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Kyoto,Japan

030904/EF35/00E/NT

EF-35

Paper Folder

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

US503008-00

FOREWORD
Paper Folder
Model EF-35

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 inadequate
maintenance by the customer; unauthorized modification or misuse; or operation outside of the environmental specifications
for 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 the
prior written consent of Horizon International Inc.

Safety Precautions
- Please read and understand all safety instructions with include the terms
instructions are ignored, personal injury may result.

WARNING, and

CAUTION. If these safety

- The repair, maintenance and safety instructions in this manual are valid only when the repair or maintenance work is performed
according 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 may
also be used to alert against unsafe practices.
- Horizon International Inc. cannot anticipate every possible situation that might involve a potential hazard. The instructions in this
manual 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, repair
or maintenance could cause injury to personnel. Do not attempt to operate any switch, valve, or other energy isolating device
when 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.

II

Service Operation Precaution


1. Turn off power switch and pull out the plug for precaution
except in case of neccesity before parts replacement or other
maintenance operations.
2. Mind rotating parts such as belt and pulley or electric cables
when operating with covers removed.
3. A single operator must operate yourself only. This manual
supposes operations by a single operator.
4. Caution that other persons do not touch the machine during
your service operations.
5. When turning on power switch again, wait for a dozen of
seconds after turning off.
6. When replacing parts, use parts shown in parts book except
when the same functions can be found among commercial
parts.

III

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.

Acrylic
Cover

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.

Shield Bag
P.C.Board

Conductive
Sponge

Clip

Put the ROM on a conductive sponge


and keep in a shield bag.

Machine
Frame

Shield Bag

Wrist
Strap

IV

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).

Description of Abbreviations in This Manual


1. Cable Colors
Abbr. BRN RED
Color Brown Red

ORN YEL
GRN
Orange Yellow Green

BLU VIO
GRY
Blue Violet Gray

WHT BLK
White Black

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.
2. Electrical Symbols
Abbr.
Axx
Bxx
Cxx
Fxx
Gxx
Kxx

Description
Inverter
Sensor
Capacitor
Fuse
Power Supply
Contactor

Abbr.
Lxx
Mxx
Hxx
Qxx
QPMxx
QPWxx

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

Abbr.
Sxx
Txx
Uxx
Xxx
Yxx
Zxx
Wxx

Description
Switch
Transformer
Driver/ Inverter
Terminal Board, Connector
Valve
Noise Filter
Power Plug

3. Other Symbols
Abbr.
AC
BK
CL
CON
CW
CCW
DC

Description
Alternating Current
Brake
Clutch
Connector
Clockwise
Counterclockwise
Direct Current

Abbr.
DSW
F.G
JSW
MS
PB
RY
SSR

Description
Dip Switch
Frame Ground
Jumper Switch
Microswitch
Parts Book
Relay
Solid State Relay
V

Abbr.
VR
Sig
S/N

Description
Volume
Signal
Serial Number (of machines)

CONTENTS
3. Troubleshooting for Folding Quality

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

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

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


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

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


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

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

3-4 The Thick (Hard) Sheets Delivered


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

1. Before You Begin

3-5 Either or both sides of the sheet edge are bent ............ 3-5
3-6 Double Step Folding Occurs ......................................... 3-6

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


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

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

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


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

4. Replacement and Adjustment

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

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


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

2. Troubleshooting

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


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

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

4-5 Replacing the Delivery Conveyor Belt


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

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


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

4-6 Replacing the Feed Rotor Belt


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

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


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

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


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

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

VI

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

VII

This page is intentionally left blank.

VIII

1. Before You Begin

1-1

1. Before You Begin

1-2

1. Before You Begin

1-1 Machine Description


1-1-1 Overview
Fixed Fold Roller

First Roller
First Nut

First Buckle Plate

The gap between the first roller


and the fixed fold roller can be
adjusted using this nut.

Second Nut

Feed Rotor

The gap between the second


roller and the first roller can be
adjusted using this nut.
0

Second Roller
Third Roller

Third Nut

The gap between the third roller


and the second roller can be
adjusted using this nut.

Feed Table

Second Buckle Plate

Tension Pulley Shaft


The tension of the feed rotor belt can
be adjusted by this shaft position.

Feed Rotor Drive Shaft


Drive Belt
Conveyor Belt
Conveyor Motor
Timing Belt

Drive Motor M01

Conveyor Motor M02


Idle Pulley Bracket

Drive Belt Tension Spring

The tension of the conveyor belt can be adjusted


by moving this bracket.

The drive belt is tensed up with


this spring.

Tension Adjusting Nut


The tension of the drive belt can be
adjusted using this nut.

1-1 Machine Description


1-1-2 Control Panel (1)
Feed Rotor Vacuum LED
This LED lights while the feed rotor is
providing vacuum to sheet, and blinks when
the continuous folding mode is selected.

Feed Sensor LED


This LED lights each time a sheet passes
through the feed section.

Pause LED
This LED lights while the machine is
paused, and also after a preset stop.

Feed Interval Knob


This knob is used to adjust the feed interval.

Pump Switch

Vacuum Time Knob

When switched on in motor running, the


air blow into feed table.

This knob is used to adjust the vacuum time for


the feed rotor. When the knob is turned all the
way to the right, the LED blinks and the feed
rotor provides vacuum continuously.

Fold Speed Knob

Pause Time Knob

This knob is used to adjust the rotating


speed of the fold rollers.
When the knob is turned all the way to
the left, the fold rollers might stop
rotating.

This knob is used to adjust the pause time


between one batch of sheets and the next
batch when the preset pause mode is selected.

Test Feed Button

3
4

When this button is pressed while the motor is


running, one sheet will be fed.

Conveyor Switch
This switch is used to change the operating mode of the conveyor.
When
is selected, the conveyor
operates continuously.
When
is selected, the conveyor
operates only after a sheet has passed
through the feed sensor, and during the
pause time.

1-3

Roller/ Feed Start Button


3
4

This button is used to start feeding the sheets.


Press this button once to start the motor, the
roller, delivery conveyor, and the pump. Press
this button again to start the feeding operation.

Conveyor Speed Adjusting Knob

Roller/Feed Stop Button

This knob is used to adjust the conveyor


belt speed. When the knob is turned all
the way to the left, the delivery conveyor
belts might stop rotating.

When this button is pressed once, the machine stops feeding the sheets. Press this
button again to stop the motor, the roller,
delivery conveyor and the pump.

1-1 Machine Description

1. Before You Begin

1-4

1. Before You Begin

1-1 Machine Description


1-1-2 Control Panel (2)
Total Counter
This indicates the total number of folded
sheets.

Total Counter Clear Button


The total counter can be reset using this button.

Preset Counter
This indicates the number of sheets to be folded
in preset stop mode or preset pause mode.

Preset Number Save Button


This button is used to save the preset number. The preset
number can be viewed again by pressing this button even if
the machine has stopped during the folding operation
because it reached the preset stop number.

3
4

Preset /Number Set Button


3
4

These button are used to set the preset number. The


buttons set the units, tens, hundreds, and thousands
digit from the right respectively.
Each number can be changed by pressing the
correct button.

Mode Select Button


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

This button is used to change the mode for


continuous folding, preset stop, and the preset
pause counter.

1-2 Other Information


The angle of the feed table
~S/N008899

Up to S/N008899
Installed by inclining about 10 degrees upward to
the sheet feeding direction.

10

The angle of the feed table is changed to


the level to feed the thin sheets stably.

S/N009001-014899

S/N009001-014899
Installed on the level.

1-5

1-2 Other Information

1. Before You Begin

1-6

1. Before You Begin

This page is intentionally left blank.

2. Troubleshooting

2-1

2. Troubleshooting

2-2
2. Troubleshooting

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


First Check
- The gap between the gate plate and the
feed 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 not
correct.
- The sheets are not separated correctly.
- The blower air is too weak.
If the pump filter is clean, make the air pressure
stronger using the regulator on the blower. Even if
the blower air is still weak after adjusting the air
pressure, check that the blower air hose is
connected tightly using the hose clamp.

The blower and vacuum pump do not


operate.
- 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 closed


completely, or closed almost, the blower
and the vacuum pump is overloaded.
Release the air from the unused outlet.

- The vacuum of the feed rotor is too weak.


If the pump filter is clean, make the vacuum
stronger using the regulator on the vacuum pump.
Even if the vacuum is still weak after adjusting the
vacuum, check that the vacuum hose is connected
tightly using the hose clamp.

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.

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

R
DE
OL
RF
PE
PA

EF
-35

- 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.

X01

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.

Q20
K20

Fig.1
2-3

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

2. Troubleshooting

2-4
2. Troubleshooting

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

Adjust the roller speed using the fold speed knob.

S14

WHT

First Check
- The roller speed setting is too slow.

Pump Switch

2 4 6

S01

WHT
RED
WHT
BLK
FG

7
6
4
3
E

7
6
4
3
E

2
29

M01

BRUSHLESS DC MOTOR
DRIVER FBLD120AW
SPEED

POWER

S.S.

ALARM

S.D.

EXT-INT

Power Lamp
Alarm Lamp

MOTOR

GRN

BLK

RED

Connector

Q20

Pump Breaker

2
3
4
5

A1

K20

A2

Pump Contactor

I/O

7
GRN

2 4 6 14

- Check if the power LED (green) of the


main motor driver (U01) lights up.

WHT
BLK

32
WHT
BLK

If it does not light up, check if the input wiring is


connected with the driver.

Main Motor

X01

WHT
BLK
BLK

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.

Control P.C. Board

QPW-589

GRN
RED
BLK
WHT
FG

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


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

CON3
BLK

BLK

BLK

9 10 11 12
WHT

WHT

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

WHT

- 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.

1 3 5
BLK

The circuit breaker Q10 is tripped.

RED
WHT
BRN
RED

Power Switch

X03

GRN

10

NC

11
12

FG
VEXTA

1 2 3

U01

Terminal Board

Pump

AC100-115V~

Main Motor Driver

M03

Fig.2

2-1 The Sheet is not Fed (Because Feed Rotor does not Rotate)
The drive mechanism of the feed rotor is
normal. 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. (

Reduction Pulley

4-6

M01

Replacing the Feed Rotor Belt and Adjusting the


Belt Tension)

Pulley
Belt

Feed Rotor Section


- Check if the feed rotor rotates smoothly.

Tension Roller

Remove the feed rotor belt and check the feed


rotor.

Feed Rotor Belt

Fig.3
2-5

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

2. Troubleshooting

2-6
2. Troubleshooting

2-2 A Sheet Jam Occurs Frequently


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 the
fold roller is too wide. (Fig.1)
- If the sheet is thick and it does not enter
the first buckle, widen the gap between the
buckle plate and the fold roller. (Fig.1)
- Actually, the double feeding occurs.
Point Driver

If the double feeding occurs, check the followings.

1. Fan the sheets.


2. Turn the rear blower air nozzle away from
the sheets to reduce the blower air.
3. Narrow the gap between the gate plate and
the feed rotor.
4. Shorten the vacuum time.
5. Make the feed interval longer.

Guide Screw

The fold roller is not cleaned up.


The gaps between the fold rollers are not
provided correctly.
- Refer to 4-3 Adjusting the Fold Roller
Gap and adjust the gaps between the
fold rollers.

Fig.1

2-3 The Total Counter does not Count Up

2-4 The Counter Sensor Keeps Lighting Up

The position of the counter sensor is not


correct

First Check
- The paper dust sticks to the sensor.

The counter sensor does not work correctly.


- When the counter sensor detects the
sheet, check if the L7 on the P.C.B lights
6-1 QPW-589 Control

- When the counter sensor detects nothing,


check if the L7 on the P.C.B does not light
up. (Fig.1)

B01
Counter Sensor

When L7 lights up,


- The signal wiring might be short circuited, or

13
CON5

CON1

the P.C.B might be damaged.


If there is no defect between the control

CON8

5 6 7

CON3

L8

L7

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


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

- 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 CON3Terminal 6 and 7 measures 24VDC.
When does not light up,
- The signal of the counter sensor might not be

5 6 7
24V
SIG
0V

When lights up,

order.
- The voltage between CON3-Terminal 5 and 7

CON3

always measures 24VDC. When the sensor


detects the sheet, the 24VDC between CON3-

L2

L1

L3

Terminal 6 and 7 is measured.

Control P.C.Board
QPW-589

1234

P.C.B)

13

When L7 does not light up,

L9

ON

up. (

The counter sensor works correctly.

BRN
BLK
BLU

- Refer to 4-8 Installing Standard for Other


Parts and check the installing position of
the count sensor.

L4 L5 L6

L10

- There are no defect in the counter sensor and


the wiring. There is a defect on the control

CON7

CON2

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

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.

2-7

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

Fig.1
2. Troubleshooting

2-8
2. Troubleshooting

2-5 The Circuit Breaker (Q01) is Tripped

2-6 The Folding Speed Reduces

The alarm LED of the main motor driver


lights up.

The drive belt slips on the pulleys.


- When the drive belt slips on the pulleys,
even if the belt is cleaned up, adjust the

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


if the rotation of the fold rollers is heavy.

belt tension. (

4-4 Adjusting the

Tension of Drive Belt)

The following wiring circuit is short circuited. (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.
Power Supply

WHT

WHT
BLK

WHT
WHT

Drive Belt

WHT 1 ACIN
BLK ACIN
3
GRN FG
5

2 4 6

S01

Q10

Power Switch

Breaker

1 3 5

230V 50Hz
115V 60Hz
BLK

WHT

BLK

W01

0V 1
0V 2
0V 3

G01

4
5
24V 6
24V 7
24V 8

Main Motor Driver

U01

BLK

FBLD120AW

WHT L
BLK N

WHT

GRN

M01

NC
FG

M01

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

(Tension Adjustment for the new belt)

Screw Part of Hook

Main Motor

12mm
(0.47)

Fig.1

Stopper Shaft

2-7 The Delivery Conveyor does not Operate


The delivery conveyor is operated in two
modes.
- Continuous Mode:
The delivery conveyor works while
the fold rollers rotates.
- Intermittent Mode:
The delivery conveyor works only
when a sheet has passed through the
counter sensor and during the pause
time.
First Check
- The connector of the delivery conveyor is
connected with the control P.C.B.
- The speed of the delivery conveyor is set to
the minimum.

GRN FG
9 9 GRN
GRN
3 3 RED
WHT
BLK

34

GRN
BLK

11

CON5

CON1
1

M02
Conveyor Motor

CON8

L7

L8

The wiring between the control P.C.B


(QPW-589), CON8 and the conveyor motor
M02 is not correct. (Fig.1)

X02

1 2

CON3

11

- If it is correct, replace the conveyor motor


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

L3

L2

Control P.C. Board


QPW-589

1234
ON

L9

L4 L5 L6

L10
1

CON7

CON2

Fig.1
2-9

2-7 The Delivery Conveyor does not Operate

2. Troubleshooting

2-10
2. Troubleshooting

This page is intentionally left blank.

3. Troubleshooting for Folding Quality

3-1

3. Troubleshooting for Folding Quality

3-2
3. Troubleshooting for Folding Quality

3-1 The Sheets are Folded Diagonally


First Check
- The feed guides are not parallel to the
feeding direction.
- The gap between the feed guide and the
sheet is too wide.
- The buckle stopper is inclined.
- The guide screws for the buckle on each
side project by the same amount. (The
buckle plate is inclined in the relation to the
rest of the machine.)
- The sheet is not square because it has
been trimmed incorrectly.
- The sheets are wavy because of the
humidity.
- The sheets are curled.

The inner ring in the needle bearing is


worn out.

The gaps between the fold rollers are not


provided 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 damaged. (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)

Set Screw
Link Spring Stopper
Roller Tension Spring
Washer

Nut

Washer
Link

Fig.1

Needle Bearing
Inner Ring

3-2 The Fold Line Moves Gradually


First Check
- The buckle stopper locking screw is tightened completely.
- The buckle plate is not correctly set in
relation 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. (

3-3

3. Troubleshooting for Folding Quality

3-4
3. Troubleshooting for Folding Quality

3-4 The Thick (Hard) Sheets Delivered are not Arranged Straight
The position of the delivery rollers are not
correct. (Fig.1)
- Set the delivery rollers so that the delivered sheet is held under the delivery
rollers immediately.

Delivery Guide
Delivery Roller

The position of the delivery guides are not


correct. (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 not
correct. (Fig.2)

Fig.1

- Set the delivery conveyor to reduce the


angle for the sheets which are thick and
easy to open.

Conveyor (Normal Angle)

Delivery Conveyor

Conveyor (Low Angle)

Easy to open

Set the flat plate under


the conveyor to make the
angle low.
Fig.2

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


(The sheet is bent downward)

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

(Either side of the sheet is bent)

(Inner edge of the sheet rolls)

(Fig.1)

- 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.

- The deflector is inclined.


(The buckle plate installing the
deflector might be inclined in rest
of the machine.)

- 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.

- The sheet is curled downward.


- The buckle plate is set at the high
position.

(Hitting the deflector) (Fig.3)


- The sheet hits a scratch on the
deflector surface.
- The pressure of the second fold
roller (press roller) is too strong.
- The distance between the buckle
chute and the fold roller is too
narrow.

2
3

2
Fig.1 Dog Ears-Downward Folding

Fig.2 Dog Ears-Upward Folding

Fig.4 Inner Folding

3
Fig.3 Hitting the Deflector
3-5

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

3. Troubleshooting for Folding Quality

3-6
3. Troubleshooting for Folding Quality

3-6 Double Step Folding Occurs

3-7 The Sheet is Wrinkled Crossing the Fold Line

The roller pressure of the third fold roller


is too strong.

- 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.

- 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)

Third Fold
Roller Shaft

Pulley

3
Air Pocket:
It is caused that the
roller pressure is too
strong and the air can
not be released from
the sheet inside.
Fig.1 Double Step Folding

Fig.2 Pulley and Fold Roller Shaft

Fig.1 Wrinkled Crossing the Fold Line

4. Replacement and Adjustment

4-1

4. Replacement and Adjustment

4-2
4. Replacement and Adjustment

4-1 Removing Feed Table


Removal

1.
2.
3.

Remove the front cover.

4.

Remove the feed table from the


machine.

Remove the belt. (Fig.1)


Remove the vacuum hose and the
blower air hose from the bottom of
the feed table. (Fig.1)

- Remove the feed table, lifting up it.

Vacuum Hose
Blower Air Hose

Belt

To Pump

Fig.1

This page is intentionally left blank.

4-3

4. Replacement and Adjustment

4-4
4. Replacement and Adjustment

4-2 Replacing the Fold Roller


Remove

Install

1.
2.
3.
4.
5.

1.

Turn off the main power.

Remove the drive belt. (Fig.1)

2.

Remove the manual drive knob. (Fig.1)


Remove the roller pulley. (Fig.1)
- The washer is also removed.

7.
8.

Remove the side plate only on the


front side. (Fig.1)
Remove the roller link on the front
side, 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 necessary to remove.

9.

Remove the fold roller to the front


side.

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.

- The washer is also removed.

6.

- Lock the roller pulley, pulling the fold


roller to the front side and pushing the
pulley to the rear side.
- After installing the roller pulley, check
if the fold rollers can be rotated
smoothly.
If it is difficult to rotate, install the
pulley at the front side a bit more.
- At the end, check if all the four fold
rollers can rotate smoothly and the
play of the fold rollers to both side are
least.

4-1

Removing Feed Table)

3.

Insert the washer and the roller pulley


into the fold roller.

Insert the fold roller.


- Before installing the fold roller, lubricate the
inner ring of needle bearing.

Remove the front and the rear cover.


Remove the feed table. (

4.

Install the side plate.

5.
6.

Install the manual drive knob.


Install the drive belt. (Fig.4)
- Attach it by the correct direction.
- After attaching the belt, adjust the tension of
it. (

7.

Drive Belt)

Adjust the gap between the fold


rollers.
(

After installing the side plate, check if the


roller link can be moved by pressing the
roller links as shown by the arrow. (Fig.3)

8.
9.

4-4 Adjusting the Tension of

4-3 Adjusting the Fold Roller Gap)

Install the feed table into the machine.


Install the front and the rear cover.

4-2 Replacing the Fold Roller

Side Plate
W5
SB5-12

Link

Washer
SS6-6 SS6-6

Manual Drive Knob


Washer
Roller Pulley

Drive Belt

Side Plate

Fig.1

Fig.3
Screw with
Hexagon Socket

Rounded Part

Buckle Locking Knob

Link Stopper Shaft

Fixed Fold
Roller Link

Set Screw
Roller Link Spring Stopper
Hole of Roller Link

Nut
Lubricate here, Before
installing.
Link

12mm

Fig.2
4-5

Fig.4
4-2 Replacing the Fold Roller

4. Replacement and Adjustment

4-6
4. Replacement and Adjustment

4-3 Adjusting the Fold Roller Gap


Before Adjusting

Adjust

1.

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 second


buckle plates.

3.

Remove the feed table from the


machine.
(

4-1 Removing Feed Table)

4.

Remove the front and the rear covers.

5.

Check if the set screw of the roller


link spring stopper is fasten firmly.

WARNING
When adjusting the fold roller
gap, keep your hands and fingers
off the fold rollers. Otherwise the
fold rollers can cause severe
personal injury.

Turn on the main power and rotate


the fold rollers.

3.

- Set the roller speed to 3 or 4.

2.

Insert the one strip between the fixed


fold roller and the first fold roller, and
check 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 gradually and evenly.

When the nut is loosen for one round, the


fold roller gap will be narrower about 0.8
mm (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.

Also, insert the one strip between the


first fold roller and the second fold
roller (Fig. 2), and adjust the pulling
force.
- Adjust it using the second nut.

4.

Next, insert the two strips between


the second fold roller and the third
fold roller (Fig. 2), and check the
pulling force.
- Adjust it using the third nut.

5.

After adjusting the pulling force,


check the roller gap as well after
changing 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.

4-3 Adjusting the Fold Roller Gap

6.

After inserting the thick sheet of the


210 gsm or thicker between each fold
rollers a few times, check the pulling
force of each fold roller again.

Set Screw

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.

Feed Table

First Buckle Plate

Second Nut

Install the buckle plate and the feed


table, and fold the required sheets
thirty times continuously.
After that, check the pulling of strip in
step 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.

Set Screw

Set Screw

3
First Nut
Third Nut
Second Buckle Plate

Number of insert
test strip
One
Strip

Drive Motor

One
Strip

0
1

2
3

Two
Strips
Rotating
Direction

Fig.2
Fig.1
4-7

4-3 Adjusting the Fold Roller Gap

4. Replacement and Adjustment

4-8
4. Replacement and Adjustment

4-4 Adjusting the Tension of Drive Belt


Adjust

1.
2.

Turn off the main power.


Adjust the tension of the drive belt
using the hook screw.

Drive Belt

(Tension Adjustment for the new belt)


- The screw part of hook comes out about 12
mm (0.47) from the stopper shaft.
M01

(Tension Adjustment for the new belt)

Screw Part of Hook

12mm
(0.47)

Stopper Shaft

Fig.1

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

1.
2.

Install

1.

Turn off the main power.


Remove the delivery conveyor from
the machine.

3.

Remove the receiving tray from the


delivery conveyor. (Fig.1)

4.
5.

Remove the motor cover. (Fig.1)

6.

Remove the conveyor stay from the


delivery conveyor. (Fig.2)

Install the delivery conveyor in the


reverse order of the removal.

Conveyor Stay

Idle Pulley

(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.

Conveyor Stay
Motor Bracket Locking Screws

Remove the idle pulley bracket from


the delivery conveyor. (Fig.2, 3)
- Loosen the tension adjusting screw.
- Remove the four locking screws.
- The delivery conveyor belts can be
removed. (Fig.1)

Locking Screw
Idle Pulley Bracket

Fig.2
Receiving Tray

Tension Adjusting Screw


Delivery Conveyor Side Frame

Delivery Conveyor Belt


Idle Pulley Bracket

Locking Nut
Locking Screw
Motor Cover
Fig.1
4-9

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

30mm
(1.2)

Fig.3
4. Replacement and Adjustment

4-10
4. Replacement and Adjustment

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

Install

1.
2.

Turn off the main power.

1.

Replace the feed rotor belt.

Remove the feed table from the


machine. (
4-1 The Feed Table

2.

Install the tension pulley shaft and


the feed adjusting shaft to the feed
rotor.

Removal)

3.

Remove the rotor link A and B together. (Fig.1)

4.
5.

Remove the rotor cover. (Fig.1)

6.

Remove the N6 nut and the W6 large


washer locking the feed rotor side
frame. (Fig.1)
Remove the bearing of the feed rotor
drive shaft from the feed table frame.

- 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.
4.

- Do not need to remove the bearing from the


shaft.

7.

Attach the rotor cover.


Install the rotor link A and B.
- Install them to the rotor so that you can
see the slit of the feed adjusting shaft
from the window of the feed table in the
view A. (Fig.5)
- After attaching them, check that the
rotor link B has no play and moves in
the B direction smoothly. (Fig.1)

Remove the tension pulley shaft and


the feed adjusting shaft from the feed
rotor. (Fig.2)
- Remove the feed adjusting shaft by lifting up
the feed rotor side plate.
- The feed rotor belts can be removed.

5.

Install the feed table to the machine.

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

Tension Pulley Shaft

Rotor Cover
Feed Adjusting
Shaft

N6
W6(L)

Feed Adjusting Shaft

22 to 23mm
(0.86 to 0.90)

Feed Rotor Drive Shaft


Bearing

SB4-8

Fig.4

ETW-5

W4S
W4

Feed Rotor
Side Frame

Rotor Link B

W-4
B4-6BC

Rotor
Link A

N6

W4
W4S

B
View A

Fig.1

You can see the wide hole of


the feed adjusting shaft.

N4
SB4-30

Fig.5

Feed Rotor Side Frame

Fig.2
Feed adjusting shaft
Feed Table

4-11

Lock the tension pulley shaft at


the lowest of the hole.
Fig.3

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

4. Replacement and Adjustment

4-12
4. Replacement and Adjustment

4-7 Replacing the Motor Driver


Remove

To Control
P.C.B.
CON7

Remove the delivery conveyor.

To
Motor
M01

Fig.1

12

VEXTA
GRN FG

GRN
11

N.C.

BRN
9

BLK

EF-35 is not
necessary to
adjust them.

10

RED

WHT

Power Box
Cover

Driver Cover
Locking Screw

WHT

YEL
4

I/O

ALARM

POWER

Remove the driver. (Fig.1)

AC100-115V

8.

S.S.

Remove the power box cover. (Three


locking screws) (Fig.1)

GRN

EXT

Remove the connector and the cable


from the driver. (Fig.2)

INT

EXT-INT

Remove the driver cover. (Four locking


screws) (Fig.1)

15

Turn the
lever to INT

Driver Cover

S.D.

Remove the rear cover.

SPEED

7.

Remove the second buckle plate.

BRUSHLESS DC MOTOR
DRIVER FBLD120AW

6.

Turn off the main power.

MOTOR

1.
2.
3.
4.
5.

Fig.2

To Power Switch
S01

4-8 Installing Standard for Other Parts


The installing position of the main
motor pulley
- Install the motor pulley 13 mm (0.5)
apart from the side plate.
- Fasten the set screw on the flat face of
the motor shaft.

The installing position of the delivery conveyor motor pulley


- Insert the motor pulley up to the flat face
of the motor shaft.
- Fasten the one of set screws on the flat
face of the shaft.

The install position of the counter


sensor
- Install the counter sensor, pushing up it.

Fasten the one of set


screws on the flat face of
the shaft.
Delivery Conveyor Motor
Lubricate 242
Adhesives

Sheet Sensor (B01)

- Set the volume to 14A.

Installing Position of Sheet


Sensor

M02
Motor
Pulley
N4F

Ground
Wire

Teethed
Washer

Installing Position of Delivery


Conveyor Motor Pulley

The current setting of the pump


breaker

Fix the sheet sensor,


pushing it up.

Pump Breaker Q20

a
a

Set
Screw

14A
14

ON

M01
9

Q20
Current Setting of
the Pump Breaker

4-13

4-8 Installing Standard for Other Parts

13mm

(0.5)
Motor Pulley

Roller Motor

Installing Position of Main


Motor Pulley
4. Replacement and Adjustment

4-14
4. Replacement and Adjustment

This page is intentionally left blank.

5. Electrical Parts Layout and Description

5-1

5. Electrical Parts Layout and Description

5-2
5. Electrical Parts Layout and Description

5. Electrical Parts Layout and Description


QPW-589
R
PE
PA

-35

EF

Y01

VR2
S15
VR1

R
DE
OL
RF

-35
EF

B01

PE
PA

ER
LD
FO

M02

S13
S14

G01
Q10
U01
X01

M01
X02
S01

Q20
K20
X03

M03

Code
B01
G01
K20
M01
M02
M03
Q10
Q20
QPW-589
S01
S11
S12
S13
S14
S15
U01
VR1
VR2
X01
X02
X03
Y01

S11
S12

Name
Counter Sensor
Power Supply
Pump Contactor
Main Motor
Conveyor Motor
Pump
Breaker
Pump Breaker
Control P.C.B
Power Switch
Roller / Feed Start
Roller / Feed Stop
Test Feed
Pump Switch
Conveyor Switch
Main Motor Driver
Conveyor Speed
Feed Speed
Pump Connector
Conveyor Connector
Pump Terminal Board
Suction Air Valve

Remarks
Light sensitive sensor
24VDC
Brushless DC motor
Gear Motor
750W
5A
Setting Value: 14A

The circuit is closed during turning on


The circuit is closed during turning on

24VDC

6. P.C.B and Wiring Diagram

6-1

6. P.C.B and Wiring Diagram

6-2
6. P.C.B and Wiring Diagram

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

CON1
1

CON5
1

CON3
1

L8

CON8
1

L7

Control ROM

L2

L1

L3

1234
ON

L9

L4 L5 L6

L10

1234

CON7

ON

DSW

CON2

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


Control ROM Revision Chart
Control
ROM

Control
P.C.B.

S/N -

V3.1

QPW-589A

1. The preset counter Off mode is added to the


002001- operation mode of the preset counter. (Mode changes
OFF-STOP-PAUSE-OFF.)

V3.4.1.1

QPW-589B

008001-

V3.4

QPW-589E

011001-

V4.2

QPW-589F

020001-

V4.2

QPW-589G

021001-

V4.2

QPW-589H

024001-

Improvement
The ROM version number can be indicated on display from V2.10.
(Indicated pressing the start button, stop button and test feed button at
the same time.)
After replacing ROM, the total counter and the preset counter might not
2. The valve sounds even when the vacuum timing is set
function correctly. Press the total counter clear button and the preset
at minimum.
number save button.
3. The feed rotor vacuum LED lights up even if a sheet is When this ROM is installed on the machine up to serial number -004938,
fed by the test feeding.
tell the new function to the users.
The delivery conveyor can be operated only
The ROM V3.4 can be used from QPW-589D.
continuously. (ROM only for QPW-589B)
The delivery conveyor had worked only while the fold
Replace the control panel and P.C.B (QPW-589E or later).
roller is driving. The intermittent operation mode is
When the P.C.Board of QPW-589E or later is installed on the machine up
added. The conveyor runs when a sheet has passed
to the serial number 010899, plug the short circuit connector into the
through the count sensor, and during the pause time.
P.C.Board, CON5. (The short circuit connector is supplied with P.C.B.)
When this P.C.Board is replaced from QPW-589F or older, plug the short
The connector (CON4) for KTU-35 is added.
circuit connector into the CON4.
The front and the back side of the ROMs are changed.
When this P.C.Board is replaced from QPW-589F or older, plug the short
This board has a compatibility with the QPW-589F.
circuit connector into the CON4.
The spare DIP switch is installed. This board has a
When this P.C.Board is replaced from QPW-589F or older, plug the short
compatibility with the QPW-589F.
circuit connector into the CON4.

LED Lighting Conditions


LED NO.
L1
L2
L3
L4
L5
L6
L7
L8
L9
L10

6-3

Lightening Condition
During the pause time and after a preset stop.
Sheet is being vacuuming. (While vacuuming the sheets continuously, it blinks.)
While the counter sensor is detecting the sheet.
While the roller/feed start button is being pressed.
While the roller/feed stop button is being pressed.
While the test feed button is being pressed.
While the counter sensor is detecting the sheet.
When the EF-354 is connected with the ED-354.
When the preset stop mode is being selected.
When the preset pause mode is being selected.

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

L1 to L3, L9, L10: The output device of micon, which lights up


and turns off according to the program.
L4 to L8: The direct monitor LED according to the signal input.

6. P.C.B and Wiring Diagram

6-4
6. P.C.B and Wiring Diagram

WHT

WHT
BLK

WHT
WHT

6-2 100VAC Power Circuit Diagram

Q10

2 4 6

Breaker

S01

BLK
WHT

BLK
GRN
7 7
RED
WHT 6 6 BLK
4 4
BLK
WHT
3 3 FG
FG

29

U01

X01

BLK

RED

BLK

WHT

Connector

WHT L
BLK N
GRN

NC
FG

Q20

Pump Breaker

A1

K20

A2

Pump Contactor

32

1 2 3

Terminal Board

M03

GRN

WHT
BLK
BLK

2 4 6 14

Pump

4
5
24V 6
24V 7
24V 8

Main Motor Driver

EE

X03

0V 1
0V 2
0V 3

WHT
BLK

W01

G01
WHT 1 ACIN
BLK ACIN
3
GRN FG
5

GRN

230V 50Hz
115V 60Hz

Power Supply

Power Switch
WHT

BLK

1 3 5

M01
Main Motor

1 INPUT COM
2 EXT.VR.
3 CW
4 CCW
5 SLOW DOWN Input Signal Terminal
6 N.C.
7H
8M
9L
10 GND
Input /Output Ground
11 SPEED OUT
12 ALARM OUT Output Signal Terminal

6-3 24VDC Wiring Diagram

X02

BLK
WHT
GRN FG
GRN
BLK

40

B01
Y01

1 2
Suction Air Valve 1 2

Main Motor

6-5

GRN
BLK

WHT
BLK

RED
WHT
BLK
GRN

WHT
BLK
BRN
BLK
BLU
24V
SIG
0V

CON8

W01

S01

FG

4 4
3 3 FG
EE

29

X01

QPW-589

Connector

Pump Breaker

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

RED

A1

K20

A2

Pump Contactor

3 2 1 1 2 3 4 3

4 3

4 3

NC

NC

NC

VR2 VR1 S13 S12 S11


Feed Conveyor Test
Speed Speed Feed

Stop

6-3 24VDC Wiring Diagram

2 4 6 14
GRN

RED
BRN

Q20

CON2

YEL
ORN

6 5 4 3 2 1

BLU
GRN

GND
CW
VR-H
VR-M
VR-L

CON7

U01

M01

WHT 7 7 GRN
RED 6 6 RED

Control P.C. Board

Main Motor Driver

1 GRN
2 YEL
3
4
5
6
7 WHT
8 RED
9 BRN
10 GRN
11
12

CON3

Conveyor Motor

1 2

CON1

CN2

INPUT COM
EXT.VR.
CW
CCW
SLOW DOWN
N.C.
H
M
L
GND
SPEED OUT
ALARM OUT

CON5

11

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

WHT
GRY
VIO

CN1

4
5
24V 6
24V 7 WHT
24V 8 RED

1 2 3 4 5 6

13

RED
BRN
BLK
WHT
GRY
VIO
BLU
GRN
YEL
ORN
RED
BRN

WHT 1 ACIN
BLK ACIN
3
GRN FG
5

1 2 3 4

RED
BRN
BLK

S01

GRN
0V 1
0V 2 BLK
0V 3

24V
24V
0V
0V

G01

GRN
YEL
WHT
RED
BRN

Power Supply

RED
ORN

14

M02
RED
WHT
BRN
RED

Conveyor switch

16

Contact Signal for ED-354


2
No use in EF-35
5
9 GRN
34
3 RED
WHT
1

WHT
BLK

S15

S14

Counter Sensor
Pump switch

2
5
9
3
1

M04

M03

Pump

Pump

Start

6. P.C.B and Wiring Diagram

6-6
6. P.C.B and Wiring Diagram

This page is intentionally left blank.