Horizon PF-P3100 User Manual
I Introduction
• This service manual is for the following product.
Paper Folder PF-P3100
• Prior consent
This service manual is intended for use when repairing and maintaining this
machine to keep it in top working condition. In order for you to safely perform
repair and maintenance work on this machine, please make sure that you fully
read and understand all of the notes related to safety that are written throughout this service manual.
- Horizon International, INC. cannot accept responsibility for any loss, damage, or
injury as a result of unauthorized modification, misuse, or use outside the
machine’s specifications, or any unsuitable or inadequate maintenance performed
by you or by authorized service personnel.
- Horizon International, INC. is continuously working to improve the design and
performance of all of its products. Consequently, the contents of this service
manual may be changed at any time in the future without prior notice.
Furthermore, Horizon International, INC. bears no additional liability for any added
contents.
- All rights with regards to copyrights are reserved. The copying or distribution of
any part or whole of this manual is strictly prohibited unless prior written
permission is obtained directly from Horizon International, INC.
• Caution when undertaking service operations
- When replacing parts or performing other such maintenance operations, switch
the power supply Off before starting unless it is necessary to keep the power on.
Also, remove the power cable from the socket before starting for additional safety.
- When removing covers, be extremely cautious of rotating objects such as belts
and pulleys, and of electrical wiring etc.
- Always perform operations alone. This manual is written on the assumption that
operations will be performed by one person.
- Make sure that other people do not touch the machine during operation.
- When turning the power back on, wait for approximately 10 seconds after turning
the power Off before switching it On again.
- When replacing parts, use the parts shown in the parts book unless commercially
available parts with exactly the same functions and performance can be obtained.
• Safety precautions
- In order to perform repair or maintenance work safely on this machine, thoroughly
read all of the warnings and cautions related to safety that are written in this
service manual BEFORE commencing any operation. Failing to heed the safety
precautions in this manual may lead to accidents resulting in injury or death.
- The maintenance procedures and safety precautions described in this service
manual are only effective if the repair/maintenance procedures specified for this
machine are followed.
- Precautions that if not followed correctly may lead to accidents resulting in injury
or death are indicated by this heading.
- Precautions that if not followed correctly may lead to accidents resulting in
machine damage or malfunctions are indicated by this heading.
- It is impossible for Horizon International, INC. to prevent all possible dangers
related to this product and its use. Therefore, the precautions shown in this service
manual and warning labels displayed on the product do not completely warn
against all possible dangers.
- Some of the diagrams in this service manual are drawn with covers removed to
describe the details or internal sections of the machine.
Edited and Published by Horizon International, INC.
070608/PFP3100/00E/TM/HI,MT US503013-00
WARNING
CAUTION
I
II Symbols used in this manual
1. Wiring color character code
Single color wire color Compound line symbol
BRN = Brown = Brown PW = Power system Cabtire
RED = Red = Red GY = Heater system Likal wire
ORN = Orange = Orange SD = Cap for stepping motor
YEL = Yellow = Yellow Tire
GRN = Green = Green IO = Cabtire for I/O signal
BLU = Blue = Blue IL = Interlock system Cabtire
VIO = Violet = Violet CC = Each unit junction cord
GRY = Grey = Grey
WHT = White = White
BLK = Black = Black
PIN = Pink = Pink
SKY = Sky = Sky blue
BRNNE = The [NE] that follows the color mark is the dark gray band that
is attached to one of the wires for identification purposes when there are
2 of the same color wires within the same bundle of wires.
RED/BLU = The /BLU that follows the color mark indicates that the
mother color of the wire is blue, and that on top there is a RED colored
stripe.
2. Identification characters of electrical parts
A** = Inverter/driver NF** = Noise filter
B** = Sensor PW** = Power cable No.
C** = Capacitor Q** = Circuit protector/
E** = Heater Breaker
F** = Fuse QPM** = (multi layer) board
G** = Power supply QPW** = (Single layer) board
H** = Indicating lamp S** = Switch
HS** = Temperature sensor T** = Transformer
K** = Connector X** = Terminal board
L** = Lamp Y** = Solenoid/clutch/
M** = Motor Valve etc.
3. Circuit configuration identification characters and symbols
AC = Alternating current MS = Micro-switch
BK = Brake MOD = Module connector
BL = Short circuit connector NF = Noise filter
CL = Clutch NC = Normal [closed] contact
terminal
CN = Connector NO = Normal [open] contact
terminal
COM = Common terminal SSR = Solid state relay
CON = Connector VR = Volume
CW = Clockwise direction SL = Solenoid
CCW = Counterclockwise SIG = Signal voltage
direction
DC = Direct current S/N = Machine number
DSW = Dip switch RAP = Trouble recovery procedure
F.G = Frame ground BSD = Electric block diagram
GND = Ground *X## = * Connector
JSW =Jumper switch
1
1
Junction connector, or
2
2
terminal board
3
3
4
4
1
1
2
2
Round connector
3
3
4
4
Short circuit connector
BL
II
III Cautions when handling the print board and ROM
Even an small amount of static electricity that it cannot be felt by people will damage the board or ROM.
Exercise caution on the following points when handling the board or ROM.
Shield Bag
P.C.Board
Conductive
Sponge
Shield Bag
Keep Board in a
shield bag.
Put the ROM on a
conductive sponge
and keep in a shield
bag.
Clip
Wrist
Strap
Acrylic
Cover
Machine
Frame
Do not put Board and ROM on the
machine, especially on the acrylic
cover. (No problem on the
conductive plate.)
And keep the Board and ROM away
from the insulators.
Insulators: Plastic, form polystyrene,
chemical fiber fabric,
dry paper, etc.
When replacing the Board and
ROM, or setting the dip switches
and volumes on the Board, wear a
wrist strap, and connect the clip to
the machine frame (not painted
surface).
III
Table of Contents
I Introduction ........................................................................I
II Symbols used in this manual..........................................II
III Cautions when handling the print board and ROM.....III
3-3 Tray Gate Position Adjustment ...........................................3-4
3-4 Belt Tension Adjustment .....................................................3-5
3-5 Delivery Belt Replacement..................................................3-6
3-6 Micro-switch Adjustment .....................................................3-7
4 Mechanical Troubleshooting............................. 4-1
1 Installation and Mechanism.............................. 1-1
1-1 Installation .......................................................................... 1-2
1-2 Main Cover Removal.......................................................... 1-3
1-3 Buckle Chute Removal....................................................... 1-4
1-4 Mechanism of Folding ........................................................ 1-5
1-5 Feed Table ......................................................................... 1-6
1-6 Table Up/Down Mechanism ............................................... 1-7
1-7 Drive Section...................................................................... 1-8
1-8 Feed Roller Section............................................................ 1-9
1-9 Double Feed Stop Section ............................................... 1-10
1-10 Fold Roller Section......................................................... 1-11
1-11 Tray Gate Section .......................................................... 1-12
1-12 Delivery Section ............................................................. 1-13
1-13 Buckle Chute Section..................................................... 1-14
2 Service Mode and Error Code.......................... 2-1
2-1 Functions of Service Mode................................................. 2-2
2-2 Error Code Chart................................................................ 2-3
3 Adjusting and Checking Procedures ................ 3-1
3-1 Buckle Chute Stopper Angle Adjustment ........................... 3-2
3-2 Feed Clutch Unit Adjustment ............................................. 3-3
4-1 Machine Is Not Powered On ...............................................4-2
4-2 M10 Main Motor Does Not Rotate ......................................4-3
4-3 Tray Gate Malfunctions.......................................................4-4
4-4 Y01 Clutch Solenoid Does Not Activate..............................4-5
4-5 Buckle Chute Proximity Sensor Error .................................4-6
4-6 Delivery Belt Does Not Move ..............................................4-7
5 Folding Quality Troubleshooting.......................5-1
5-1 Sheets Are Wrinkled ...........................................................5-2
5-2 Corner of the Sheets Are Folded (Dog Ear)........................5-3
5-3 Uneven Folding...................................................................5-4
5-4 Fold Skewing ......................................................................5-5
5-5 Delivered Sheets Are Not Neatly Stacked ..........................5-6
5-6 Sheet Jams at the Tray Gate ..............................................5-7
6 Electrical Circuit................................................6-1
6-1 Electrical Parts Location and Description ...........................6-2
6-2 Power Circuit Wiring Diagram and Interlock Circuit ............6-5
6-3 QPM-243 Control P.C.B......................................................6-6
6-4 QPW-767/QPW-768 Buckle Chute LED P.C.B...................6-8
6-5 Firmwae Update................................................................6-10
IV
1 Installation and Mechanism
1-1............... Installation ............................................................................ 1-2
1-2............... Main Cover Removal ........................................................... 1-3
1-3............... Buckle Chute Removal ........................................................ 1-4
1-4............... Mechanism of Folding .......................................................... 1-5
1-5............... Feed Table............................................................................ 1-6
1-6............... Table Up/Down Mechanism.................................................. 1-7
1-7............... Drive Section........................................................................ 1-8
1-8............... Feed Roller Section.............................................................. 1-9
1-9............... Double Feed Stop Section.................................................... 1-10
1-10............. Fold Roller Section............................................................... 1-11
1-11 ............. Tray Gate Section................................................................. 1-12
1-12............. Delivery Section.................................................................... 1-13
1-13............. Buckle Chute Section........................................................... 1-14
1
Installation and Mechanism
1-1
1 Installation and Mechanism
1 - 1 Installation
Caution
- Do not install the PF-P3100 on an
unstable or tilted floor. Otherwise,
the folder may fall over or the
machine frame may be distorted,
and this could affect the machine
performance.
- The PF-P3100 weighs 37kg (81.4 lb.).
Install the PF-P3100 on the table
which can support this weight.
- This machine must be moved by at
least two people.
1 - 1 Installation
503013
1_1_1A
Delivery Roller
Assembly
Pin
1-2
1
2
503013
1_1_1B
Open the package and take the folder
out of the box.
- Take all the accessories out of the box, too.
Place the folder on the table. (Fig.1)
Attach the support table. (Fig. 2)
Open the delivery tray. (Fig. 2)
Attach the delivery roller assembly.
(Fig. 3)
- Insert the rear end of the pin in the rear hole, and
push back in the direction shown by arrow 1. Pull
the front end of the pin into the front hole in the
direction shown by arrow 2.
Plug the power cable to the PF-P3100.
(Fig. 4)
Delivery Tray
Fig.1
Fig.2
Support Table
503013
1_1_1C
Fig.3
Fig.4
Power Cable
503013
1_1_1D
1 Installation and Mechanism
Lock Screw for Control Panel
B4-8B
1 - 2 Main Cover Removal
Remove the cover F.
- Remove three lock screws.
- Loosen two lock screws of the control
panel.
- Lift the control panel, and disengage the
control panel from the cover F.
- Remove the cover F.
Remove the cover R.
- Remove four lock screws.
- Remove the cover R.
When attaching the cover, it is easier to attach
the cover once the buckle chute unit is
removed.
Engagement
Control Panel
Cover F
Cover F
Lock Screw for Control Panel
Lock Screw for Control Panel
Control Panel
B4-8B
B4-8B
Cover R
B4-8Bx4
1
Installation and Mechanism
1 - 2 Main Cover Removal
B4-8Bx3
503013
1_2_1A
1-3
1 Installation and Mechanism
A
1 - 3 Buckle Chute Removal
1 - 3 Buckle Chute Removal
1-4
Pull out the buckle chute.
- Pull out the buckle chute to the arrow direction
slowly until it stops. (Fig. 1)
Remove the stopper bracket.
- Remove four lock screws of the stopper bracket
on the buckle chute at the bottom of the buckle
chute. (Fig. 2)
Remove the buckle chute.
- Pull out the buckle chute to the arrow direction to
remove. (Fig. 3)
- Remove the stopper bracket from the main body.
(Fig. 3)
Fig.1
Buckle
Chute
503013
1_3_1
Buckle Chute
Frame R
Support Shaft 1
Support Shaft 2
Stopper
Bracket
Fig.3
Frame F
Stopper Bracket
Buckle Chute
503013
1_3_1C
Bottom Plane
Buckle Chute and Stopper Bracket
503013
Lock Screws
B4-6B4
1_3_1B
Fig.2
separated from the main body
Fig.4
503013
1_3_1D
1 Installation and Mechanism
1 - 4 Mechanism of Folding
Sheets are fed.
- The feed roller rotates and feeds sheet one by one
to the buckle chute. (Fig. 1)
The sheet hits the stopper.
- The sheet hits the stopper on the 1st buckle chute
and stops. (Fig. 2)
The sheet is bent slightly.
- The sheet stopped by the stopper is bent, and the
fold rollers catch the sheet bend. (Fig. 3)
- When the folding speed is set to “High”, the amount of
sheet bend is slightly changed. Set the stopper position 1 mm (0.04”) shorter than the normal setting.
- When the heavier sheet is folded, the amount of sheet
bent becomes smaller. Set the folding speed to “High”
to create bigger sheet bend.
The sheet is folded.
- The fold rollers catch the bending part of sheet
and sheet is folded.
- The fold position changes depending on the stopper position.
Feed Roller
Fig.1
Sheets
Double Feed Stop Plate
Stopper
1st Buckle Chute
2nd Buckle Chute
503013
1_4_1A
Feed Roller
Fold Roller
Bending Part
Fold Roller
Fig.3
Stopper
503013
1_4_1B
1
Installation and Mechanism
503013
1_4_1C
Fig.2
1 - 4 Mechanism of Folding
Fig.4
503013
1_4_1D
1-51-5
1 Installation and Mechanism
A
Slide Spring
1 - 5 Feed Table
Feed Table Sheet
Actuator
Sheet Guide
Support Table
1 - 5 Feed Table
The sheet guides can be
adjusted on this pivot.
Slide Spring
Slide Spring
1-6
Feed Angle
Adjusting Mechanism
Feed Table Sheet
Actuator
S12
Sheet Detection
Switch
This rod is
eccentric.
Feed Angle Adjusting Mechanism
Eccentric Rod
Lever Knob
Guide Shaft
The lever knob plates hold
the guide shaft and this fix
the guide position.
Slide Block
Guide Shaft
Slide SpringSlide Spring
503013
1_5_1
1 Installation and Mechanism
(Strong)
(Normal)
Section B
Section A
Section A
Section B
1 - 6 Table Up/Down Mechanism
Feed Roller
Feed Table
Feed Table
Fulcrum Shaft
Section A
Section A
Feed Table
Pressure Adjusting Lever
Feed Roller
Section A
Section A
(Strong)
(Strong)
(Normal)
(Normal)
Feed Table
Pressure Adjusting Lever
Pressure Lever
Feed Tray Lever
Feed Table
Pressure Spring
Pressure Lever
Lever Cam Spring
Section B
Section B
Feed Table
Feed Table
Pressure Spring
Feed Tray Lever Cam
Feed Tray
Lever
Feed Table
The tip of the feed table lowers
when the feed tray lever pushes
this shaft down.
This switch detects
that the feed table
is lowered.
Set the lever to "Strong" to
increase the feed table pressure.
Section B
Section B
Feed Tray Lever
S12
Feet Table
Pushdown Shaft
503013
1_6_1A
1
Installation and Mechanism
1 - 6 Table Up/Down Mechanism
1-7
1 Installation and Mechanism
M10 Main Motor
(DC brushless motor)
1 - 7 Drive Section
Feed Roller
1 - 7 Drive Section
1-8
Feed Drive Belt
Fold Roller
Delivery Section
Clutch Solenoid
Drive Timing Belt
M10 Main Motor
(DC brushless motor)
Delivery Drive Belt
Delivery Belt
Conveyor Pulley
Power Transport System
503013
1_7_1A
1 Installation and Mechanism
A
Inner diameter of the clutch spring
1 - 8 Feed Roller Section
Free Bearing
Fixed Bearing
Feed Roller Shaft
Feed Roller
Feed Roller
Clutch Unit
Double Feed Stop Plate
Sheet
Double Feed Stop Plate
Feed Table
Feed Table
Clutch Stopper
Clutch Pulley
Fixed Bearing
Feed Roller
Insert the feed roller shaft.
Clutch Lever
Clutch SolenoidClutch Solenoid
Inner diameter of the clutch spring
Twist
Inner
Diameter
Clutch Spring
Clutch
Stopper
Clutch Pulley
Enlarged
Inner
Diameter
Clutch Bushing
Clutch Lever
Clutch
The feed roller rotates to the
arrow direction and feeds sheet.
The rotation of the clutch stopper
stops when the clutch lever lowers.
The clutch spring is twisted to
the arrow direction, and the inner
diameter of
the clutch spring is enlarged.
Since the inner diameter of the
clutch spring is enlarged, the power
transmission to the feed roller shaft is
shut off, and the clutch bushing is
slipped on the clutch pu
lley.
The feed roller does not rotate although
the clutch pulley rotates.
Solenoid
503013
1_8_1
1
Installation and Mechanism
1 - 8 Feed Roller Section
1-9
1 Installation and Mechanism
1 - 9 Double Feed Stop Section
1 - 9 Double Feed Stop Section
1-10
Feed Roller
Double Feed
Stop Plate
Double Feed Stop Plate
Double Feed
Stop Pressure
Feed
Pressure
Feed Table
Feed Roller
Sheet
Feed Table
Plate Pressure Spring
Plate Stand Lever
Double Feed Stop Plate
Plate Bracket Lever
Feed Roller
Feed Roller
Double Feed Stop Plate
Plate Pressure Adjusting Plate
Plate Pressure Spring
Second sheet is stopped by the
friction of the double feed stop plate.
Plate Bracket
Plate Pressure Adjusting Plate
Plate Pressure
Low"
"
503013
1_9_1A
1 Installation and Mechanism
Solenoid O
N =
When the tray gate
is at right.
- When the solenoid
turns ON, the tray gate
comes close to the third
roller.
- The sheet that comes
through the second and
third
roller goes over
the tray gate and is
delivered.
Solenoid OFF =
When the tray gate is at left.
-
When the solenoid
turns OFF, the tray gate
moves to the left and
makes a space between
the tray gate and the
third roller.
- The sheet that comes
through the second and
third roller deflects at
the tray gate, then goes
to the second buckle
chute through the third
and fourth roller.
1 - 10 Fold Roller Section
Transport Rubber Roller
Upper Guide Plate
Transport Rubber Roller
Hold Spring
R Gate
Fold Roller 2
Tray Gate
Fold Roller 4
1
Installation and Mechanism
2
4
1
3
5
Fold Roller 1
Fold Roller 3
Fold Roller 5
Feed Roller
Feed Roller
1st Buckle Chute
Solenoid O
When the tray gate
- When the solenoid
turns ON, the tray gate
comes close to the third
roller.
- The sheet that comes
through the second and
third
Feed Table
2nd Buckle Chute
roller goes over
the tray gate and is
delivered.
Solenoid OFF =
When the tray gate is at left.
When the solenoid
turns OFF, the tray gate
moves to the left and
makes a space between
the tray gate and the
third roller.
- The sheet that comes
through the second and
third roller deflects at
the tray gate, then goes
to the second buckle
chute through the third
and fourth roller.
1 - 10 Fold Roller Section
N =
is at right.
Press the fold driven rollers.
Roller Pressure Link
2
4
2
4
Fold Roller Spring
Feed Roller
Sheet
3
1
2
3
Tray Gate
3
4
1st Buckle
nd Buckle
2
5
5
503013
1_10_1A
1-11
1 Installation and Mechanism
A
When Solenoid ON:
When Solenoid OFF:
1 - 11 Tray Gate Section
1 - 11 Tray Gate Section
1-12
Gate Solenoid
(front)
Gate Lever (front)
Tray Gate Section
Gate Bracket
Tray Gate
Gate Fulcrum Shaft
Gate Fulcrum Shaft
Gate Solenoid (front)
When Solenoid ON:
When Solenoid OFF:
Adjust the tilt of the tray gate and the
internal contact with the 14 hole by adjusting
the tray gate bracket using these two holes.
Gate Lever (front)
Tray Gate
Side Plate
Gate Bracket
The stop position of the tray
gate is where the gate hits
inside the 14 hole on the
side plate.
14 hole on the side plate
Lock the tray gate with this screw.
Tray Gate Bracket
503013
1_11_1
1 Installation and Mechanism
A
M10
M10M10M10M10M10M10
M10
Tension Adjustment
of the Delivery Belt
1 - 12 Delivery Section
M10
M10
M10M10M10
Main Motor
M10
M10
Delivery Tray
Conveyor Pulley
Delivery Belt
Main Motor
M10M10
Delivery Belts
Tension Adjustment
of the Delivery Belt
Adjust the belt tension
by fixing position of the
shaft.
Conveyor Pulley
503013
1_12_ 1
1
Installation and Mechanism
1 - 12 Delivery Section
1-13
Loading...