make the feed interval longer.

The fold roller is not cleaned up.

The gaps between the fold rollers are notprovided correctly.

- Refer to “4-3 Adjusting the Fold Roller

Gap” and adjust the gaps between the

fold rollers.

2-2 A Sheet Jam Occurs Frequently

Guide Screw

Point Driver

Fig.1


2-4 The Counter Sensor Keeps Lighting Up2-3 The Total Counter does not Count Up

B01Counter Sensor

L1

L9

L10 L4 L5

L8L7

1

1 1

1

L6

L2 L3

CON1CON1CON1

1

CON8CON8CON8

CON7CON7CON7 CON2CON2CON2

CON5CON5CON5 5 6 7

CON3

1234

ON

CON324V

SIG 0V

BRN

BLK

BLU

5 6 7

13

13

Control P.C.Board QPW-589

Fig.1

The position of the counter sensor is notcorrect

- Refer to “4-8 Installing Standard for Other

Parts” and check the installing position of

the count sensor.

The counter sensor does not work cor-rectly.

- When the counter sensor detects the

sheet, check if the L7 on the P.C.B lights

up. ( “6-1 QPW-589 Control

P.C.B”)When lights up,

- The signal of the counter sensor is input to the

P.C.B, but there is a defect on the P.C.B.

Replace the P.C.B.

- The voltage between CON3-Terminal 5 and 7

measures 24VDC always. When the sensor

detects the sheet, the voltage between CON3-

Terminal 6 and 7 measures 24VDC.

When does not light up,

- The signal of the counter sensor might not be

input to the P.C.B, or the P.C.B might be

damaged. Check the wiring between the

control P.C.B, CON 3 and the counter sensor

B01. (Fig.1)

- If there is no defect in the wiring, replace the

counter sensor and the control P.C.B in order.

First Check

- The paper dust sticks to the sensor.

The counter sensor works correctly.

- When the counter sensor detects nothing,

check if the L7 on the P.C.B does not light

up. (Fig.1)When L7 lights up,

- The signal wiring might be short circuited, or

the P.C.B might be damaged.

If there is no defect between the control

P.C.B, CON3 and the counter sensor, replace

the counter sensor and the control P.C.B in

order.

- The voltage between CON3-Terminal 5 and 7

always measures 24VDC. When the sensor

detects the sheet, the 24VDC between CON3-

Terminal 6 and 7 is measured.

When L7 does not light up,

- There are no defect in the counter sensor and

the wiring. There is a defect on the control

P.C.B. Replace the P.C.B.

2-3 The Total Counter does not Count Up / 2-4 The Counter Sensor Keeps Lighting Up


2-5 The Circuit Breaker (Q01) is Tripped

The alarm LED of the main motor driverlights up.

- If it lights up, turn the power off and check

if the rotation of the fold rollers is heavy.

The following wiring circuit is short cir-cuited. (Fig.1)

- The wiring between the power switch S01

and the power supply.

- The wiring between the power switch S01

and the main motor driver.

2-6 The Folding Speed Reduces

The drive belt slips on the pulleys.

- When the drive belt slips on the pulleys,

even if the belt is cleaned up, adjust the

belt tension. ( “4-4 Adjusting the

Tension of Drive Belt”)

12345678

135

G01ACINACINFG

0V0V0VWHT

BLKGRN

BLK

BLK

WHT

BLK

WH

T

WHT

WH

T

WH

TB

LKWH

T

WHTBLK

GRN

24V24V24V

123456789101112

LNNCFG

U01FBLD120AW

Power Supply

S01Power Switch

Main Motor

Main Motor Driver

M01

Q10Breaker

21 3 5

2 4 6

W01230V 50Hz115V 60Hz

Fig.1

12mm

(Tension Adjustment for the new belt)

Stopper Shaft

Drive Belt

M01

Screw Part of Hook

(0.47”)


2-7 The Delivery Conveyor does not Operate

The delivery conveyor is operated in twomodes.

- Continuous Mode:

The delivery conveyor works whilethe fold rollers rotates.

- Intermittent Mode:

The delivery conveyor works onlywhen a sheet has passed through thecounter sensor and during the pausetime.

First Check

- The connector of the delivery conveyor isconnected with the control P.C.B.

- The speed of the delivery conveyor is set tothe minimum.

The wiring between the control P.C.B(QPW-589), CON8 and the conveyor motorM02 is not correct. (Fig.1)

- If it is correct, replace the conveyor motor

and the control P.C.B in order.L1

L9

L10 L4 L5

L8 L7

1

1 1

1

L6

L2 L3

CON1CON1CON1


CON5CON5CON5

1

CON3CON3CON3

1234

ON

GRN FGGRNBLK

GRNREDWHT

X02

931

931

GR

NB

LK

11

34

Conveyor Motor

M02

1 2CON8CON8CON8

Control P.C. Board QPW-589

Fig.1

2-7 The Delivery Conveyor does not Operate



3. Troubleshooting for Folding Quality3-1

3. Troubleshooting for Folding Quality


3-1 The Sheets are Folded Diagonally

First Check

- The feed guides are not parallel to thefeeding direction.

- The gap between the feed guide and thesheet is too wide.

- The buckle stopper is inclined.

- The guide screws for the buckle on eachside project by the same amount. (Thebuckle plate is inclined in the relation to therest of the machine.)

- The sheet is not square because it hasbeen trimmed incorrectly.

- The sheets are wavy because of thehumidity.

- The sheets are curled.

The gaps between the fold rollers are notprovided correctly.

- Refer to “4-3 Adjusting the Fold Roller

Gap” and check the gaps between the

fold rollers.

- Check if the roller tension spring is dam-

aged. (Fig.1)

There is a thrust play in the fold rollers.

- Check if there is any play in the fold

rollers because the washer is worn out.

(Fig.1)

Fig.1

Set Screw

Link Spring Stopper

Nut

Roller Tension Spring

Link

Washer

Washer

Needle BearingInner Ring

The inner ring in the needle bearing isworn out.


3-2 The Fold Line Moves Gradually

First Check

- The buckle stopper locking screw is tight-ened completely.

- The buckle plate is not correctly set inrelation to the rest of the machine.

The drive belt slips on the pulleys.

- When the drive belt slips on the pulley,

even if the belt is cleaned up, adjust the

belt tension. (

AA

BB

Parallel ConditionA=B

Set the feed guides atthe narrowest position.

Fig.1

W4

W4S

SB4-12 SB4-15

W4S

W4

Fig.2

First Buckle Plate: 1.5 mm(0.06”)

Second Buckle Plate: 2.0 mm(0.08”)


3-4 The Thick (Hard) Sheets Delivered are not Arranged Straight

The position of the delivery rollers are notcorrect. (Fig.1)

- Set the delivery rollers so that the deliv-

ered sheet is held under the delivery

rollers immediately.

The position of the delivery guides are notcorrect. (Fig.1)

- Set the delivery guides according to the

sheet size so that the sheets are hold by

them.

The angle of the delivery conveyor is notcorrect. (Fig.2)

- Set the delivery conveyor to reduce the

angle for the sheets which are thick and

easy to open.Conveyor (Normal Angle) Conveyor (Low Angle)

Delivery Roller

Delivery Guide

Easy to open

Set the flat plate underthe conveyor to make theangle low.

Delivery Conveyor

Fig.1

Fig.2


3-5 Either or both sides of the sheet edge are bent

(The sheet is bent downward)(Fig.1)

- The sheet is curled downward.

- The buckle plate is set at the high

position.

12

3

Fig.1 Dog Ears-Downward Folding

3-5 Either or both sides of the sheet edge are bent

(The sheet is bent upward) (Fig.2)

- The sheet is curled upward.

- The buckle plate is set close to the

fold roller too much.

- The pressure of the first fold roller

(press roller) is too strong.

(Either side of the sheet is bent)

- The deflector is inclined.

(The buckle plate installing the

deflector might be inclined in rest

of the machine.)

(Hitting the deflector) (Fig.3)

- The sheet hits a scratch on thedeflector surface.

- The pressure of the second foldroller (press roller) is too strong.

- The distance between the bucklechute and the fold roller is toonarrow.

Fig.2 Dog Ears-Upward Folding

Fig.3 Hitting the Deflector

Fig.4 Inner Folding

12

3

1

3

2

1

3

2

(Inner edge of the sheet rolls)

- The buckle plate is set so that the

inner side of sheet is too long. If it

still rolls after adjusting the inner

length, curl it in reverse to prevent

the inner edge rolling, and load the

sheets.


3-7 The Sheet is Wrinkled Crossing the Fold Line

- The sheets are wavy because of the

humidity.

- The gate plate is set too low.

- The roller pressure of the first fold roller is

too strong.

3-6 Double Step Folding Occurs

The roller pressure of the third fold rolleris too strong.

- Reduce the roller pressure to allow the air

to release.

The third fold roller rotates correctly.

- Check that the pulley is fixed with the

roller shaft firmly. (Fig.2)

12

3

Fig.1 Double Step Folding Fig.2 Pulley and Fold Roller Shaft

Air Pocket:It is caused that theroller pressure is toostrong and the air cannot be released fromthe sheet inside.

Third FoldRoller Shaft

Pulley Fig.1 Wrinkled Crossing the Fold Line

4. Replacement and Adjustment4-1

4. Replacement and Adjustment


Removal

1. Remove the front cover.

2. Remove the belt. (Fig.1)

3. Remove the vacuum hose and theblower air hose from the bottom ofthe feed table. (Fig.1)

4. Remove the feed table from themachine.- Remove the feed table, lifting up it.

4-1 Removing Feed Table

a

a

Fig.1

Belt

Vacuum Hose

To Pump

Blower Air Hose




4-2 Replacing the Fold Roller

Remove

1. Turn off the main power.

2. Remove the front and the rear cover.

3. Remove the feed table. ( “4-1Removing Feed Table”)

4. Remove the drive belt. (Fig.1)

5. Remove the manual drive knob. (Fig.1)

- The washer is also removed.

6. Remove the roller pulley. (Fig.1)

- The washer is also removed.

7. Remove the side plate only on thefront side. (Fig.1)

8. Remove the roller link on the frontside, which should be removed. (Fig.2)

1. Fasten the nut to widen the gap between the

fold rollers. (Both side)

2. Loosen the set screw of the roller link spring

stopper on the front side and remove the

roller link. (Only on the front side)

- If the fixed roller is replaced, remove the

screw with the hexagon socket. (Fig.2)

- The roller link on the rear side is not neces-

sary to remove.

9. Remove the fold roller to the frontside.

4. Insert the washer and the roller pulleyinto the fold roller.

- Lock the roller pulley, pulling the foldroller to the front side and pushing thepulley to the rear side.

- After installing the roller pulley, checkif the fold rollers can be rotatedsmoothly.If it is difficult to rotate, install thepulley at the front side a bit more.

- At the end, check if all the four foldrollers can rotate smoothly and theplay of the fold rollers to both side areleast.

5. Install the manual drive knob.

6. Install the drive belt. (Fig.4)

- Attach it by the correct direction.

- After attaching the belt, adjust the tension of

it. ( “4-4 Adjusting the Tension of

Drive Belt”)7. Adjust the gap between the fold

rollers.

( “4-3 Adjusting the Fold Roller Gap”)

8. Install the feed table into the ma-chine.

9. Install the front and the rear cover.

Install

1. Insert the fold roller.- Before installing the fold roller, lubricate the

inner ring of needle bearing.

2. Install the roller link.- Before installing the roller link, lubricate the

inner ring of needle bearing and the hole of

the roller link. (Fig.2)

- Install all the roller links facing to the outside

so that you can see the letters carved on the

bearing.

- If the roller link can not be installed smoothly,

install the roller link into the fulcrum shaft by

turning the nut. (Fig.2)

- If the roller link is installed on the fixed fold

roller, loosen the link stopper shaft, fit it with

the rounded part of the link and lock the screw

with hexagon socket using the nut (Fig.2).

And then lock the link stopper shaft.

3. Install the side plate.

After installing the side plate, check if theroller link can be moved by pressing theroller links as shown by the arrow. (Fig.3)



12mm

SS6-6 SS6-6

SB5-12

W5

Fig.1

Fig.2

Fig.3

Fig.4

Washer

Manual Drive Knob

WasherRoller Pulley

Drive Belt

Side Plate

Fixed FoldRoller Link

Link Stopper Shaft

Set Screw

Roller Link Spring Stopper

Nut

Side Plate

Link

Buckle Locking KnobRounded Part

Lubricate here, Beforeinstalling.

Link

Hole of Roller Link


Screw withHexagon Socket


Before Adjusting

1. Prepare the test strip.Coated Paper, 73-79 gsm,

Width: about 20 mm (0.8”),

Length: about 100 mm (4.0”)

2. Remove the first and the secondbuckle plates.

3. Remove the feed table from themachine.( “4-1 Removing Feed Table”)

4. Remove the front and the rear cov-ers.

5. Check if the set screw of the rollerlink spring stopper is fasten firmly.

WARNINGWhen adjusting the fold rollergap, keep your hands and fingersoff the fold rollers. Otherwise thefold rollers can cause severepersonal injury.

4-3 Adjusting the Fold Roller Gap

3. Also, insert the one strip between thefirst fold roller and the second foldroller (Fig. 2), and adjust the pullingforce.- Adjust it using the second nut.

4. Next, insert the two strips betweenthe second fold roller and the thirdfold roller (Fig. 2), and check thepulling force.- Adjust it using the third nut.

5. After adjusting the pulling force,check the roller gap as well afterchanging the speed of the fold rollers.

Check

- The pulling force is even on both front and

rear side at any speed, but it can be changed

according to the speed.

Adjust

1. Turn on the main power and rotatethe fold rollers.- Set the roller speed to 3 or 4.

2. Insert the one strip between the fixedfold roller and the first fold roller, andcheck the pulling force.- First, fasten the nut to provide the roller gap.

- Loosen the first nut gradually to adjust so that

the pulling is adjusted as indicated below.

- The pulling force will be stronger by loosing

the nut.

- Loosen the nuts on front and rear side gradu-

ally and evenly.

When the nut is loosen for one round, thefold roller gap will be narrower about 0.8mm (0.03”).

(Standard)

- A little wider than roller gap where the

inserted test strip is torn.

- The pulling force is even on front and rear

side.

- Adjust the roller gap so that the speed of the

fold rollers does not reduce by the friction of

the test strip and the fold rollers.



Fig.1

0

12

3

0

12

3

Feed Table

First Buckle Plate

Second Nut

First Nut

Third NutSecond Buckle Plate

Drive Motor

RotatingDirection

Number of inserttest strip

OneStrip

Set Screw

Set Screw

Set Screw

Fig.2


6. After inserting the thick sheet of the210 gsm or thicker between each foldrollers a few times, check the pullingforce of each fold roller again.Check

- Before and after inserting the thick sheet, the

pulling force does not change.

- The pulling force might change until the parts

related on the fold roller gap are settled. If it

changes, adjust the fold roller gap until it does

not change.

7. Install the buckle plate and the feedtable, and fold the required sheetsthirty times continuously.After that, check the pulling of strip instep 2, 3 and 4.Check

- Check if the pulling force does not change.

- The pulling force might change until the parts

related on the fold roller gap are settled. If it

changes, adjust the fold roller gap and check

the pulling of the strip repeatedly until it does

not change.

OneStrip

TwoStrips


4-4 Adjusting the Tension of Drive Belt

Adjust


2. Adjust the tension of the drive beltusing the hook screw.


- The screw part of hook comes out about 12

mm (0.47”) from the stopper shaft.

12mm

Fig.1


Stopper Shaft

Screw Part of Hook

Drive Belt

M01

(0.47”)


Remove


2. Remove the delivery conveyor fromthe machine.

3. Remove the receiving tray from thedelivery conveyor. (Fig.1)

4. Remove the motor cover. (Fig.1)

5. Remove the conveyor stay from thedelivery conveyor. (Fig.2)

6. Remove the idle pulley bracket fromthe delivery conveyor. (Fig.2, 3)

- Loosen the tension adjusting screw.

- Remove the four locking screws.

- The delivery conveyor belts can be

removed. (Fig.1)

4-5 Replacing the Delivery Conveyor Belt and Adjusting the Belt Tension

30mm

Fig.1

Fig.2

Fig.3

Receiving Tray

Motor Cover

Conveyor Stay

Motor Bracket Locking Screws

Conveyor Stay

Idle Pulley

Tension Adjusting Screw

Delivery Conveyor Side Frame

Install

1. Install the delivery conveyor in thereverse order of the removal.

(Adjusting the tension of the delivery conveyor

belt)

- The standard tension: The idle pulley bracket

is 30 mm (1.2”) from the delivery conveyor

side plate (Fig.3). After adjusting the tension,

lock the tension adjusting screw using the nut.

Delivery Conveyor Belt

Locking Screw

4-5 Replacing the delivery Conveyor Belt and Adjusting the Belt Tension

Idle Pulley Bracket

Idle Pulley Bracket

Locking Nut

Locking Screw(1.2”)


4-6 Replacing the Feed Rotor Belt and Adjusting the Belt Tension

Remove


2. Remove the feed table from themachine. ( “4-1 The Feed TableRemoval”)

3. Remove the rotor link A and B to-gether. (Fig.1)

4. Remove the rotor cover. (Fig.1)

5. Remove the N6 nut and the W6 largewasher locking the feed rotor sideframe. (Fig.1)

6. Remove the bearing of the feed rotordrive shaft from the feed table frame.- Do not need to remove the bearing from the

shaft.

7. Remove the tension pulley shaft andthe feed adjusting shaft from the feedrotor. (Fig.2)

- Remove the feed adjusting shaft by lifting up

the feed rotor side plate.

- The feed rotor belts can be removed.

Install

1. Replace the feed rotor belt.

2. Install the tension pulley shaft andthe feed adjusting shaft to the feedrotor.- Lock the tension pulley shaft at the lowest

position of the hole. (Fig.3)

- The screw of hexagon socket (SB4-30) is not

only the locking screw but also the stopper, so

fix the screw as shown in the Fig. 4.

3. Attach the rotor cover.

4. Install the rotor link A and B.

- Install them to the rotor so that you cansee the slit of the feed adjusting shaftfrom the window of the feed table in theview A. (Fig.5)

- After attaching them, check that therotor link B has no play and moves inthe B direction smoothly. (Fig.1)

5. Install the feed table to the machine.



AB

View A

ETW-5

N6

W4W4S

SB4-8

22 to 23mm

W4

W4S

N4SB4-30

W-4B4-6BC

N6W6(L)

Fig.1

Tension Pulley Shaft

Feed Adjusting Shaft

Rotor Cover

Feed AdjustingShaft

Lock the tension pulley shaft atthe lowest of the hole.

Feed adjust-ing shaft

Feed Table

RotorLink A

You can see the wide hole ofthe feed adjusting shaft.

Bearing

Feed Rotor Drive Shaft

Feed RotorSide Frame

Feed Rotor Side Frame


Fig.5

Fig.3

Fig.4

Fig.2

Rotor Link B

(0.86 to 0.90”)


4-7 Replacing the Motor Driver

Remove


2. Remove the second buckle plate.

3. Remove the delivery conveyor.

4. Remove the rear cover.

5. Remove the driver cover. (Four lockingscrews) (Fig.1)

6. Remove the connector and the cablefrom the driver. (Fig.2)

7. Remove the power box cover. (Threelocking screws) (Fig.1)

8. Remove the driver. (Fig.1) BRU

SHLE

SS D

C M

OTO

RD

RIV

ER F

BLD

120A

W

SPEE

DP

OW

ER

S.S

.

S.D

.

I/O

VE

XT

A

AC10

0-11

5V

ALA

RM

EX

T- I

NT

1 4 5 6 11 12

N.C.

MOTOR

WH

T

BLK

GR

N

EXT

INT

15

2

YE

L

GR

N

WH

T

RE

D

BR

N

GR

N

2 3 7 8 9 10

L FGN

Fig.1 Fig.2

Driver CoverLocking Screw

Power BoxCover

ToMotorM01

EF-35 is notnecessary toadjust them.

To Power SwitchS01

To ControlP.C.B.CON7

Turn thelever to INT

Driver Cover


a

a

ON14

9

Q20

14A

13mm

M01M01M01

M02M02

N4F

M02

4-8 Installing Standard for Other Parts

The installing position of the mainmotor pulley

- Install the motor pulley 13 mm (0.5”)apart from the side plate.

- Fasten the set screw on the flat face ofthe motor shaft.

The installing position of the deliv-ery conveyor motor pulley

- Insert the motor pulley up to the flat faceof the motor shaft.

- Fasten the one of set screws on the flatface of the shaft.

The install position of the countersensor

- Install the counter sensor, pushing up it.

The current setting of the pumpbreaker

- Set the volume to 14A.

Fasten the one of setscrews on the flat face ofthe shaft.

Delivery Conveyor Motor

TeethedWasher

GroundWire

MotorPulley

Lubricate 242Adhesives

Pump Breaker Q20

Motor Pulley Roller Motor

SetScrew

Fix the sheet sensor,pushing it up.

Sheet Sensor (B01)

Installing Position of DeliveryConveyor Motor Pulley

Installing Position of MainMotor Pulley

Installing Position of SheetSensor

Current Setting ofthe Pump Breaker

4-8 Installing Standard for Other Parts

(0.5”)



5. Electrical Parts Layout and Description5-1



5-2

EF-35

PAPER FOLDER

PAPER FOLDER

EF-35

PAPER FOLDER

PAPER FOLDER

S13

VR2S15

VR1

S11S12

S14

QPW-589

M02

M01

X03 M03

G01

Q20

K20

X02

X01

S01

Q10

B01Y01

U01


Code Name RemarksB01 Counter Sensor Light sensitive sensorG01 Power Supply 24VDCK20 Pump ContactorM01 Main Motor Brushless DC motor M02 Conveyor Motor Gear MotorM03 Pump 750WQ10 Breaker 5AQ20 Pump Breaker Setting Value: 14AQPW-589 Control P.C.BS01 Power SwitchS11 Roller / Feed StartS12 Roller / Feed StopS13 Test FeedS14 Pump Switch The circuit is closed during turning onS15 Conveyor Switch The circuit is closed during turning onU01 Main Motor DriverVR1 Conveyor SpeedVR2 Feed SpeedX01 Pump ConnectorX02 Conveyor ConnectorX03 Pump Terminal BoardY01 Suction Air Valve 24VDC

6. P.C.B and Wiring Diagram6-1

6. P.C.B and Wiring Diagram


6-1 QPW-589 Control P.C.B

1234

ON

L1

L9

L10

DSW

L4 L5

L81

1 1

1 1 1L7

L6

L2 L3

CON1CON1CON1


CON5CON5CON5 CON3CON3CON3 CON8CON8CON8

1234

ON

Control ROM


Control ROM Revision Chart

LED Lighting Conditions

L1 to L3, L9, L10: The output device of micon, which lights upand turns off according to the program.

L4 to L8: The direct monitor LED according to the signal input.

ControlROM

ControlP . C . B . S/N - Improvement

V3.1 QPW-589A 002001-1. The preset counter Off mode is added to theoperation mode of the preset counter. (Mode changesOFF-STOP-PAUSE-OFF.)

The ROM version number can be indicated on display from V2.10.(Indicated pressing the start button, stop button and test feed button atthe same time.)

2. The valve sounds even when the vacuum timing is setat minimum.

After replacing ROM, the total counter and the preset counter might notfunction correctly. Press the total counter clear button and the presetnumber save button.

3. The feed rotor vacuum LED lights up even if a sheet isfed by the test feeding.

When this ROM is installed on the machine up to serial number -004938,tell the new function to the users.

V3.4.1.1 QPW-589B 008001- The delivery conveyor can be operated onlycontinuously. (ROM only for QPW-589B)

The ROM V3.4 can be used from QPW-589D.

V3.4 QPW-589E 011001- Replace the control panel and P.C.B (QPW-589E or later).When the P.C.Board of QPW-589E or later is installed on the machine upto the serial number 010899, plug the short circuit connector into theP.C.Board, CON5. (The short circuit connector is supplied with P.C.B.)

V4.2 QPW-589F 020001- The connector (CON4) for KTU-35 is added. When this P.C.Board is replaced from QPW-589F or older, plug the shortcircuit connector into the CON4.

V4.2 QPW-589G 021001- The front and the back side of the ROMs are changed.This board has a compatibility with the QPW-589F.

When this P.C.Board is replaced from QPW-589F or older, plug the shortcircuit connector into the CON4.

V4.2 QPW-589H 024001-The spare DIP switch is installed. This board has acompatibility with the QPW-589F.

When this P.C.Board is replaced from QPW-589F or older, plug the shortcircuit connector into the CON4.

The delivery conveyor had worked only while the foldroller is driving. The intermittent operation mode isadded. The conveyor runs when a sheet has passedthrough the count sensor, and during the pause time.

LED NO. Lightening ConditionL1 During the pause time and after a preset stop.L2 Sheet is being vacuuming. (While vacuuming the sheets continuously, it blinks.)L3 While the counter sensor is detecting the sheet.L4 While the roller/feed start button is being pressed.L5 While the roller/feed stop button is being pressed.L6 While the test feed button is being pressed.L7 While the counter sensor is detecting the sheet.L8 When the EF-354 is connected with the ED-354.L9 When the preset stop mode is being selected.L10 When the preset pause mode is being selected.




6-2 100VAC Power Circuit Diagram

12345678

135

G01ACINACINFG

0V0V0VWHT

BLKGRN

BLK

BLK

WHT

BLK

WHT

GRNREDBLKWHT

RED

GR

N

GR

N

BLK

BLK

BLK

BLK

WH

TW

HT

BLK

WH

T

BLKFG FG

WH

T

WHT

WH

T

WH

TB

LKWH

TWHTBLK

GRN

24V24V24V

123456789101112

LNNCFG

U01

Power SupplyS01Power Switch

X01Connector

Q20Pump Breaker

K20Pump Contactor

X03Terminal Board

Pump

Main Motor

Main Motor Driver

Input Signal Terminal

Output Signal Terminal

Input /Output Ground

INPUT COMEXT.VR.CWCCWSLOW DOWNN.C.HMLGNDSPEED OUTALARM OUT

M01

M03

Q10Breaker

2

29

32

2 4 6 14

1 2 3

W01

230V 50Hz115V 60Hz

A1

A2

7643E

7643E

1 3 5

2 4 6


6-3 24VDC Wiring Diagram

1 2

Contact Signal for ED-354No use in EF-35

S15Conveyor switch

Y01Suction Air Valve

B01Counter Sensor S14

Pump switch

2

40

16

WHT

BLKWHT

GRN FGGRNBLK

GRN

GRNREDWHT

RED RED

RED

GR

N

FG FG

X01Connector

X02

Q20Pump Breaker

VR2Feed

Speed

VR1Conveyor

Speed

S13TestFeed

S12Stop

S11Start

K20Pump Contactor

PumpPump

M03

29

2 4 6 14

A1

A2

7643E

7643E

25931

25931

12345678

135

G01ACINACINFG

CN1

CN2

CON1

CON5 CON3

CON2

CON8

CON7

0V0V0V 24

V24

V 0V 0V 24V

SIG 0V

GN

DC

WV

R-H

VR

-MV

R-L

WHTBLK

GRN

GRNYEL

RE

DW

HT

BLK

GR

N

RE

DO

RN

WH

TB

LK

WHT

BLK

WHT

BLK

RE

DB

RN

BLK

WH

TG

RY

VIO

BLU

GR

NY

EL

OR

NR

ED

BR

N

RE

DB

RN

YE

LO

RN

BLU

GR

N

WH

TG

RY

VIO

RE

DB

RN

BLK

BRN

BLK

BLU

GR

NY

EL

WH

TR

ED

BR

N

GRNBLK

WHTREDBRNGRN

WHTRED

24V24V24V

123456789101112

U01

Power Supply

QPW-589Control P.C. Board

Main Motor Driver

INPUT COMEXT.VR.

CWCCW

SLOW DOWNN.C.

HML

GNDSPEED OUTALARM OUT

S01 S01W01

1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12

12 11 10 9 8 7 6 5 4 3 2 1

1 21 2

6 5 4 3 2 1

BR

NR

ED

RE

DW

HT

GR

NB

LK

14 13 11

34

Conveyor Motor

M02

3 2 1 1 2 3 4 3

NC

4 3

NC

4 3

NC

Main Motor

M01M04

6-3 24VDC Wiring Diagram



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EF-35 - Service Manual

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