Fastback-20 ServiceManual VC

COPYRIGHT INFORMATION
Copyright Information
This document contains proprietary and confidential information of Powis Parker Incorporated (“Powis Parker”).
Copyright Powis Parker Incorporated 2004

All Rights Reserved.
No part of this document may be photocopied, reproduced in any form, or translated into another language without prior written
consent of Powis Parker, except as allowed under the copyright laws.
Warranty
The information contained in this document is subject to change without notice.
Powis Parker makes no warranty of any kind with respect to this information. Powis Parker specifically disclaims the implied warranty of
merchantability and fitness for a particular purpose.
PPI shall not be liable for any direct, indirect, incidental, consequential, or other damage alleged in connection with the furnishing or use
of this information.
Notice
Changes are periodically made to this document. Revisions, changes, any technical inaccuracies, and typographical errors will be
corrected in any subsequent editions.
Page ii FB20 Service Manual, Rev.C 1/18/13

CONTENTS
1 SUMMARY
2 OVERVIEW
2.1 Main Components of the FB20

2.2 Diagram of the User Menu
2.3 System Block Diagram
2.4 Specifications
2.5 Getting the Best Bind Quality
2.6 Contacting Technical Support
3 REQUIRED SERVICE TOOLS
4 TROUBLESHOOTING
4.1 Power Problems

4.2 Error Messages
4.3 Machine Errors
4.4 Poor Bind Quality
5 SERVICE MENU
5.1 Accessing the Service Menu

5.2 Calibration Service Menu
5.3 Auto Cycle Mode
5.4 Testing and Calibration
6. SERVICE AND CALIBRATION PROCEDURES
6.1 Covers 6.2 UI Board

6.3 Controller Assembly 6.4 Motors and Belts
6.5 Sensors 6.6 Power Supply and Transformer
6.7 Heater Assemblies 6.8 Tape Feed Bar
6.9 Tape Feed Roller 6.10 Strip Deflector
6.11 Rear and Front Clamp 6.12 Top Frame Latches
6.13 Linear Bearing Replacement 6.14 IR Communication
6.15 Cooling Rack
7 UPGRADING FIRMWARE
8 SERVICE KIT LISTING
9 SERVICE KIT PICTURES
10 PACKING PROCEDURE
11 ASSEMBLY DRAWINGS
FB20 Service Manual, Rev.C 1/18/13 Page iii

CONTENTS
THIS PAGE IS INTENTIONALLY LEFT BLANK
Page iv FB20 Service Manual, Rev.C 1/18/13

1 SUMMARY
The FB20 is the ideal binding machine for all corporations, financial institutions, copy shops, print en-
vironments, or education establishments that require professional-looking presentations, yearbooks or
bound documents at a fraction of the time required to bind with alternative binding solutions such as
coil, comb, or wire. This machine offers unprecedented ease of use with its LCD display that guides the
user through each operation using animated illustration. The Fastback 20 works with all of the Powis
binding materials, from the versatile Super Strip to the customized Image Strip to the Perfectback strips
for perfect binding books. It can create anything from a simple report to a 350-sheet hard cover book.
THE FASTBACK® BIND CYCLES

Familiarity with the Fastback® Bind Cycle is a key to effective troubleshooting. The best way to under-
stand the cycle is to remove a machine’s cover and bind a number of books while watching the machine
bind from several vantage points.
Basic steps to observe during Superstrip™and Perfectback™strip binding cycle:
The machine…
1. Clamps the book.
2. Positions the feed bar for accepting binding strip.
3. Engages the tape feed mechanism.
4. Feeds the binder strip.
5. Rotates the feed bar upward, lifting the binder strip and turning the rotating platen into its vertical
position.
a. Lifter motor levels the rotating platen to the top of the strip edge.
6. Forms the book’s back cover seal by sandwiching the book between the front backup bar, the binder
strip, and the rotating platen.
a. For Image strip the rotating platen does a second bind while aligned with the bottom edge of
the front wrap; if the wrap is 1 inch (25.4 mm) or larger the machine perform a third bind in the
middle of the wrap.
7. Lowers the feed bar free of the strip.
8. Backs the book away from the rotating platen.
9. Rotates the feed bar further down, allowing the rotating platen to return to its horizontal position.
10. Moves the book towards the rotating platen, stopping momentarily at the rotating platen to soften
the binder strip prior to folding.
11. Lowers the heater assembly down slightly by rotating the feed bar to its lowest point.
12. Folds the binder strip under the book by advancing the book over the front edge of the heater as-
sembly.
13. Forms the bottom seal by raising the heater.
14. Advances the book until its front cover is just past the axis of the rotating platen.
15. Folds the binder strip to the front cover by turning the rotating platen to its vertical position.
a. Lifter motor levels the rotating platen to the top of the strip edge.
16. Forms the book’s front cover seal by sandwiching the book between the rear backup bar and the
rotating platen.
17. Allows the rotating platen to return to its horizontal position.
18. Heats the book and the binder strip sufficiently so, that the adhesive can bond to the book’s pages.
19. Returns and unclamps the finished book.
Most of the problems the machine may encounter during the bind cycle can be seen providing there is
a good view into the machine when the problem
occurs. Problems are also often accompanied by loud noises that can point to their cause.
FB20 Service Manual, Rev.C 1/18/13 Page 1

2 OVERVIEW- Main Components
2.1 MAIN COMPONENTS OF THE FB20
Cooling Rack Rest
Book Rest
SELECT
Button
Strip
Guide
Front Cover OPEN Button 4-Way Cursor Button BIND Button
LCD Screen
Positioner Motor, Feed Motor, M2

M3
Power Indicator Controller Latch Release
Page 2 FB20 Service Manual, Rev.C 1/18/13

2.1 MAIN COMPONENTS OF THE FB20 CONTINUED
Rotating Lifter Platen
Rotating Lifter Platen Gear Positioner Gear Assembly

Lifter Sensor
Carriage Sensor Carriage Sensor
Strip Rejector Guide Tape Edge Sensor
Linkage Lifter Motor, M4

Carriage Motor,
M1
Front Back-up Bar Clamp Springs
Back-up Bar Shoes
Rear Back-up Bar Linear Bearings

Power Supply Cover
Lifter Motor
Interlock Power Switch
Stationary Heater
Rotating Heater
Cool Platen
Lid Stops
Cover Latches
Thermalfuse
Thermalfuse
T2/T3 Sensors / Top & Bottom
Support Strip Assy. Tape Feed Roller
Tape Feed Bar

Positioner Sensor

CONTROLLER ASSEMBLY
J1 Power LED connector
J7 J8 J2 N/A
J3 UI (User Interface) connector
J4 N/A
J6 N/A
F2 F1 TBA
F4
J5 N/A
F3 TBA
F4 TBA
F2 TBA
J7 N/A
J18
J8 Power to PSU (Power Supply U nit)
connector
J18 Motor connector (All motors)
F3
J15 Carriage sensor connector
J14 Chassis sensor connector (Rest of the
sensors)
J13 Heater Control to PSU (Power Supply
Unit)
J17 N/A
J16 N/A
J12 N/A
J11 Rotating heater thermocouple.
J10 Stationary Heater thermocouple.
J15
J5
F1 J14
J6
J4
J13
J3
J17
J2
J16
J1
J12
J10 J11

2 OVERVIEW- User Menu
2.2 USER MENU
Please refer to your FB20 User Manual or download one from the Powis website.

2 OVERVIEW - System Block Diagram
2.3 SYSTEM BLOCK DIAGRAM

2 OVERVIEW - System Block Diagram
2.3 SYSTEM BLOCK DIAGRAM CONTINUED

2 OVERVIEW- Specifications
2.4 SPECIFICATIONS
Power Requirements: USA: 120V, 50-60 Hz, 10 Amps
EU: 230V, 50-60 Hz, 5 Amps
JAPANESE: 100V, 50-60 Hz, 10 Amps

Power Consumption: 120 V 60Hz 9 Amps 1080 Watts
(Cold Start Up)
230V 60Hz 4.5 Amps 1035 Watts
100V 60Hz TBA Amps TBD Watts

Weight: 57.5 lbs
Dimensions: 23.5”W x 9”H x 23”D (60 cmW x 23 cmH x 58 cmD
Bind Capacity: Spine Lengths: Max. 12” (30.5cm) (A4); Min. 5.5” (13.97 cm)
Spine Thickness: Narrow, Medium, Wide
Binding Capacity: 10 sheets to 350; 1.5” max. thickness (3.8 cm)
Page Sizes: Max. 12” (30.5cm) and Min. 5.5” (13.97cm)
Optimal Paper Weight: 20 lb standard (80 gsm) to 32 lb (120 gsm)
Bind Speed: 12-60 seconds, dependent on strip type and book thickness
Safety Certifications: UL, CE, CUL
Packing & Unpacking Refer to the Section 10.
Noise level: The ambient noise floor was less than 50db with a peak of 70 db when the
machine is moving.

2 OVERVIEW

2 OVERVIEW- Getting the Best Bind Quality
2.5 GET TING THE BEST BIND QUALIT Y
• Before binding, tap the pages several times to ensure that they are even when the document is in the
binding recess. The right edge of the strip and right edge of the document should line up and be justified
against the right side of the binding recess.
• The grain of the paper should run parallel to the binding edge of the document. All paper has a grain — it
is a result of the fibers that make up the paper. If the grain runs parallel to the long side of the sheet, the
paper is “grain long”. When the grain runs parallel to the short side of the paper, it is “grain short”.
• A sheet of paper will naturally flex more easily along the direction of its grain. Try it and see. (Hold a piece
of paper the long way lightly in your fingertips and gently bow the paper, allowing it to flex. Now try it the
other way. See the difference?
• •
• Most copy papers are grain long, so you should not have any problems with the bind. Grain long paper
will give you the best bind. Occasionally you may find papers that are grain short, so we recommend you
test unfamiliar papers before binding large numbers of documents.
• Coated papers, and papers with heavy ink or toner coverage may also experience problems with binding.
If you have documents with heavy ink or toner coverage, always do a test bind first to ensure that your
documents will bind properly.
• After the binding cycle, be sure to place your document entirely upright, with the bound side down,
against one of the two Cooling Rack book support fences for five minutes. Improper cooling of your
document may result in a crooked spine. Bind strength reaches the maximum strength after 24 hours.

2 OVERVIEW- Technical Assistance
2.6 CONTAC TING TECHNICAL SUPPORT
Technical Support
If there are any questions not answered in this service manual, please contact the Powis
Parker Technical Support Dept: 510-848-2463 or via email at techservice@powis.com
Spare Parts Order
You can still purchase small quantities of spare parts but the overall Spares
Order must meet the minimum order amount of $25.00 USD (not including
shipping). Any order less than this amount will have a surcharge added so that it
will total $25.00 USD.
We ask that when you place your spare parts orders you use a Purchase Order
that includes the following:
• P.O. #, item number and description
• Price and quantity
• Bill to and Ship to information
• Shipping method
• Shipping terms
If you wish to have the items shipped on your account please include the carrier
and account number.
This information will help us to process your order in a timely manner and will
help to eliminate any confusion.
Email or fax your Purchase Orders to techservice@powis.com or 510-848-1586
Machine and Controller Repair
We ask that when you place your RMA request include the following:
• item number, description and serial number
• Symptom or issue
• P.O. # (if non warranty)
• Bill to and Ship to information
• Shipping method
• Shipping terms
If you wish to have the items shipped on your account please include the carrier
and account number.
This information will help us to process your RMA in a timely manner and will
help to eliminate any confusion.
Email or fax your Purchase Orders to techservice@powis.com or 510-848-1586

3.1 REQUIRED SERVICE TOOLS
When servicing a Model 20 binder the following tools are required:
3.1 HAND TOOLS
Phillips Screwdrivers #1 and #2

Flat-head Screwdriver
Needle Nosed Pliers
Diagonal Cutters
Allen Wrench Set (Hex)
11/32” & 7/16” Open Ended Wrench
Feeler Gauge; .015 inch, .020 inch, .025 inch, & .080 inch
Inspection Mirror
Magnetic Wand
Platen Level Gauge (K-825-002)
90 Degree Level Gauge
Tape Feed Bar Gauge (K-825-003)
Tape Feed Gauge (K-820-3576)
Interlock Override Tool (K-820-008)
Oven Glove (K-820-001)
Tweezers (not pictured)
Dentist Pick (not pictured)

3.2 TOOLS TO SERVICE THE HEATERS
Temperature Meter
Straight Temperature Probe
Digital Multimeter
Heat Gun (not pictured)
3.3 TOOLS FOR FLASH UPGRADE OF FIRMWARE
SD Card/SD Card Reader

Windows Based PC
Internet Access
3.4 TOOLS NEEDED TO INSPECT THE CONTROLLER ASSEMBLY
ESD Ground Strap and Mat
3.5 CLEANING SUPPLIES
Citrus Cleaning Solution (K-212-001)

Lint Free Cloth

3.1 REQUIRED SERVICE TOOLS CONTINUED

4 TROUBLESHOOTING GUIDE
4.1 POWER PROBLEMS
• NO POWER
Possible Cause Solution
Power Cord is not securely plugged in. Check that the Power Cord is securely plugged into the machine
and into the outlet in the wall.
Electrical outlet is not functioning. Plug the machine into another electrical outlet.
Machine is plugged into the wrong voltage outlet. Use the correct voltage outlet to power the machine.
Wire Harness connections are loose. Check that all wire connectors are securely plugged
into the Controller Assembly.
Blown Fuse. Check fuse on rear of unit. Replace if blown.Check fuse
on the PSU. Replace if blown. See Section 6.6
Failed PSU/Transformer assembly Replace PSU/Transformer. See Section 6.6
Failed Controller Assembly. Replace the Controller Assembly. See Section 6.3
• POWER FLICKERS ON AND OFF

A 230v machine in plugged into a 115v outlet. Plug the machine into a 230v outlet.
Check display cable. Ensure Cable is plugged in and has continuity and/or re-
place and check, see section 6.1 and 2.3 for reference
Failed UI PCA (user interface) / Display. Replace UI PCA (user interface) / Display.
See Section 6.1.
Failed Controller Assembly. Replace the Controller Assembly. See Section 6.3
• WHEN TURNED ON NOTHING IS ON THE DISPLAY

No SD card present in the slot. Install SD card and perform firmware upgrade procedure. See
Section 7.1
Unplugged or faulty display cable. Ensure Cable is plugged in and has continuity and/or re-
• FUSES BLOW REPEATEDLY
Short circuit in heaters. Check the resistance of the Heaters. See Section 5.4.1 “Checking
the Resistance of the Heater Power Connectors”.
Short in the Controller Assembly. Replace the Controller Assembly. See Section 6.3
Short in the wiring or heater cartridge Check each wire harness for a short. Replace if necessary, see
section 6.7
Other See Heater Problem for additional trouble shooting

4.2 ERROR MESSAGES
• Error Message: Insert Strip Further.

Firmware was not loaded properly. Reload firmware. See Section 7.1.
• Detection Error
Bad Pattern on strip Try strip from different lot#
Invalid calibration value for SMS Recalibrate Smart sensor, see section 5.2.8
Faulty Smart Sensor Check and replace Smart Sensor if necessary, see section
6.5.5
Faulty Smart sensor harness, 208802 Ensure Cable is plugged in and has continuity and/or re-
Inner and/or Outer Tape Sensor Failure (T2 and/or T3) Recalibrate Inner and Outer Tape Sensor to check for
failure, replace if necessary, see sections 5.2.5, 5.2.6, and
6.5.4
Failed Main Controller board Replace Main Controller board and check, see section 6.3
• Initialization Error 8
Files on SD card are corrupted/firmware download was Reformat SD card and redownload firmware, see section
performed incorrectly 7.1 and 7.2
Connectors on controller board are loose Check and replug connectors if necessary, see section 6.3,
reference section 2.3
Failure of display harness, 208805 Ensure Cable is plugged in and has continuity and/or re-
Failed User Interface board Replace board and check, see section 6.2
Failed Controller board Replace Main Controller board and check, see section 6.3
• Hardware Error 10
Failed Opto sensor Replace sensor(s). Carriage, Positioner, or Lifter, see sec-
tion 6.5.5 - 6.5.7
Faulty/unplugged/loose OptoSensor,Photintr harness con- Replace or reconnect/wiggle back into sensor, see section
nectors 6.5.5 - 6.5.7, reference section 2.3
Loose motor pulley set screw Check and retight if necessary, see section 6.4
Bad Motor Harness/ loose connector Ensure Cable is plugged in and has continuity and/or re-
Failed Controller Assembly Replace failed controller assembly. See section 6.3

4.2 ERROR MESSAGES CONTINUED
• Error 11
Improper Firmware upgrade Reflash firmware, see section 7.1
• Error 22 / Error 23
SD card is not installed Install SD card, see section 7.2
Failure of display harness, 208805 Ensure Cable is plugged in and has continuity and/or re-

4.3 MACHINE ERRORS
• M1, M2, M3, or M4 Makes Erratic Movements Upon Power Up

Failed Motor Harness, 208804 Ensure Cable is plugged in and has continuity and/or re-
Failed Motor Replace Motor, see section 6.4
Invalid calibration value for motor Enter service menu and look at report (1), out range of +/-
20, recalibrate if necessary, See
section 5.2
• Heater Problem
Cause Solution
Fuse blows repeatedly Failed thermocouple, check and replace, see
section 5.4.2
Replace Main Controller board and check, see section 6.3
Stuck on warming up Thermofuse is blown, check and replace, see sections

5.4.3 and 6.7.3 or 6.7.5 depending on heater assembly
Improper Firmware upgrade, reflash firmware, see section
7.2
Failure of heater control harness, 208801. Ensure Cable
is plugged in and has continuity and/or replace and check,
see section 6.1 and 2.3 for reference
Strip feed but than machine gets stuck on temperature Failed thermocouple or blown thermofuse, check and
adjusting replace, see section 5.4.2 and 5.4.3
Temperature too low/high/not steady Failed heater, check and replace, see section 5.4.1 and
6.7.3 or 6.7.5 depending on heater assembly
Check and recalibrate heater values, see section 5.2
Failed thermocouple, check and replace, section 5.4.2

Replace Main Controller board and check, see section 6.3
Failed Power Supply, check and replace, see section 6.6.1

4.3 MACHINE ERRORS CONTINUED
• Clamps Will Not Open

Fuse blows repeatedly Bad Thermocouple, check and replace, see
section 5.4.2
Failed Controller board, replace Main Controller board and
check, see section 6.3
See Heater Problem for additional trouble shooting
Stuck on warming up Thermofuse is blown, check and replace, see section 5.4.3
Improper Firmware upgrade, reflash firmware, see section
7.1
Thermocouple open circuit, check and replace, see section
5.4.2
Temperature too low/high/not steady Check and recalibrate heater value, see section 5.2.1 and
5.2.2
Bad Thermocouple, check and replace, see
section 5.4.2
Failed Controller board, replace Main Controller board and
check, see section 6.3
• Clamp Slam Shut When Open Button Is Pressed

Stay Clamp is incorrectly positioned Correct the stay clamp position within the machine, see
section 10
Bad Motor Harness/loose connector Ensure Cable is plugged in and has continuity and/or re-
Invalid calibration value for M1 Enter service menu and look at report (1), out range of +/-
20, recalibrate if necessary, see section 5.2
• Clamps Do Not Close After Power Down

Drive nut bracket is incorrectly positioned Remove top cover and recalibrate lead screw nut bracket,
see section 6.10
Drive nut bracket bent or damaged Replace drive nut bracket or slightly bend bracket with pli-
ers, see section 6.11
Assembly, Roller, Clamp is rubbing against the top frame Recalibrate clamps to heater, see section 6.10

• Fails To Respond Or Responds Wrong When Buttons Are Pressed

Improper Firmware upgrade Reflash firmware, see section 7.2
Keypad is out position/bad (carbon pad missing) Check keypad and replace if necessary, see
section 6.2
• Blank Image Or No Text On Display

• Displays “Slide Book In Place” or “Ready to Bind” When Book Is Present

The sheets are not fully justified against the right side of the Tap the edges of sheets until the book is flush against the
binding recess right side of the binding recess
Invalid calibration value for book sensor Enter service menu and look at report (1), out range of is
less than 100, recalibrate if necessary, See section 5.2.7
Damaged book sensor Replace book sensor and recalibrate, see section 6.5.1
and 5.2.7
Damaged or failed Book sensor harness, 208803 Ensure Cable is plugged in and has continuity and/or re-
• Book Is Removed, But “Place Book in Cooling Rack” Screen Is Present

Invalid calibration value for book sensor Enter service menu and look at report (1), out range of is
less than 100, recalibrate if necessary, See section 5.2.7
Damaged book sensor Replace book sensor and recalibrate, see section 6.5.1
and 5.2.7
Damaged or failed Book sensor harness, 208803 Ensure Cable is plugged in and has continuity and/or re-
• “Slide Book to Right” Video Plays When Bind Button Is Pressed

The operator pressed the Bind button without inserting a Place a book into the machine and then press the Bind
book into the binding recess. button.
The sheets are not fully justified against the right side of the Tap the edges of the sheets until the book is flush against
binding recess. the right side of the binding recess prior to pressing the
BIND button.
Damaged Book Sensor Replace the Book Sensor. See Section 6.5.1
Failed Controller. Replace the Controller Assembly. See Section 6.3

• Strip Drops When Feed

Glue on Tape feed bar. Clean tape feed bar
Invalid tape feed bar calibration Calibrate tape feed bar to .0625”, see section 6.8.1
20, recalibrate if necessary, See section 5.2
Invalid calibration value for M4/linkage Enter service menu and look at report (1), out range of +/-
Strip Deflector is incorrectly positioned Check and correct the strip deflector position if necessary,
see section ??? I think you may have left this out????
• Machine will not feed strip

Invalid linkage calibration Check and recalibrate, see sections 6.9.3
Worn Feed roller, 208091 Check and replace, see section 6.9.1
Nip roller bearing has failed Check and replace, see section 6.9.4
Failed Feed motor, M2 Check and replace, see section 6.4.4
Invalid calibration value for lifter motor, M4; causing not Enter service menu and look at report (1), out range of +/-
enough pressure or crashing the lifter motor so the feed 20, recalibrate if necessary, See section 5.2
arm springs back up
Failed Motor Harness, 208804 Ensure Cable is plugged in and has continuity and/or re-
• Mechanical Noises
Linear bearings making clicking sound Check Drive screw nut and reposition/ Check linear bear-
ings and replace, see sections 6.10 and 6.11
M1 pulley rubbing against front skirt causing a clicking Check and position pulley on M1 motor shaft, see section
sound 6.4.2
Sqeaking noise coming from tape feed bar rubbing the M3 Check tape feed bar calibration to rotating platen, and
home sensor recalibrate if necessary, see section 6.8.
Sqeaking noise caused by edge sensor rubbing against Recalibrate linkage and/or feed bar if necessary, see sec-
linkage tions 6.9.3 or 6.8.2
Tape feed arm hitting feed bar during binding process Linkage is adjusted incorrectly and/or linkage pivot post
inproperly installed and/or M4 calibration value incorrect,
see sections 6.9.3 and 5.2.10
Linkage hitting Lower T2/T3 sensor board Reinstall T2/T3 board in correct position within the slot of
the Chassis, see section 6.5.4
Squeaking from Clamp Cause is either side bearing mount rubbing due to clamp
calibration or top cover screws, see sections 6.1.1 and
6.10

4.4 POOR BIND QUALIT Y
• Bind Quality Is Unsatisfactory

Heater temperature is incorrect. Check heater temperatures and recalibrate if necessary,

see section 5.2.1 and 5.2.2
Front or rear clamps mis-aligned. See section 6.10.1 Front and Rear Clamp Calibration.
• Spine Is Not Square

Cause Solution
The book was not placed in the Cooling Rack after being After binding, make sure the book is placed in the Cooling
bound Rack to properly cool down
Clamps not calibrated correctly to rotating heater Check and recalibrate if necessary, see section 6.10
Stationary heaters not calibrated level with cool platen Check and recalibrate if necessary, see section 6.7.?
Rotating heater not calibrated to 90 degrees Check and recalibrate if necessary, see section 6.7.8
If still not satisfied, recommend installing the back-up bar See section 6.11.4
shim
• Pages Do Not Adhere To The Strip Very Well

Some paper stocks and some heavy cover material can be The bind may be improved by increasing the Spine Bind
difficult to bind. time in the Setting Menu.
• Sheet Separation From Spine

Heaters Temperature calibrated hot Check and recalibrated if necessary, see section 5.2.1 and
5.2.2
Stationary heater not calibrated level with cool platen Check and recalibrate if necessary, see section 6.7.?
Gap between rotating heater and stationary heater not Check and recalibrate if necessary, see section 6.7.2
calibrated correctly

4.4 POOR BIND QUALIT Y CONTINUED
• Strip Skewed
Missing taping pad (for 11" strips only) Check and install if necessary, see section 6.??
Gap between tape feed bar and rotating heater not parallel Calibrate gap to .020" Cold or .015" Hot
Tape feed bar not calibrated to rotating platen correctly Check and recalibrate if necessary, see section 6.8.2
Tape Feed Bar is bent Check and replace if necessary, see section 6.8.?
Strip Deflector not Calibrated correctly Check and recalibrate if necessary, see scetion 6.9.?
• Strip Sealing Issues

Heaters Temperature calibrated low Check and recalibrated if necessary, see section 5.2.1 and
5.2.2
Rotating heater not calibrated to 90 degrees Check and recalibrate if necessary, see section 6.7.8
Back-up bar not calibrated to clamp correctly Check and recalibrate if necessary, see section ???
Tape feed bar not calibrated to rotating platen correctly Check and recalibrate if necessary, see section 6.8.2
• Book Wrap Is Uneven

User wrap setting has been changed Check Wrap setting in users menu and reset set to 0
Loose motor pulley set screw or belt, positioner motor, M3 Check and retight if necessary, see section 6.4.5
M3 calibration is incorrect Check and recalibrate if necessary, see section 5.2.13
need to add tigthing belt to this section
• Seals are not flat

Back-up bar not calibrated to clamp correctly Check and recalibrate if necessary, see section ???

4.4 POOR BIND QUALIT Y CONTINUED
• Strip Edge is not Aligned with Book

User Strip End alignment setting has been changed Check Strip End alignment setting in users menu and reset
set to 0
Linkage spring calibration is incorrect Check and recalibrate if necessay, see section 6.9.3
Loose motor pulley set screw or belt, positioner motor, M2 Check and retight if necessary, see section 6.4.4
M2 calibration is incorrect Check and recalibrated if necessary, see section 5.2.11
Tape Feed Bearing is not aligned properly to roller Check and recalibrate if necessary, see section 6.9.2
• Glue Seepage
User Bind time setting has been changed Check Bind time in users menu and reset set to zero
Heaters Temperature calibrated hot Check and recalibrate if necessary, see section 5.2.1 and
5.2.2
• Glue Leakeage
User Bind time added Check Bind time in useres menu and reset set to zero
Split Book Carrige springs installed Check and install FB20 carrige springs
Heaters Temperature calibrated hot Check and recalibrate if necessary, see section 5.2.1 and
5.2.2


5 SERVICE MENU
5.1 ACCESSING THE SERVICE MENU
Accessing the Service Menu
1) The following section will go through all service calibrations for the machine.
2) The service menu can be accessed by using the User Interface display and going into General Settings Menu
then by going into Service Mode. Enter pass code 775 and press the Bind button.

3) Page one of the service menu look like this. There are 8 selections 0 – 7. The selection number will appear at
the bottom of the screen and defaults to 000
=== Service Menu ===

0. Next page
1. Calibration report
2. Calibrate Stationary Platen temp.
3. Calibrate Rotating Platen temp.
4. Calibrate carriage clamp
5. Calibrate M1 (carriage) home
6. Calibrate inner tape sensor
7. Calibrate outer tape sensor
Make a selection:

5 SERVICE MENU
5.1 ACCESSING THE SERVICE MENU CONTINUED

3) Page one of the service menu look like this. There are 8 selections 0 – 7. The selection number will appear at

0. Next page
1. Calibration report
2. Calibrate Stationary Platen temp.
3. Calibrate Rotating Platen temp.
4. Calibrate carriage clamp
5. Calibrate M1 (carriage) home
6. Calibrate inner tape sensor
7. Calibrate outer tape sensor
Make a selection:
Use arrows to select and change digits
and press BIND to continue
00
4) Page two of the service menu look like this. There are 10 selections 8 – 17. The selection number will appear at
Note: Selections 14-16 are offsets only to be used to reset motor calibration to 0 incase of malfunctioning mo-
tors, recalibration of motors must be done after reset.

8. Exit to User Menu.
9. Calibrate book sensor
10. Calibrate sms sensor
11. Calibrate M3 (Positioner) home
12. Calibrate M4 (Lifter) home
13. Calibrate M2 (Tape Feed) offset
14. Set M1 (carriage) home offset
15. Set M3 home offset
16. Set M4 home offset
17. Save calibrations
Make a selection:
Use arrows to select and change digits
and press BIND to continue
Press Exit to return to previous menu
08

5 SERVICE MENU
5) The following is a list of the service menu selections and their basic functions
0. Next page - Goes to page two of the service menu

1. Calibration report - Displays the calibration values on the Main Controller and the User Interface (if saved)
2. Calibrate Stationary Platen temp. - Calibration for stationary heater temperature
3. Calibrate Rotating Platen temp. - Calibration for rotating heater temperature
4. Calibrate carriage clamp - Calibration for book thickness calculation
5. Calibrate M1 (carriage) home - Calibration of front back up bar to rotating platen position
6. Calibrate inner tape sensor - Calibration of inner tape sensor circuit
7. Calibrate outer tape sensor - Calibration of outer tape sensor circuit
8. Exit to User Menu. - Exits the Service Menu and go back to the User Menu
9. Calibrate book sensor - Calibration of book tape sensor circuit
10. Calibrate sms sensor - Stores smart sensor value on Main Controller
11. Calibrate M3 (Positioner) home - Calibrates the Tape feed bar position
12. Calibrate M4 (Lifter) home - Calibrates the rotating heater position
13. Calibrate M2 (Tape Feed) offset - Calibrates the tape edge position
14. Set M1 (carriage) home offset – Only used when unable to calibrate using # 5
15. Set M3 home offset - Only used when unable to calibrate using # 11
16. Set M4 home offset - Only used when unable to calibrate using # 12
17. Save calibrations - Saves the Bind & Auto cycle counts and calibration values from the Main Controller to the
User Interface

5 SERVICE MENU
Service Menu Calibration Report
Next Page (0)

1) Power on the machine and go to the service menu
2) Selection 00 is the default at the bottom. Press Bind and the Next page feature will display the second screen
of the service menu.
3) Press the yellow exit button to go back to the first screen
Calibration menu (1)
1) Power on machine and go to the service menu
2) Use the up arrow on the directional pad to change the number to 01 and press Bind.
3) The User Interface display will show the current Main Controller calibrations, Serial number (SN), Bind Count
(BC) and Auto cycle counts
MC Calibration settings
Carriage Home Offset =#
Carriage Clamp Offset =#
Tape Feed (M2) Offset =#
Positioner (M3) Home Offset =#
Lifter (M4) Home Offset =#
Inner Tape Sensor Cal = ##
Outer Tape Sensor Cal = ###
Book Sensor Cal = ###
Smart Sensor Cal = ##
Main platen (CH0) cal = #####
Rotating platen (CH1) cal = #####
SN = ##### BC: # #
Press Bind to continue
4) Pressing the Bind button again will show the current calibrations, Serial number (SN), Bind Count (BC) and
Auto cycle counts stores on the User Interface
Calibrations in the UI:

Carriage Home Offset = Unknown
Carriage Clamp Offset = Unknown
Tape Feed (M2) Offset = Unknown
Positioner (M3) Home Offset = Unknown
Lifter (M4) Home Offset = Unknown
Inner Tape Sensor Cal = Unknown
Outer Tape Sensor Cal = Unknown
Book Sensor Cal = Unknown
Smart Sensor Cal = Unknown
SN = Unkn BC: Unkn Unkn
5) Pressing the Bind button again will go back to the first page of the service menu.

5 SERVICE MENU
5.2 SER VICE MENU CALIBRATIONS
5.2.1 Calibrating the Stationary Heater Temperature (2)
1) Open the machine cover and latch it up and insert an interlock switch override tool.
2) Power on the unit, go to the Service Menu, choose selection 2 and press Bind.
3) The User interface will display the following:
Selection 2
WARNING: HEATERS WILL BE EXTREMELY HOT
Current offset = #####
Wait for temperature to settle ...
4) Once the temperature stabilizes to the current calibration value the User interface will display the following:
Enter Temperature calibration for
stationary heater.
Press Bind to continue or
Exit to return to Service Menu
Min = 10000, Max = 12566
+#####
5) Using a thermometer read the temperature at the middle of stationary heater.
6) If required enter a new value using the direction pad and press Bind.
Note: 100 points is about 3-4 degrees
7) The User Interface will display the following:

New value: #####
Saving value ...Done
Please be sure both Heater calibrations
have been set before power cycling.
8) Once the temperature stabilizes to the new value the User interface will display the following:
stationary heater.
Min = 10000, Max = 12566
+#####
9) Press Bind to repeat this calibration until the temperature reads (415-425 deg. F) or (213-218 deg.C) on the
thermometer.

5 SERVICE MENU
5.2 SER VICE MENU CALIBRATIONS CONTINUED
5.2.1 Calibrating the Stationary Heater Temperature (2) Continued
10) Press Exit (yellow button) to go back to the Service Menu.

11) Verify the calibration of the Rotating Heater (Selection 3) before powering the unit off.
12) Power down unit while holding the backup bars so they do not slam down on the carriage stops.
13) Remove the interlock switch override tool.
14) Unlatch and close the machine cover.

5 SERVICE MENU
5.2.2 Calibrating the Rotating Heater Temperature (3)
1) Open the machine cover and latch it up and insert an interlock switch override tool.
Selection 3
WARNING: HEATERS WILL BE EXTREMELY HOT
Current offset = #####
4) Once the temperature stabilizes to the current calibration value the User interface will display the following:
rotating heater.
Min = 10000, Max = 12566
+#####
5) Using a thermometer read the temperature at the middle of rotating heater.
6) If required enter a new value using the direction pad and press Bind.
Note: 100 points is about 3-4 degrees
7) The User Interface will display the following:
New value: #####
Please be sure both Heater calibrations
have been set before power cycling.
8) Once the temperature stabilizes to the new value the User interface will display the following:
rotating heater.
Min = 10000, Max = 12566
+#####
9) Press Bind to repeat this calibration until the temperature reads (370-380 deg. F) or (188-193 deg.C) on the
thermometer.

5 SERVICE MENU
5.2.3 Calibrating the Rotating Heater Temperature (3) Continued
11) Verify the calibration of the Stationary Heater (Selection 2) before powering the unit off.
5.2.3 Calibrate carriage clamp (4)
1) Power on the unit with the cover closed, go to the Service Mode, choose selection 4 on the Service Menu and
press Bind.
2) The front clamp will close against the back clamp and then reopen.
Selection 4
Carriage Clamp Offset =##
Remove any book from the clamps
Press Bind to perform calibration or
4) Remove any book in between clamps and press the Bind button.
Carriage Clamp Offset =##
Press Bind to Save or Exit to ESC
6) Press the Bind button to save the calibration.
8) Press Bind to repeat this calibration.

5 SERVICE MENU
5.2.4 Calibrate M1 (carriage) home (5)
1) Open top cover and remove two screws holding in Finger guard
2) Remove the finger guard.

3) Remove the front panel cover (Section 6.1.4)
4) Close top cover
5) Power on the unit, go to the Service Mode, choose selection 5 on the Service Menu and press Bind.
Selection 5
Remove any book from the clamps
Current offset = 0
8) The front clamp will move toward the back clamp and then reopen.
Remove any book from the between the clamps
Press Bind to continue or Exit to ESC
WARNING PRESSING THE BIND BUTTON
WILL CAUSE THE CLAMPS TO
COME TOGETHER QUICKLY
12) Press the Bind button to continue
13) The rotating platen will move into a vertical position and the clamps will come together and carriage motor
will not have any holding force.
Move carriage to platen
15) Manually move the front clamp/back-up bar by turning the
carriage belt counter-clockwise by hand until front back-up bar is fully
touching the front of the rotating platen and then stop.

5 SERVICE MENU
Calibrate M1 (carriage) home (5) Continued
16) Press the Bind button to continue.

17) The clamps will move toward the front of the unit.
Seek M1 home sensor...Step count: ####
19) Press Bind to save this calibration.
New M1 Carriage Home offset = ##
21) Press Bind to repeat this calibration.
23) Power down the unit.
24) Reinstall the finger guard and font cover panel.
5.2.5 Calibrate Inner Tape Sensor, (6)
1) Power on the unit with the cover closed, go to the Service Menu, choose selection 6 and press Bind.
Selection 6
Calibrate inner tape sensor
Measured ##
Saving ... Done
Press the Bind button to continue
3) Press the Bind button to go back to the Service Menu.
4) It sensor fails to calibrated replace both sensor boards one at a time until it works. If that doesn’t fix the prob-
lem, check continuity of the wire harnesses with a voltmeter.

5 SERVICE MENU
5.2.6 Calibrate Outer Tape Sensor, (7)
1) Power on the unit, go to the Service Menu, choose selection 7
CAUTION: FEED ARM AND FEED BAR WILL AUTOMATICALLY MOVE TO THE STRIP FEED POSITION
FOR THIS CALIBRATION

Selection 7
Calibrate outer tape sensor
Measured ##
Saving ... Done
3) Press the Bind button again to go back to the Service Menu.
4) If a sensor fails to calibrated replace both sensor boards one at a time until it works. If that doesn’t fix the prob-
lem, check continuity of the wire harnesses with a voltmeter.
5.2.7 Calibrate Book Sensor, (9)
1) Power on the unit with the cover closed, go to the Service Menu.
2) Remove any book in the clamps, choose selection 9 and press Bind.
Selection 9
Calibrate book sensor
Measured ###
Saving ... Done
5) If the sensor fails to calibrated replace both sensor boards one at a time until it works. If that doesn’t fix the
problem, check continuity of the wire harnesses with a voltmeter.

5 SERVICE MENU
5.2.8 Smart Sensor, (10)
1) Power on the unit with the cover closed, go to the Service Menu.
2) Remove any book in the clamps, choose selection 9 and press Bind.
Selection 9
Calibrate book sensor
Measured ###
Saving ... Done
5) If the sensor fails to calibrated replace both sensor boards one at a time until it works. If that doesn’t fix the
problem, check continuity of the wire harnesses with a voltmeter.
Smart Sensor (10)
1) Open the top cover and record the smart sensor mv reading found on the white label on the smart sensor
bracket – Note Image is shown with right side panel off.
2) Close the top cover.

Selection 10
Calibrate sms sensor
Enter Smart Sensor Number
From Label on Sensor Min = 50, Max = 500
5) Change the value on the display to value on the label in the FB20 and press Bind. Each value can be change
individually.
6) The User interface will display the following
New value: ###
You entered ###
8) Reinstall the right side panel if previously removed.

5 SERVICE MENU
5.2.9 Calibrate M3 (Positioner) Home, (11)
1) Open up the top cover and install the Interlock override tool.
2) Remove the left side panel.
3) Power up machine go to the Service Menu, choose selection 11 and press Bind.
Selection 11
Current M3 offset = +/-##
5) Press the Bind button to continue with the calibration.
6) The positioned motor will not have any holding force.
Rotate positioner gear and
insert Tape Feed Bar Gauge.
Level cool platen to Gauge
WARNING: REMOVE TAPE FEED GAUGE
AND PRESS BIND
8) Following the following steps before you press the Bind button
9) Rotate up tape feed bar and place the tap feed gauge (.062”) into tape feed bar. Double check the calibration.
If the gauge is tight recalibrate the tape feed gap before continuing with the next step.

5 SERVICE MENU
Calibrate M3 (Positioner) Home, (11) Continued
10) With .062” gauge in the feed bar, hold the parallel tool flat against platen frame and against the rotating
platen. While holding the tool in place rotate up the strip positioner by turning the positioner motor pulley until top of
the .062” gauge touches the bottom of parallel.
11) Check that both sides of the tape feed bar are level by moving parallel tool to other side without moving the
positioner motor. If one side is low you must add a shim before moving onto the next step.
12) With the tape feed bar still level with the platen frame (by leveling with the parallel tool, done previous steps)
remove the tape feed gauge without moving the tape feed bar.
14) Positioner motor should rotate down stopping at its home position
Seek m3 home sensor...Step count: ####
Current M3 offset = +/-#
18) Press Exit to go to the Service menu
21) Reinstall the left side panel.

5 SERVICE MENU
5.2.10 Calibrate M4 (Lifter) Home, (12)
1) Open up the top cover and install the Interlock override tool.
2) Remove the right side panel.
3) Power up machine, go to the Service Menu, and choose selection 12 and press Bind.
Selection 12
6) The lifter motor will move to its home position and will not have any holding force.
Move lifter level with platen
8) Move up the rotating platen using the lifter motor belt until rotating platen is level with the stationary platen,
by using a parallel tool across the platen frame and stationary platen.
9) Stop once the rotating platen is level and without moving the rotating platen.
11) The lifter motor will move rotating platen down until it is at its home position.
15) Press Exit to go to the Service menu.
18) Reinstall the left side panel.

5 SERVICE MENU
5.2.11 Edge Sensor, M2 (Tape Feed) Home Calibration (13)
1) With machine on, lid close, go into the user menu and check the tape edge calibration is at center point.
2) Bind a narrow book and evaluate the placement of the tape to the right edge of the book.
3) If tape is not aligned then go to the Service Menu, and choose selection 13 and press Bind.
Selection 13
Current offset = ##
Enter the M2 (Tape Feed) offset
and press Bind
Min = -120, Max = 120
5) Change the value on the display accordingly - Numbers in this case may be positive or negative
a. If the strip is over shooting on the book make the number smaller which will move the strip to the right.
b. If strip was an under shoot on the book then make the number larger which will move the strip to the left
6) Press the Bind button

7) User interface will display the following:
New value: 6
8) Exit the service menu by selecting 00 and pressing Bind to go to the Next page
9) Elect 08 and press Bind to exit to the User menu
10) Bind a narrow book and repeat this calibration as required

5 SERVICE MENU
5.2.12 Set M1 (carriage) home offset (14)
1) WARNING THIS PROCEDURE SHOULD ONLY BE DONE IF YOU ARE UNABLE TO CALIBRATION USING
SELECTION 05
Selection 14
Current offset = #
Enter the carriage home offset
and press Bind
Min = -120, Max = 120
+###
4) Enter 000 and Press the Bind button
New value: 0
6) Press Bind to return to the Service Menu
7) Perform the calibration for selection 05
5.2.13 Set M3 (Positioner) home offset (15)
SELECTION 11
Selection 15
Current offset = #
Enter the M3 (Positioner) home offset
and press Bind
Min = -120, Max = 120
+###
New value: 0

5 SERVICE MENU
5.2.14 Set M4 (Lifter) home offset (16)
SELECTION 12
Selection 16
Current offset = #
Enter the M4 (Lifter) home offset
and press Bind
Min = -120, Max = 120
+###
New value: 0
5.2.15 Save Calibration (17)
1) Access the service menu and perform selection 17 Save Calibration to store the Serial Number, Calibrations,
Bind and Autocycle counts that are on the MC to the UI.
2) With machine on, lid close, go to the Service Menu, and choose selection 17 and press Bind.
Selection 17
Enter Serial Number0000
4) Use the directional pad to move to each number and change the serial number to match what is on the back
of the machines near the power cord
New value: #####
6) The new calibrations will be stored on the User Interface board
7) Display will return to the Service Menu
8) Run selection 1 to verify that the value on the MC and UI are the same
MC Calibration settings
Positioner (M3) Home Offset = #
SN = ##### BC: # #
5 SERVICE MENU
5.2.15 Save Calibration (17) Continued
9) Pressing the Bind button again will show the current calibrations, Serial number (SN), Bind Count (BC) and
Auto cycle counts stores on the User Interface
Calibrations in the UI:
Positioner (M3) Home Offset = #
SN = ##### BC: # #

5 SERVICE MENU
5.3 AUTO CYCLE MODE
5.3.1 AUTOCYCLE

1. Power on the binder. (If it’s a cold start, wait 3-5 minutes
for machine to become ready to bind)
2. Insert a small book into the binder, Blocking the book

sensor (Fig 1) .
3. Press the “Open” and the “4-Way Cursor button” at the

same time, Pressing the Up arrows on both the buttons Fig 1
(Fig 2).
4. If the buttons were pressed right, the machine should

display in the top left corner “AUTO”, then in the bottom
“BIND COUNT: 0000”, if nothing shows up then try again
(Fig 3).
5. Move the small book to the left side, just enough to

clear the book sensor beam, then move it back to block
the book sensor beam, then automatically the binder will
start the autocycling mode (Fig 4).
Fig 2
NOTE: AUTOCYCLING IN FIRMWARE 1.3.1 AND UP WILL AU-
TOMATICALLY STOP, ONCE THE MACHINE REACHES 1000
CYCLES, AND PUT THE MACHINE TO SLEEP.
Fig 3
Fig 4

5 SERVICE MENU

5 SERVICE MENU
5.4 TESTING AND CALIBRATIONS
TOOLS REQUIRED: Ohmmeter
5.4.1 Checking the Resistance of the Heater Power Connectors
1. Turn off the machine. Make sure the machine is unplugged.

2. Open the machine.
WARNING! - HEATERS MAY BE HOT - WARNING!
3. Disconnect the Heater Power Connectors (Fig 1 & 2).
Note: Early models used a “0” and a “1” for the connectors instead of the color dots.
4. Touch the two probes to the Heater Power connector (Pins 1 & 2.) (Fig 3).
5. Verify the readings on the Ohmmeter are as follows:
HEATER RESISTANCE
HEATER 115V 22.4 ohm +/- 10%
HEATER 220v 88.17 ohm +/- 10%
HEATER 100v 16.67 ohm +/- 10%
6. Ensure all connectors are re-attached back to their original locations, or damage may occur on the heater elements or
thermal fuses may blow (Fig 1).
7. Replace platen assembly if necessary, refer to sections 6.7.1, Stationary Platen Removal and Replacement, or 6.7.4,
Rotating Platen Removal and Replacement.
Stationary Connector Rotating Connector
Fig 1 Fig 2
Fig 3

5 SERVICE MENU
5.4 TESTING AND CALIBRATIONS CONTINUED
TOOLS REQUIRED: Ohmmeter
5.4.2 Checking the Thermofuse

2. Open the machine.
WARNING! - HEATERS MAY BE HOT - WARNING!
3. Lift the cool platen until it engages with the magnet (Fig 1).
4. Touch the two probes across the thermofuse leads

(Fig 2 & Fig 3).
Fig 1
5. Verify the readings on the Ohmmeter is Less than 1 Ohm.
6. If reading is larger than 1 Ohm (normally a reading in the

Mega Ohms), the thermofuses have failed and need to be
replaced refer to 6.7.3 and 6.7.4.
Fig 2
Fig 3

5 SERVICE MENU
5.4 TESTING AND CALIBRATIONS CONTINUED
TOOLS REQUIRED: Temperature Meter, #1 Phillips Screwdriver,

& Heat Gun
5.4.3 Checking the Thermocouple
2. Remove front Skirt and unplug themrocouple to be tested

(Fig 1). (Refer to 6.1.4)
Note: Earlier models used a “0” and a “1” for connectors instead
Fig 1
of colored dots (blue for stationary, orange for rotationg).
Stationary Thermocouple Rotating Thermocouple
3. Remove thermocouple from machine by unscrewing thermo- Connector Connector
couple from heater assembly and removing all necessary wire
ties / mounting brackets. Refer to 6.7.3 and 6.7.4 for removal of
thermocouple.
4. To test if thermocouple has failed open, plug connector into

a temperature meter (Fig 2). If there is no reading the thermo-
couple has failed and needs to be replaced (K-208515).
5. To test if thermocouple has a short at high temperatures,

plug connector into a temperature meter, and hold the end
over a heat gun. Allow temperature to reach 425 degrees F (218
degrees C) (Fig 3). Fig 2
Note: Do not allow the thermocouple to reach a temperature

above 500 degrees F (260 degrees C) for this may damage the
thermocouple and/or thermocouple potting.
6. If the temperature reading has a slow response, a nonaccu-

rate reading, or no reading at all at high temperature, the
thermocouple has failed and needs to be replaced (K-208515).
Note: If thermocouple has failed with a short, you may remove

connector cover and check for shorted wires (Fig 4).
Fig 3
7. To reinstall reverse the procedure above.
Note: The approiate heater temperature calibration procedure

must be performed after replacing a thermocouple or the
machine will not function correctly. (Refer to 5.2.1 or 5.2.2)
Fig 4
5 SERVICE MENU

5 SERVICE MENU

6 SER VICE AND CALIBRATION PROCEDURES
6.1 COVERS
The focus of these service procedures is to explain how to safely and efficiently remove and replace components
of the binder. Each part of this section deals with a specific component. At the end of each procedure any
calibrations required will be noted.
TOOLS REQUIRED: #1 & #2 Phillips Screwdriver
6.1.1 Top Cover removal and replace-

ment
1. First remove the 2 screws on the finger

guard (Fig 1).
2. Unplug the display connector and remove

the ground wire screw. (Fig 2)
Fig 1
3. The top cover is attached by 6 phillips
head screws, 4 across the top and 2 at the
bottom. To access the screws at the bottom
you’ll need to turn the carriage belt clock-
wise to expose them. Remove all 6 screws
and set the cover aside (Fig 3). Fig 3
4. To reattach the top cover reverse the

above steps.
Fig 2
TOOLS REQUIRED: #2 Phillips Screwdriver
6.1.2 Left Cover Panel removal

and replacement
1. The left cover panel is attached by

6 phillip head screws, 2 in the front,
2 in the rear, and 2 inside the unit.
Fig 1 Fig 2
2. To access the screws inside the
unit, lift the cool platen until it en-
gages with the magnet.
3. Remove all screws and set left

cover panel aside.
4. To reattach the left cover panel re-

verse the above steps.
Fig 3

6.1 COVERS CONTINUED
6.1.3 Right Cover Panel removal

and replacement
1. The right cover panel is attached by

6 phillip head screws, 2 in the front,
2 in the rear, 1 on the outside and 1
inside the unit.
Fig 1 Fig 2
2. To access the screws inside the
unit, lift the cool platen until it
engages with the magnet.
3. Remove all screws and set right cov-

er panel aside.
4. To reattach the right cover panel re-

verse the above steps.
Fig 3 Fig 4
TOOLS REQUIRED: #2 Phillips Screwdrivers
6.1.4 Front Cover Panel removal and replacement
1. The front cover panel is attached by 10 phillip head screws,

8 in the front and 2 inside the unit (Fig 1 & 2)
2. To access the screws inside the unit, lift the cool platen until
it engages with the magnet. Fig 1
3. Remove all screws and set front cover panel aside.
4. To reattach the front cover panel reverse the above steps.
Fig 2

6.2 UI BOARD
TOOLS REQUIRED: #2 Phillips Screwdriver & a ESD Strap
WARNING:THE FOLLOWING PROCEDURE SHOULD ALWAYS

BE PERFORMED ON A GROUNDING MAT WITH AN ANTI-STATIC
WRIST BAND ATTACHED.THIS IS DUE TO THE SENSITIVITY OF THE
UI BOARD TO ESD.
6.2.1 UI Board Removal and Replacement
1. Disconnect the power cord and open the top cover.

Fig 1
2. Remove the top cover (Refer to 6.1.1).
3. Remove UI shield from top cover by removing the 2 screws located on top
with retainers (Fig 1).
4. While lifting the UI shield up slightly, slide it towards the right to clear the
UI board, then remove. (Fig 2).
5. Using your finger nail flip up the connector lock on the display to UI board
connector (Fig 3).
WARNING:THE CONNECTOR’S SURFACE (END OF RIBBON) IS VERY Fig 2

SENSITIVE AND SHOULD NOT BE TOUCH WHILE REMOVAL OR IN-
STALLATION OF THE UI BOARD.
6. Using your finger tips, on the ribbon, only slide out the display connector
(Fig 4).
7. Remove the 2 screws with retainers that hold the UI board (Fig 5).
8. Lift up on the UI board to clear the stand off and then slide the board out
of the front hooks (molded into the front lip of the top cover ) and remove Fig 3
board (Fig 6).
9. Inspect contact pads on button pad, if carbon pad is missing then replace
button pad, remove by peeling back, during installation be sure that button
pad is fully installed onto the button pins (Fig 7 & 8).
10. Remove display from top cover for replacement
Note: During installation be sure display is located against top stop of the
window (Fig 9).
Fig 4
11. To reinstall reverse the steps above.

6.2 UI BOARD CONTINUED
Fig 5 Fig 9
Fig 6
Fig 7
Fig 8

6.3 CONTROLLER ASSEMBLY
TOOLS REQUIRED: #2 Phillips Screwdriver & ESD Ground Strap
6.3.1 Inspecting the Controller Assembly
The Controller Assembly can be accessed by removing the Front

Cover Panel (Refer to 6.1.4). The Controller Assembly is attached
with two phillips head screws located inside the unit (Fig 1).
WARNING:THE FOLLOWING PROCEDURES SHOULD

ALWAYS BE PERFORMED ON A GROUNDING MAT WITH
AN ANTI-STATIC WRIST BAND ATTACHED.THIS IS DUE
Fig 1
6.3.2 Removing the Controller Assembly
1. Disconnect the power cord from the machine.
2. Disconnect all the Wire Harness connections except the

Thermocouples from the Controller Assembly (Fig 2).
3. Remove the controller bracket screws (Fig 1).
4. Gently remove the Controller Assembly and disconnect the

two
Fig 3thermocouples (Fig 3 & 4). Fig 2
5. Note the position of each thermocouple connector.
6. Remove the Controller Assembly.
6.3.3 Installing the Controller Assembly
1. Reverse the steps in 6.3.2 to install the controller. Ensure you

reconnect the thermocouples to their original positions. Fig 3
2. Refer to the Service Menu Section 5 for complete calibration

instruction.
Fig 4


6 . 4 M OTO R S A N D B E LTS
6.4.1 Belt Removal and Replacement
Refer to each motor section for the belt removal and replacement.
TOOLS REQUIRED: #2 Phillips Screwdriver & Diagonal Cutters
6.4.2 Carriage Motor Removal and Replacement
1. Cut the cable tie attaching the Wire Harness to the wire saddle using
Diagonal Cutters (Fig 1).
2. Disconnect the Wire Harness

Connector from the Carriage Motor.
3. Remove the belt from the Carriage Motor pulley (Fig 2).
Fig 1
4. While holding the Motor remove the four phillip head screws, washers,
and nuts.
5. Remove the Motor (Fig 3).
Fig 2
Fig 3
Fig 3

6 . 4 M OTO R S A N D B E LTS CO N T I N U E D
6.4.3 Lifter Motor Removal and Replacement
1. Remove the right cover panel (Refer to 6.1.3).
2. Remove the belt from the lifter pulley (Fig 1).

Connector from the Lifter Motor.
4. While holding the motor remove the three phillip

head screws, washers, and nuts.
5. Remove the Motor (Fig 2). Fig 1
Note: Position of the motor wires must be

facing towards the top.
7. No Mechanical adjustment is required after replacing

the motor.
Fig 2 Fig 3

6.4.4 Tape Feed Motor Removal and Replacement
1. Open the top cover and latch in place.
2. Remove the front cover panel (Refer to 6.1.4).
Fig 1
4. Push and hold down on the pivot arm to allow room to remove the
belt.
5. Remove the belt from the Tape Feed pulley (Fig 2).
6. Disconnect the Wire Harness connector from the Tape Feed Motor
(Fig 3).
7. While holding the Motor remove the phillips head screw and washers
from the bottom left and the phillip head screw, washer and nut from
the upper right. Fig 2
Note: Early models have a pem nut in the upper right position
8. Remove the Motor (Fig 4).
Note: Position of the motor wires must be facing towards the top.
10. After installing the motor and the belt, loosen the screws and pivot
the motor to increase the belt tension so the belt flexes slightly when Fig 3
pressed with a finger.
Note: For early models that have a pem nut in the upper right position
just lift up on the motor to perform this calibration.
Fig 4

6.4.5 Positioner Motor Removal and

Replacement
1. Open the top cover and latch in place.
2. Remove the left cover panel (Refer to

6.1.2).
3. Remove the front panel cover and co-

troller assembly. Fig 1 Fig 2

connector from the Positioner Motor
and remove the motor wiring from the
wire saddle (Fig 1).
5. Remove spring from positioner gear

(Fig 2).
6. Remove captive E-Clip from positioner

Fig 3
gear shaft (Fig 3). Fig 4
7. Remove positioner gear from the shaft

(Fig 4).
8. While holding belt remove the idler

gear and then the belt (Fig 5).
9. Close the top cover and place the ma-

chine on its back side (Fig 6).
Fig 6
Fig 5
10. While holding the motor remove the
two phillips head screws and washers.
(Fig 7).
Note: Position of the motor wires must be

facing towards the top.
12. No Mechanical adjustment is required

after replacing the motor. Fig 7

6.5 SENSORS
TOOLS REQUIRED: #1 & #2 Phillips Screwdrivers
6.5.1 Book Sensors Removal and Replacement
1. Open unit and remove the top cover (Refer to 6.1.1).
2. Close the unit.
3. Unplug the front and back book sensor connectors

(Fig 1 & 2).
4. Remove each sensor and replace.

Fig 1
Note: Replace both sensors.
6. Refer to 5.2.7 for the electronic book sensor calibration

procedure.
Note: The calibration procedure must be performed after re-

placing the book sensors or the machine will not function
correctly.
Fig 2
TOOLS REQUIRED: #1 & #2 Phillips Screwdrivers
6.5.2 Carriage Sensors Removal and Replacement
1. Open unit and remove the top cover (Refer to 6.1.1).
2. Close the unit.
3. Unplug either the front or the back carriage sensor

Connectors
Fig 2 (Fig 1).
4. Remove the sensor and replace.
6. Refer to 5.2.3 and 5.2.4 for the electronic Carriage Clamp Fig 1
and M1 (Carriage) Home calibration procedures.

placing the carriage and clamp home sensors or the ma-
chine will not function correctly.

6.5 SENSORS CONTINUED
6.5.3 Tape Edge Sensor Removal and Replacement
1. Open unit and lift the cool platen until it

engages with the magnet (Fig 1).
2. Remove the right side cover panel (Refer to 6.1.3).
3. Rotate the Positioner gear on the left side of the unit clockwise
until it stops.
4. Unplug the tape edge sensor connector (Fig 2). Fig 1
5. Hold the tape feed bar from underneath and remove the two
phillip head screws (Fig 3).
6. Remove and replace the tape edge sensor
Note: Ensure the Tape Feed Sensor does not touch the Strip Rejec-
tor Guide. (Fig 4).
8. Refer to Section 5.2.11 for the electronic Edge Sensor, M2 (Tape

Feed), calibration procedure.
Fig 2
Note: The calibration procedure must be performed after replacing
the edge sensor or the machine will not function correctly. Fig 2
Fig 3 Fig 4

6.5.4 Tape Sensor Set Removal and Replacement

2. Remove the right side cover panel (Refer to 6.1.3).
3. Rotate the Positioner gear on the left side of the unit coun-
ter clockwise until it stops.
4. Unplug the top and bottom tape sensor connectors

Fig 1
(Fig 2).
5. Hold the top tape sensor and remove the two phillip head
screws. (Fig 2)
6. Hold the bottom tape sensor and remove the one phillips
head screw.
7. Remove and replace the both tape sensors
Note: When installing the bottom tape sensor ensure it is

placed in the slotted area (Fig 3).
Fig 2
9. Refer to 5.2.5 and 5.2.6 for the electronic Inner and Outer
Tape Sensor calibration procedure.

placing the edge sensor or the machine will not function
correctly.
Fig 3

6.5.5 Smart Sensor Removal and Replacement

2. Remove the right side cover panel. (Refer to
3. Rotate the Positioner gear on the left side of the unit counter
clockwise until it stops.
Fig 1
4. Press the pivot arm down half way to allow access to the phillips
head screw holding the smart senor on the bracket (Fig 2).
5. Remove the phillip head screw (Fig 2). See kit for new screw.
6. Unplug the smart senor connectors (Fig 3).
7. Remove and replace the smart sensor .
Note: Record the new smart sensor value that is on the white label on
the bracket. This will be used for re-calibration purposes (Fig 3). If Fig 2
not recalibrated machine may not function properly.
9. Refer to Section 5.2.8 for the electronic Smart Sensor calibration

procedure.
10. When replacing the smart sensor you must also replace the short-
er circled screw (Fig 4) with the longer screw supplied with your
smart sensor (Part# 200477) in order to ensure smart sensor stabil-
ity.
11. Once the screw has been replaced, you will notice it will slightly
rest on top of the bottom screws head. Thus providing less prob-
ability of movement (Fig 5). Fig 3
Fig 5 Fig 4
TOOLS REQUIRED: #2 Phillips Screwdriver & Diagonal Cutters
6.5.6 Lifter Sensor Removal and Replacement

2. Remove the left side cover panel (Refer to 6.1.2).
3. Rotate the Positioner gear on the left side of the unit

counter clockwise until it stops.
4. Using your left hand index finger press in on the sensor

through the cutout in the left side panel and unplug the
sensor connector using your right hand (Fig 2). Fig 1
5. Remove the one phillip head screw. (Fig 3)
6. Remove the lifter sensor
Note: Prior to installing this sensor you need to cut off the
black round tab (Fig 4).
8. Refer to Section 5.2.10 for the M4 (Lifter) Home electronic

calibration procedure.

placing the M4 Home sensor or the machine will not func-
tion correctly.
Fig 2
Fig 3 Fig 4

6.5.7 Positioner Sensor Removal and Replacement

2. Rotate the Positioner gear on the left side of the unit

clockwise until it stops.
3. Unplug the positioner sensor connector (Fig 2).
4. Hold the positioner sensor and remove the one phillip

Fig 1
head screw. (Fig 2)
5. Remove and replace the positioner sensor.
7. Refer to Section 5.2.9 for the M3 (Positioner) Home elec-

tronic calibration procedure.
Note: The calibration procedure must be performed after

replacing the M3 (Positioner) Home sensor or the ma-
chine will not function correctly.
Fig 2

6.6 POWER SUPPLY AND TR ANSFORMER
TOOLS REQUIRED: #2 Phillips Screwdriver, Feeler Gauge, & 11/32” Open End Wrench
6.6.1 Power Supply and Transformer Removal and Replacement
2. Remove the left side cover panel (Refer to 6.1.2).
3. Remove the magnet using the wrench (Fig 1).
4. Lift the cool platen vertical and then pull up until the white bushings on Fig 1
both sides dislodge. Continue to lift the cool platen up so the white bushing
are in the upper holes (Fig 2).
5. Remove either the left or right white bushing (Fig 3).
6. Remove the cool platen and set on the top of the lid stops (Fig 4).
7. Remove the 4 phillips heads screws on the rear of the machine. 2 are for
the PS bracket and 2 are for the PS cover (Fig 5).
8. Remove the 4 phillips heads screws inside the machine. 2 are for the PS Fig 2
and 2 are for the PS cover (Fig 6).
9. Remove the PS cover.
10. Unplug all PS connectors and remove the 1 phillips head screw for the
transformer. (Fig 7).
11. Remove the 2 phillips head screws on the left side of the unit (Fig 8).
12. Remove the PS and transformer.
13. To reinstall reverse the steps above. Fig 3
Note: The PS and Transformer are calibrated as a set at the factory. The trans-
former is labeled with the serial # of the PS (Fig 9).
Note: When replacing the magnet ensure there is a .025” gap between the
locking nut and the rear of the magnet. Use a feeler gauge when calibrating
this distance.
Fig 4

6.6 POWER SUPPLY AND TR ANSFORMER (CONTINUED)
Fig 5 Fig 9
Fig 6
Fig 7
Fig 8

6.7 HEATER ASSEMBLIES
TOOLS REQUIRED: #2 Phillips Screwdriver & Platen Level Gauge
6.7.1 Stationary Heater Assembly Removal and Replacement
2. Lift the cool platen until it engages with the magnet. Remove the tie wrap
holding heater wires to the frame (Fig 1).
Fig 1
3. Remove the front cover panel and the controller assembly (Section 6.1.4).
4. Disconnect the thermocouple connector (for the Stationary heater) from Stationary Connector
the controller assembly (J10). Reter to Section 6.3. Rotating Connector
5. Feed thermocouple back in to the machine through the access hole.
6. Unplug the heater connector from the power supply (Fig 2).
7. Remove the heater wires from the wire saddles.

Fig 2
8. Lower the cool platen and remove the 4 phillips head screws from the top of
the stationary heater (Fig 3).
9. Lift up on the cool platen and remove the stationary heater.
Note: Mica washer (Part# K-208076) are used to level the heater to the cool
platen. Keep these for re-installation (Fig 4).

Fig 3
11. Check the level between the cool platen and the stationary heater. Ensure
that they are level. Add or remove Mica washers as required.
Note: CAUTION!!! This check should be perform while the machine

Fig 3 is HOT!!!
12. Perform the Stationary to Rotating Platen calibration procedure 6.7.2.

Check Rotating Platen Stop Angle calibration procedure 6.7.6, Rotating Platen
Level calibration procedure 6.7.7, and Rotating Platen 90 Degree Level calibra-
tion procedure 6.7.8; recalibrate if necessary.
Fig 4
13. Refer to Section 5.2.1 for the Stationary Heater Temperature calibration
procedure.
Note: The calibration procedures in steps 11-13 must be performed after re-
placing the Stationary Platen or the machine will not function correctly.
Fig 5
6.7 HEATER ASSEMBLIES CONTINUED
TOOLS REQUIRED: #2 Phillips Screwdrivers, Platen Level Gauge, & Feeler gauge
6.7.2 Stationary to Rotating Platen Calibration
1. Bring the rotating platen level with the stationary platen using the lifter
pulley (Fig 1).
2. Loosen the 4 screws that hold the stationary platen in place, using a .020”
feeler gauge adjust the stationary platen along the entire length and re-
tighten the screws (Fig 2). Fig 1
Note: .020” is the cold measurement and .015” is the hot measurement be-
tween the rotating and stationary platen. We suggest calibrating when
cold.
Note: Be cautious when adjusting stationary platen not to pull platen frame
from its normal operating position. Otherwise your calibration may not
be correct.
Fig 2

TOOLS REQUIRED: #1 Phillips Screwdrivers, 11/32” Open End Wrench, & Diago-
nal Cutters
6.7.3 Stationary Platen Thermal Fuse or Thermocouple Removal

and Replacement
2. Remove the magnet using the wrench (Fig 1).

Fig 1
3. Lift the cool platen vertical and then pull up until the white bushings
on both sides dislodge. Continue to lift the cool platen up so the white
bushing are in the upper holes (Fig 2).
4. Remove either the left or right white bushing (Fig 3).
5. Remove the cool platen and set on the top of the lid stops (Fig 4).
THERMAL FUSE:
6. Remove the terminals on the Thermalfuse and bend the legs to get Fig 2
access to the screws (Fig 5).
7. Remove the thermal fuse.
THERMOCOUPLE:
6. Remove front Skirt and unplug stationary platen themrocouple(Fig 6).
(Refer to 6.1.4)
Fig 3
Note: Early models used a “0” and a “1” for connectors instead of colored
dots (blue for stationary, orange for rotating).
7. Remove thermocouple from heater, wire clip, and wire ties (Fig 7).
8. Remove thermocouple.

Stationary Thermocouple
Connector Fig 4
Thermocouple Wire Clip

Fig 7
Fig 7 Fig 6 Fig 5

TOOLS REQUIRED: 9/64” allen wrench
6.7.4 Rotating Heater Assembly Removal and Replacement
3. Remove the front cover panel and the controller assembly (Section 6.1.4). Fig 1
4. Disconnect the thermocouple connector (for the Stationary heater) from

the controller assembly (J11). Refer to Section 6.3. Stationary Connector
Rotating Connector
5. Feed thermocouple back in to the machine through the access hole.
6. Unplug the heater connector from the power supply (Fig 2).
7. Remove the heater wires from the wire saddles.

Fig 2
8. Remove the allen head screws and washers from the rotating platen.(Fig 3).

Fig 5
10. When installing the left side of the rotating platen hold the acuator arm as
shown (Fig 4).
11. Check the Stationary to Rotating Platen calibration procedure 6.7.2., Ro-
tating Platen Stop Angle calibration procedure 6.7.6, Rotating Platen Level
calibration procedure 6.7.7, and Rotating Platen 90 Degree Level calibration
procedure 6.7.8; recalibrate if necessary. Fig 3
12. Refer to Section 5.2.2 for the Stationary Heater Temperature calibration
procedure.
Note: The calibration procedures in steps 11 and12 must be performed after

replacing the Rotating Platen or the machine will not function correctly.
Fig 4

TOOLS REQUIRED: #1 Phillips Screwdrivers & 9/64” allen wrench
6.7.5 Rotating Platen Thermal Fuse and Thermocouple Removal

and Replacement
Fig 1
3. Remove the left hex screw from the rotating platen (Fig 2).
4. Turn the rotating platen to allow access to the thermal fuse (Fig 3).
THERMAL FUSE:
6. Remove the terminals on the Thermalfuse and bend the legs to get
access to the screws (Fig 4).
7. Remove the thermal fuse.
8. To reinstall reverse the procedure above. Fig 2
THERMOCOUPLE:
6. Remove front Skirt and unplug rotating platen themrocouple(Fig 6).
(Refer to 6.1.4)
Note: Early models used a “0” and a “1” for connectors instead of col-
ored dots (blue for stationary, orange for rotating).
7. Remove thermocouple from heater, wire clip, and wire ties (Fig 7).
Fig 3
8. Remove thermocouple.
Rotating Thermocouple
Connector Fig 4
Wire Tie
Wire Clip Thermocouple
Fig 5 Fig 6

TOOLS REQUIRED: 11/32” Open End Wrench & 5/64” allen wrench
6.7.6 Rotating Platen Stop Angle Calibration
2. First rotate positioner gear just before bearing makes contact with
rotating platen cam, this will ensure stationary platen is riding on
the high position of the positioner shaft cams (Fig 1 & 2). Fig 1
3. Bring rotating platen level with the stationary platen, using a level
gauge to check to see if rotating platen is sitting level with station-
ary platen (Fig 3).
4. If not level loosen the lock nut using an 11/32 wrench, with the lock
nut loose, adjust the set screw in and out to set the stop angle of
the rotating platen (Fig 4).
5. Once the rotating platen stop angle is found use the 11/32 box end
wrench to retighten the lock nut while hold the set screw in place Fig 2
with an hex key, as shown above.
Fig 3
Fig 4

TOOLS REQUIRED: #2 Phillips Screwdriver & Platen Level Gauge
6.7.7 Rotating Platen Level Calibration
2. Bring rotating platen level with the stationary platen using the lifter
motor pulley (Fig 1).
Fig 1
3. Using a level gauge across the cool platen to the stationary platen
check that the rotating platen is level on the left, right, and middle
(Fig 2).
4. If not level, loosen the 2 screw on the left side lifter gear, bring the
right side of rotating platen level to stationary platen (Fig 3 & 4).
5. Lift the left side of the rotating platen by the acuator arm until the
rotating platen is level with stationary platen. Retighten lifter gear
screws (Fig 5).
Fig 2
Note: If the left side can not be leveled then a readjustment of the
right side lifer gear may need to be performed (Fig 6).
Note: If this does not work then either the left or right lifter gear is not
clocked right and must be reinstalled.
Fig 3
Fig 4
Fig 5 Fig 6

TOOLS REQUIRED: #2 Phillips Screwdriver & 90 degree angle gauge
6.7.8 Rotating Platen 90 Degree Level Calibration
2. Bring rotating platen to first bind position, with the bearing in

the middle of the cam (Fig 1).
Fig 1
3. Using a 90° angle gauge check that rotating and stationary
platen make a 90° angle (Fig 2).
4. If not loosen the screw on the rotating platen catchment on

the left side and slide it back and forth slightly until the bear-
ing makes contact with the catchment while in it’s 90° position
(Fig 3 & 4).
Fig 2
Fig 3
Fig 4

TOOLS REQUIRED: None
6.7.9 Cool Platen Check and Calibration
Note: This procedure should only be done if needed.
1. First rotate positioner gear just before bearing makes contact

with rotating platen cam, this will ensure stationary platen
is riding on the high position of the positioner shaft cams
(Fig 1 & Fig 2).
2. Check that the platen frame rides evenly on positioner shaft

cams by pressing down one side of the platen frame at a Fig 1
time. Check for any rocking motion. Check both along the
cool platen and front tabs (Fig 3).
3. If platen frame does not ride evenly, twist the frame with a
small amount of force until it rides evenly on cams (Fig 4).
Fig 2
Fig 4 Fig 3

6.8 TAPE FEED BAR
TOOLS REQUIRED: # 1 Phillips Screwdriver & Tape Feed Bar Gauge
6.8.1 Tape Feed Bar Calibration
3. Using the tape bar gauge (0.0625”) insert in to the tape feed
channel and check the width and smoothness by sliding Fig 1
tool back and forth, including gap on the T1 sensor (Fig 2).
4. If gauge does not move smoothly than readjust by loosing

and retightening the screws ( Fig 3).
5. To check for a bent tape feed bar, place the tape bar gauge
into the channel and check for rocking by pressing down
on one side after the other (Fig 4). If there is excessive rock-
ing the tape feed bar is bent and needs to be replaced.
Fig 2
Fig 3
Fig 3

6.8 TAPE FEED BAR CONTINUED
TOOLS REQUIRED: # 1 Phillips Screwdriver ,Platen Level gauge and Feeler gauges
6.8.2 Rotating Platen to Tape Feed Bar Calibration
2. Bring rotating platen level with the stationary platen using the lifter mo-
tor pulley (Fig 1).
Fig 1
3. Bring rotating platen to first bind position using the positioner gear,
with the bearing in the middle of the cam (Fig 2).
4. Move the rotating platen downwards with the lifter motor until it makes
contact with the linkage bearing (Fig 3).
5. Lift the cool platen until it engages with the magnet
6. Use the positioner gear to rotate the tape feed bar to it’s closest position
to the rotating platen . Fig 2
Note: the gap is .015” when hot or .020” when cold.
7. Use a feeler gauge to check the distance between the tape feed bar and
the rotating platen (Fig 4).
8. If the tape feed bar needs to be adjusted loosen the four screws then
adjust the position of the tape feed bar, and tighten the screws.
Fig 3
Fig 4
Fig 4
Fig 5

6.9 TAPE FEED ROLLER
TOOLS REQUIRED: #2 Phillips Screwdriver, Needle

nose pliers, & 1/16” & 5/64” allen wrench
6.9.1 Tape Feed Roller Removal and Re-

placement
1. Disconnect the power cord and open the top

cover.
Fig 1 Fig 2
2. Lift the cool platen until it engages with the
magnet (Fig 1).
3. Remove the front and right cover panels (Re-

fer to 6.1.3 and 6.1.4).
4. Remove the lower T3/T2 PCA (Fig 2).
5. Carefully place the machine on its back side

and remove the collar and spacer on the Fig 3 Fig 4
tape feed roller shaft (Fig 3).
6. Set the machine back on its bottom.
7. Remove the screw holding tape feed roller

bracket (Fig 4).
8. Slide the feed roller assembly out . Leave the

belt attached to the feed motor pulley.
Fig 5 Fig 6
9. Remove the e-clip, the spacer and the bear-
ing from the end of the feed roller assembly
(Fig 5).
10. Remove the pulley from the feed roller shaft.

This pulley will be installed on the replace-
ment feed roller (Fig 6.)
11. Reinstall the pulley on the new feed roller. Fig 8

Fig 7
Align the front edge of the pulley with the
notch on the shaft (Fig 7 and 8).

Before installing the right side cover perform
steps 13 and 14.
Note: Slide the feed roller shaft and pulley in
through the belt before securing the bracket.
Note: When installing the bottom tape sensor
ensure it is placed in the slotted area (Fig 9). Fig 9
13. Check the tape feed roller and bearing align- 14. Check the Linkage calibration procedure 6.9.3
ment procedure 6.9.2.
6.9 TAPE FEED ROLLER CONTINUED
6.9.2 Tape Feed Roller and Bearing Alignment/Replacement
3. Remove right cover panel (Refer to 6.1.3). Fig 1
4. Manually hold the feed arm bearing in contact with the roller
(Fig 2).
5. Looking through the right side opening check that the bearing
on the feed arm and the feed roller line up on the side facing
the rear of the machine(Fig 3).
Note: Bearing must be inline with roller when viewed from the top,
if bearing is not pressed on striaght or feed arm does not come
Fig 2
down straight, then the strip will not feed straight (Fig 4). Either
replace the bearing or adjust the feed arm by loosen feed arm
bracket screw (Fig 5).
6. If not remove the tape feed roller and adjust the roller position
by pressing the shaft in or out of the roller
7. Follow procedure 6.9.1 to remove and replace the feed roller as-
sembly.
8. To replace Tape Feed Bearing, remove screw locate on feed arm Fig 3
(Fig 6).
Fig 4
Fig 5 Fig 6
6.9 TAPE FEED ROLLER CONTINUED

Fig 1
6.9.3 Linkage Calibration Procedure
2. Remove right cover panel (Refer to 6.1.3).
3. Close the cover, turn the machines on and allow it to

come to ready.
4. Insert a book into the clamp and press the Bind but-
ton.
5. The clamps will close and the tape feed arm will be in
the downward position.
6. Look at the torsion spring arm, if not slightly off of Fig 2

the right side of the bracket to the middle of its travel
(Fig 1) then press the open button.
7. Readjust the linkage distance by loosing the screw in

the middle of the linkage arms (Fig 2) and pulling the
arms of the linkage apart or closer and then tighten-
ing the screw.
Note: Unclamp the book before making any adjust-

ments.
8. Repeat steps 4 through 7 until the torsion spring arm

is slightly off of the right side of the bracket to the
middle of its travel.

6.10 STRIP DEFLEC TOR
TOOLS REQUIRED: #2 Phillips Screwdriver & Tape Feed Gauge
6.10.1 Strip Deflector Removal, Replacement, Calibration Procedure
1. Remove Front Cover (Refer to 6.1.4), and unplug both thermocouples

(Refer to 6.3).
Note: This will override the heaters and allow the machine to come to
ready and clamp a book without being HOT!!! Fig 1
2. Open up the top cover and install the Interlock override tool (Fig 1).
3. Turn the machines on and allow it to come to ready.
4. Insert a narrow book into the clamp and press the Bind button.
5. The clamps will close and the tape feed arm will be in the downward
position. Fig 2
6. Check strip deflector with tool (Fig 3), make sure front notch lines up
with the deflector when slid in the tape feed bar (Fig 4). Adjust strip
deflector if necessary by loosening the screw.
Note: By adding a long post to the Tape Feed Gauge it makes it easier to
handle during calibration.
7. To remove and replace, remove the screw that holds the strip deflector.
To reinstall reverse the procedure above.
Fig 3
Fig 4

6.11 REAR AND FRONT CLAMP
TOOLS REQUIRED: #1 & #2 Phillips Screwdriver and

9/64” allen head
6.11.1 Rear and Front Clamp Calibration
1. Open the cover and remove the left and right

clamp springs (Fig 1).
2. Move rotating platen level with the stationary

platen, and then turn the positioner gear clockwise Fig 1 Fig 2
until the rotating heater comes to a 90 degree angle
and close the cover (Fig 2).
3. Using the carriage motor belt open the front

clamp to allow access to the rotating heater (Fig 3).
4. Insert a piece a paper on the left, middle and right

side on the back of the rotating platen closing the
rear clamp each time. Ensure the pull force is even
for each. Perform the calibration in steps 5 through
15 if necessary. (Fig 4) Fig 3 Fig 4
5. Open the top cover and remove the finger guard

and then unplug the display cable and un-screw
ground wire. There are 6 screws total that hold the
top cover to the frame, 4 across the top and 2 at the
bottom. To access the screws at the bottom you’ll
need to turn the carriage belt clockwise to expose
them. Remove all 6 screws (Fig 5). (Refer to 6.1.1)
6. Move rotating platen level with the stationary

platen, and then turn the positioner gear clockwise
until the rotating heater comes to a 90 degree angle.
Fig 5 Fig 6
(Fig 2).
7. Close the lid and loosen the 5 socket head screws

on the rear clamp (Fig 6).
8. The rear clamp will be loose, pull it forward to-

wards you until it makes contact across the face of
rotating heater, and then begin tightening the socket
heads screws again. (Fig 4).

6.11 REAR AND FRONT CLAMP CONTINUED
6.11.1 Rear and Front Clamp Calibration Con-

tinued
9. Open the rear clamp and inserts a piece a paper on

the left, middle and right side closing the rear clamp
each time. Ensure the pull force is even for each. Re-
calibrate the rear clamp if necessary (Fig 8).
10. Open the cover and re-attached the left and right
clamp springs. Turn the positoner counter-clockwise
until the rotating heater is level with the cool platen. Fig 8 Fig 9
Close the cover (Fig 9).
11. Loosen the front clamp socket head screws, the

clamp springs will automatically pull the front clamp
into alignment with the rear clamp. Re-tighten the
socket head screws(Fig 10).
12. Rotate the carriage motor using the belt and open
the clamp and insert a narrow book in to the clamps.
Let the clamps close (Fig 11). Fig 10 Fig 11
13. Pull up on the top of the book on the left, center

and middle to ensure that the clamps are holding each
area with even pressure. Recalibrate the front clamp
if necessary (Fig 12).
14. Loosen the 2 screws that hold the lead screw nut
bracket. Pull the front clamp towards you about an
inch and then use the carriage belt to move the front
clamp back to allow access to the screws. Retighten Fig 12 Fig 13
the screws . This will ensure the bracket is aligned
properly. (Fig 13).
15. Re-install the top cover, plug in the display cable,

reconnect the ground wire, and re-install the finger
guard.
Note: The Front Back Up Bar calibration to the ro-

tating heater is not required as the front back up bar
has the ability to self align to the rotating heater.

TOOLS REQUIRED: #2 Phillips Screwdriver, 9/64” allen

head, 2 C-Clamps, Wood Prop, & Modified Backup Bar
Calibration Tool (Fig 1)
6.11.2 Rear and Front Back-Up Bar Calibration
NOTE: CALIBRATION IS DONE DURING MANU-

FACTURING AND SHOULD NEVER NEED TO BE Fig 1 Fig 2
ADJUSTED IN THE FIELD, EXCEPT IN VERY RARE
CIRCUMSTANCES.
PLEASE CONTACT TECH. SERVICES IF THE NEED

ARISES.

and then unplug the display cable and un-screw
ground wire. There are 6 screws total that hold the Fig 3 Fig 4
top cover to the frame, 4 across the top and 2 at the
bottom. To access the screws at the bottom you’ll
need to turn the carriage belt clockwise to expose
them. Remove all 6 screws.(Fig 2). (Refer to 6.1.1)
2. Loosen the 10 bolts on the top of the clamps,

move the clamps back and forth until there is even
clamping force along their length, retighten the bolts
(Fig 3). Fig 6
Fig 5
3. Open top frame and remove the clamp springs

(Fig 4). Place tool in between clamps and reinstall the
clamp springs (Note: The taller feet and smaller face
change go towards the front of the machine).
4. C-Clamp the Backup Bar Calibration tool in place

and place a prop between the middle top frame and
chassis to take out any twisting or sag from the top Fig 7 Fig 8
frame (Fig 5).
5. Loosen the 4 screws on the front back-up bar and

with a light force in the middle hold the back-up bar
against the tool and its stops (Fig 6 & Fig 7).
6. Make sure the back-up bar brackets are on there

clamps stop, tool face and back-up bar meet evenly,
and then tighten screws (Fig 8).
Fig 9
7. Check that back-up bar is calibrated sliding a piece
of paper in and out of the tool along its length (Fig 9). Note: Rear and Front Clamp Calibration, 6.11.1, procedure must
be performed.
8. Repeat steps 4-6 for the rear back-up bar

TOOLS REQUIRED: 11/3” open end wrench, .080” Feeler

Gauge, & Flat-head Screwdriver
6.11.3 Rear Restraint Bar Calibration
THE REAR RESTRAINT BAR IS ONLY USED WITH

LARGE SPLIT BOOKS BEING BOUND IN SPLIT
BOOK MODE.
Note: This calibration is perform during manufactur-

ing, and not all machines require the cam installation. Fig 1
1. Open the top cover and move rear clamp to the

rear of the machine.
2. Test distance between rear back-up bar screw and

restraint bar with .080” tool. (Fig 1 & Fig 2).
3. If the distance between the backup bar and tool is

greater than .080” than install a locking nut and re-
straint bar cam. First install the lock nut with blue lock
tight, than install the restraint bar cam with blue lock
tight, making sure the middle of the cam is under the Fig 2
restraint bar (Fig 3).
4. Adjust the cam until distance between back-up bar

screw and restraint bar is .080”. Hold the cam in posi-
tion with a slotted head screw driver and tighten the
locking nut with the 11/32” open end wrench (Fig 4).
Fig 3
Fig 4

6.11.4 Rear Shim Installation Instructions
THE REAR SHIM SHOULD NOT BE INSTALLED

ON MACHINE WHICH ARE USED FOR BINDING
SPLIT BOOKS IN SPLIT BOOK MODE.
Fig 1 Fig 2
Note: Retrofitting the rear back-up bar with the shim
will increase the squareness of the wrap. Currently
the rear back-up bar has a radius at the bottom which
means during the wrap it is unable to apply pressure
near the spine of the book. The shim eliminates the
radius found on the bottom of the rear back-up al-
lowing for even pressure along the length of the bind
near the spine of the book. It is not necessary for to
achieve normal bind quality. Fig 3 Fig 4
1. Open the top frame and remove clamp springs, ex-

posing the rear back-up bar face (Fig 1).
2. Peel back double sided tape on the back of the shim

(Fig 2).
3. Before installation line up the shim with the back up

bar in the orientation shown justifying the shim the
Fig 5 Fig 6
right, aligning the cut out for the back-up bar shoes
(justification is done to the right because the book is
justified to the right before a bind) (Fig 3).
4. Line the shim up the right side and bottom at a

slight angle so that the shim doesn’t get stick to the
back-up bar (Fig 4).
5. Once aligned, carefully rock the shim downwards

Fig 7
into contact with the back-up bar while holding the
shim and bottom of the back-up bar in contact at all
times (Fig 5).
6. Apply pressure across the length of the back-up bar

to insure good tape contact, do this by patting down
and/or sliding your hand across the length of the shim
(Fig 6).
NOTE: The goal of installation is to have the shim

flush against the back-up bar, justified to the right
(same side as book), and with the shim also touching
the bottom of the back-up bar so that the back-up bar
shoe still protrudes from the bottom of the back-up
bar; meaning the bar will ride across the heaters on
the shoe and not the shim (Fig 7).
6.11.5 Rear Back-Up Bar Tapping Pad
THE REAR BACK-UP BAR TAPPING PAD IS ONLY

NEED FOR DOMESTIC MACHINES THAT RUN 11
INCH STRIP.
1. Open the top cover.
2. Peel back double sided tape on the back of the Fig 1

shim (Fig 1).
3. Align Tapping pad with the left rear back-up bar

shoe and outline of the rear back-up bar (Fig 2). This
approximately 0.13” from front of the rear back-up
bar (Fig 3).
4. Apply pressure on the tapping pad to insure good

tape contact.
Fig 2
Fig 3

6.12 TOP FRAME LATCHES
TOOLS REQUIRED: #2 Phillips Screwdriver & 11/32” open

end wrench
6.12.1 Latch Cam Calibration
1. Check calibration by pressing and pulling up on top

cover. on both sides. If there is movement in both the
upwards and downward direction the cams need to
be adjusted (Fig 1).
Fig 1
and then unplug the display cable and un-screw ground
wire.There are 6 screws total that hold the top cover
to the frame, 4 across the top and 2 at the bottom. To
access the screws at the bottom you’ll need to turn
the carriage belt clockwise to expose them. Remove
all 6 screws (Fig 2). (Refer to 6.1.1)
3. With the top frame assembly closed place a 7/16”

box end wrench over the hex of the latch cam(Fig 3). Fig 2
4. With the phillips screw loose enough to turn the

latch cam, rotate the latch cam until the middle of the
latch in sitting on top of the bushing (Fig 4).
5. Holding the cam in place with the 7/16” open end

wrench, tighten the screw until cam is locked into
place.
6. Repeat steps 3-5 for oppisite side.
7. Replace top cover and finger guard. Fig 3
Fig 4

6.13 LINEAR BEARING REPLACEMENT
TOOLS REQUIRED: #2 Phillips Screwdriver, Needle nose pli-

ers, Channel Lock Pliers, & 5/64” allen wrench
6.13.1 Liner Bearing Removal and Replacement
1. Remove top cover (Refer to 6.1.1).
2. Remove carriage belt (Fig 1).

Fig 1 Fig 2
3. Loosen set screw on pulley (Fig 2). Remove top screw
from carriage pulley to remove pully (Fig 3).
Note: When reinstalling, lightly tighten the set screw of

the puley on the lead screw’s flat. Then tighten the top
screw on the pulley to remove any movement or slack
from the lead screw. Only after the top screw has been
tighten, torque down the pulley’s set screw.
4. Remove the two closing guide screws (Fig 4).

Fig 3 Fig 4
5. Remove lead screw bearing (Fig 5).
Note:That there are 3 spacer washer on top - careful not

to lose them. Lead screw bearing and 3 spacer washers
(Fig 6).
6. Remove right clamp spring.
Note: This will allow the lead screw nut to come out. Fig 5 Fig 6
7. Remove lead screw by turning it counter-clock wise.

The brown nut and brass bushing will be free, so take cau-
tion they don’t fall to the bottom of the machine (Fig 7).
8. Remove left clamp spring.
9. Remove the liner shaft while holding the clamps to-

gether (Fig 8).
Fig 7 Fig 8
10. Remove clamps by working them out of the top frame.
Do this by first clearing the right side of the clamp with
the top frame (Fig 9). Then clear the left side with bear-
ings from the top frame. The clamps should be held near
the middle of the top frame while this step is perfromed.
Note: This can be made easier if the restraint bar is re-

move from the top frame (Fig 10). This can be achieve by
removing the three screws from the rear of the top frame
and then pulling out the restraint bar. Fig 9 Fig 10

6.13 LINEAR BEARING REPLACEMENT CONTINUED
6.13.1 Linear Bearing Removal and Replacement Continued
11. Once the clamps are out, pull the clamps apart (Fig 11).
12. Remove bearing by bending the linear bearing bracket tabs up

with channel lock pliers and/or needle nose pliers (Fig 12 & Fig 13).
Note: If tabs look fatigued or weak, break them completely off. The
service kit comes with bearing sheelves and clips to reinstall the Fig 11
bearing if the tabs have been removed or have broken (Fig 14).
13. Reinstall the linear bearings and bend tabs back into place.
Note: Tabs need to be bent over 90 with enough clearance for the
linear shaft (Fig 15).
14. To reinstall reverse the steps 1-11.
Note: Be cautious when reinstalling the linear shaft. If any balls are Fig 12
knock out of the linear bearing, then the linear bearing must be re-
placed.
Fig 13
Fig 14
Fig 15

6.14 IR COMMUNICATION
TOOLS REQUIRED: #2 Phillips Screwdriver, Tweezers, & Dentist Pick

REMOVE
6.14 IR Communication Assembly Installation
1. Remove front cover and right cover (Refer to 6.1.4 and 6.1.3).
2. Using the tweezers, gently remove shunt found at J6, pins 5 and
REPLACE
replace the shunt at J6, pins 7 and 8 (Fig 1).
Fig 1
Note: This will activate the IR receive circuit on the controller
board.
3. Locate the IR Communication wiring harness

near the lifter motor, M4, inside the machine (Fig 2).
Lift the cool platen until it engages with the magnet and pull
wire harness forward pass the rotating heater for inspection (Fig
INSPECT THE IR COMMUNICATION WIRING HARNESS FOR

CORRECT PINOUT, FAILURE TO DO THE FOLLOW STEPS Fig 2
CAN RESULT IN MAIN BOARD AND IR BOARD FAILURES.
4. With the harness pulled forward inspect the pinout of the har-
ness. The correct pinout for IR communication should be RED,
BLUE, WHITE, BLACK when view from the top of the connector
(Fig 4). (Reference to 2.3 wiring diagram if necessary)
Note: If wiring is RED, WHITE, BLUE, BLACK when viewed from

the top of the connector, rework is required. Please perform
steps 5 and 6, otherwise skip to step 7. Fig 3
5. Using the dentist pick, remove the two middle wires. This is
done by lifting on the stop tab located on the underside of the
connector while pulling out the wire (Fig 5).
6. Replace the two middle wire so pinout is RED, BLUE, WHITE,

BLACK when view from the top of the connector (Fig 4). Make
sure the stop tab are push back down completely after reinsert-
ing the wire to insure the wire does not come loose. Fig 4
Note: this can be check by pulling on the wire. If the wire pulls
out of the connector then you must push down on the tab when
reinserted.
Fig 5

6.14 IR COMMUNICATION CONTINUED
6.14 IR Communication Assembly Installation Continued
7. Route IR wire harness through the right side of the Chassis.

Make sure the harness is routed underneth the wires (Fig 6 & Fig 7).
8. Install IR board onto bracket using 1 screw and the half shear
(Fig 8).
9. Plugged assembly into IR wire harness. Fig 6
10. Reinstall right cover (Refer to 6.1.3) and install IR Board as-
sembly using remaining screw onto the right cover’s mounting
holes (Fig 9 & Fig 10).
11. Line up the machine, using P31 tabs and FB 20’s external Tape
Guide and turn on the machines to verify that they have detected
each other (Fig 11).
Note: Firmware 1.3.1 or newer must be installed in the FB20 for

Fig 7
the machine to function with the IR communication feature.
Fig 8
MOUNTING PEM NUTS
Fig 9
Fig 11 Fig 10

6.15 COOLING RACK
TOOLS REQUIRED: 11/32” open end wrench or none,

depending on revision
6.15.1 Cooling Rack Assembly and Calibration
1. Check cooling rack fins for any back and forth

movement, if there is movement calibration is needed
(Fig 1).
Note: When cooling rack fins are not held tight and Fig 1
straight, it allows the cooling book to slump while
cooling. This can affect spine sqaureness.
Note: There are 2 different revision of the cooling

rack in the field, to know which revision cooling rack
you have simply look on the underside of the cool-
ing rack base. If the fins are held on by nuts then the
cooling rack is the newer revision.
OLDER REVISION
2. The older style cooling rack have three brackets Fig 2
found on the underside and the cooling rack fins can
be remove by simply pulling up; and installed by push-
ing the fin down into place. Remove cooling rack fins.
3. Now loosen the nuts found on the brackets to ad-

just bracket to proper positioning (Fig 2). If done cor-
rectly the fins should be held tight once place back
into the cooling rack assembly.
NEWER REVISION
2. Remove Wrench found on underside of the cool-
ing rack by loosening the thumb nut (Fig 3).
3. Tighten cooling rack fin nuts with wrench until

there is no movement (Fig 3). Replace wrench.
Fig 3

7.1 UPGRADING FIRMWARE
TOOLS REQUIRED: Standard SD card, PC/Laptop with SD card reader or an external SD card reader.
7.1.1 Upgrading the SD Card
1. Login in to the Powis website as a dealer and download the executable FB20 Firmware to your Desktop.
2. Once the download is complete click on the .EXE file and follow the on-screen instructions.

7.1 UPGRADING FIRMWARE CONTINUED
7.1.1 Upgrading the SD Card Continued
2. Insert the SD card into your PC’s/Laptop’s card reader or external card reader.
3. Right click on the SD card and select format, then select quick format and click Start.

7.1.1 Upgrading the SD Card Continued
4. A WARNING message will pop up. Click OK.
4. After this continue with the firmware installation by clicking OK (see image above).
5. Now locate your FB20 Firmware file and double click it, now browse to select the location of the SD Card and then
click unzip.
6. After completed close the unzip window and remove SD car from computer. Follow the next steps for installing and
updating the Firmware on the FB20.

7.1.2 Upgrading the FB20
1. Turn Power switch off.

2. Open and lift the cover until it engages.
3. Remove screws in cover panel on inside of top cover and remove finger guard.
4. Press the SD card slightly to let it release from the socket.
5. Pull the old SD card out.

6. Gently insert the updated SD card in the same orientation, with electric traces facing the top.
cover, until you hear the SD card click.
7. Replace the finger guard.
8. Close the Cover.
9. Press yellow and open buttons simultaneously.
10) If done Correctly Display should show “Firmware upgrade in progress”.

11) After completed the display will show a single screen with the Current firmware version. This can
also be checked by power cycling the machine.
Note: The Single vs. two screens showing the Firmware version was implemented in Ver. 1.2.0 .
12) The User Interface display will ask for the Serial number of the machine, only machine is upgrade
from a version older then 1.2.0.

7.1.2 Upgrading the FB20 Continued
13) Enter the Serial number of the machine and press the bind button.
14) If there is an issue with the machine not accepting the SN please contact technical service.

8 Service Kit Part Numbers
8.1 SERVICE KIT LISTING
K-200-026-R Service Kit, FB20/FB15xs/FB25 Series, Grip Tape, Roll

K-200-027 Service Kit, FB20 Series, Grip Tape/Clamp
K-200-511-R Service Kit, FB20/FB11/FB15/FB25 Series, Feed Bar Tape, Fiberglas/Teflon
1/2 ROLL ( 108’ )
K-200787 Service Kit, FB20 Series, Fuse, 5x20mm 1A, 250V (QTY 5)
K-200795P Service Kit, FB20 Series, Positioner Motor w/Pulley (M3)
K-200795T Service Kit, FB20 Series, Tape Feed Motor w/Pulley (M2)
K-200796C Service Kit, FB20 Series, Carriage Motor w/Pulley (M1)
K-200796L Service Kit FB20 Series Lifter Motor w/Pulley (M4)
K-207952 Service Kit, FB20 Series, Right Side Panel
K-207953 Service Kit, FB20 Series, Left Side Panel
K-207954 Service Kit, FB20 Series, Front Panel
K-207981 Service Kit, FB20 Series, Tape, Feed Bar Assembly
K-207986 Service Kit, FB20 Series, Tape Edge Sensor (T1)
K-207946 Service Kit, FB20 Series, Main PCA with bracket
K-207948 Service Kit, FB20 Series, Display, TFT, QVGA, 3.5 inch Diagonal
K-208400 Service Kit, FB20 Series PCA E2 User Interface
K-208515 Service Kit, FB20 Series, Assembly, Thermocouple
K-208528 Service Kit, FB20 Series, Stay Clamp w/Screws and Caps
K-208559 Service Kit, FB20 Series, Teflon Tapping Pad
K-208076 K-208076 - service kit, FB20 Series, Washer, Mica, .17” ID, .39” OD, .004”
Thick
K-208540 K-208540 - Service Kit, FB20 Series, Cam, Restraint, Bar, with nut
K-208800 Service Kit, FB20 Series, Harness DC Power (PS to Main PCA)
K-208801 Service Kit, FB20 Series, Harness (Heater Control from PS to Main PCA)
K-208802 Service Kit, FB20 Series, Harness (Chassis Sensors T1, T2/T3, S3, S4, Smart,
& IR)
K-208803 Service Kit, FB20 Series, Harness (Book and Carriage Sensors)
K-208804 Service Kit, FB20 Series, Harness (Main PCA to Motor 1-4)
K-208805 Service Kit, FB20 Series, Cable (Main PCA to Display PCA)
K-311-7131 Service Kit, FB20 Series, Rubber Feet w/Screws (Qty 4)
K-356-236 Service Kit, FB20/FB15/FB25/FB11 Series, Thermal Fuse (QTY 1)
K-3897 Service Kit, FB20 Series, Panel Screws
K-547-007 Service Kit, FB20/FB11/P31/S41 Series, Optosnsr, Photointr
K-560-002 Service Kit, FB20/FB11 Series, Fuse, 5x20mm, 2A 250V (QTY 5)
K-A113-17 Service Kit, FB20 Series, Book Sensor Set

8 Ser vice Kit Par t Numbers
8.1 SERVICE KIT LISTING CONTINUED
K-A207966E Service Kit, FB20E, Assembly Stationary Platen and Heater

K-A207966J Service Kit, FB20J, Assembly Stationary Platen and Heater
K-A207971 Service Kit, FB20, Assembly Rotating Platen and Heater (115V)
K-A207971E Service Kit, FB20E, Assembly Rotating Platen and Heater (220V)
K-A207971J Service Kit, FB20J, Assembly Rotating Platen and Heater (100V)
K-A208000 Service Kit, FB20 Series, Belts
K-A208004 Service Kit, FB20 Series, Smart Sensor Assembly
K-A208054 Service Kit, FB20 Series, Cooling Rack Base
K-A208089D Service Kit, FB20 Power Supply and Transformer (115V)
K-A208089E Service Kit, FB20E Power Supply and Transformer (220V)
K-A208089J Service Kit, FB20J Power Supply and Transformer (100V)
K-A208091 Service Kit, FB20 Series, Feed Roller and Shaft
K-A208091HK Service Kit, FB20 Series, Feed Roller Hardware Kit
K-A321-20 Service Kit, FB20 Series, T2/T3 PCA Set
K-A208107 Service Kit, FB20 Series, IR Board with Bracket
K-A208560 Service Kit, FB20, Assembly, Shim, Rear, Backup Bar
K-A209012 Service Kit, FB20, Assembly, Shim, Rear, Backup Bar, International Only
Tools and Cleaning
K-212-001 Service Kit, All, Cleaner 4 oz (1 box of 12 ea)

K-820-001 Service Kit, Oven Glove (Pack of 5)
K-825-002 Service Kit, FB20/FB15/FB25 Series, Cool Platen Level Gauge
K-825-003 Service Kit, FB20/FB15/FB25 Series, Tape, Feed Bar Gauge
K-820-008 Service Kit, FB20/FB11 Series, Interlock Override Tool
K-820-3576 Service Kit, FB15/FB25/FB20 Series, Tape, Feed Gauge
Accessories
K-208717 Accessory Kit, Common FB20

K-208727 Accessory Kit, Regional FB20
K-208716 Accessory Kit, Regional FB20E
K-208731 Service Kit, FB20 Series, Tongs
K-208718 Service Kit, FB20, Outer Box, Complete Packaging, Stay Clamp & Acces-
sory box
K-208066 Service Kit, FB20 Series, External Strip Guide
K-A208054C Service Kit, FB20 Series, Cooling Rack Base with Fins
D= Domestic, 115v
J= Japan, 100v
E= European, 230v
9 Service Kit Pictures
9.1 SERVICE KIT PIC TURES

Panels
Side and Front Panels Cooling Rack Base
Item Qty. Item Qty.

K-207953 - Left Side Panel 1 K-A208054 - Cooling Rack Base 1
K-207952 - Right Side Panel 1
K-207954 - Front Panel 1
K-3897 - Panel Screws (Fig 1) Top Cover

Item Qty. Item Qty.
Black 13 K-A207889 - Top Cover with Display and PCA 1
Silver 5 K-208528 - Stay Clamp w/Screws and Caps
K-311-7131 - Rubber Feet w/Screws (Qty 4) 1

9 Ser vice Kit Pictures
9.1 SERVICE KIT PIC TURES CONTINUED

Sensors
Book Sensors/Smart Sensor Tape Sensor set

Item Qty. Item Qty.
K-A113-17 - Book Sensor Set 1 1
K-A321-20 - T2/T3 PCA Set
K-A208004 - Smart Sensor Assembly 1
K-547-007 - Optosnsr, Photointr Tape Edge sensor

Item Qty. Item Qty.
Carriage 2 K-207986 - Tape Edge Sensor (T1) 1
Positioner 1
Lifter - cut tab circled in photo. 1

Other Assemblies
Domestic, European and Japanese sets Main PCA
Item Qty. Item Qty.

K-A207971- Assembly Rotating Platen and 1 K-207946 - Main PCA with bracket 1
Heater (115V)
K-A207966 - Assembly Stationary Platen and 1
Heater (115V)
K-A207971E - Assembly Rotating Platen and 1
Heater (220V)
K-A207966E - Assembly Stationary Platen 1
and Heater (220V)
K-A207971J - Assembly Rotating Platen and 1
Heater (100V)
K-A207966J - Assembly Stationary Platen and 1
Heater (100V)
K-356-236 - FB20/FB15/FB25/FB11 Series, 1
Thermal Fuse (QTY 1)
Domestic, European, and Japanese sets
Item Qty.
K-A208089D - Power Supply and Trans- 1
former (115V)
K-A208089E - Power Supply and Trans- 1
former (220V)
K-A208089J - Power Supply and Trans- 1
former (100V)


Other Assemblies
User Interface PCA Display Screen
Item Qty. Item Qty.

K-208400 - PCA E2 User Interface 1 K-207948 - Display TFT, QVGA, 3.5 inch Diagonal 1
Thermocouple Tape Feed Bar

Item Qty. Item Qty.
K-208515 - Service Kit, FB20 Series, Assembly, 1 K-207981 Service Kit, FB20 Series, Tape, Feed Bar 1
Thermocouple Assembly


Motors/Belts
Positioner (M3) Tape (M2)

Item Qty. Item Qty.
K-200795P - Positioner Motor w/Pulley 1 K-200795T - Tape Feed Motor w/Pulley 1
(M3) (M2)
K-200796C - Carriage Motor w/Pulley 1 K-200796L - Lifter Motor w/Pulley (M4) 1
(M1)
Feed Roller Complete Belt Set Feed Roller Hardware Kit
Item Qty. Item Qty.

Item Qty.
K-A208091 - Feed Roller and Shaft 1 K-A208091HK - Feed Roller Hard- 1
K-A208000 - Belts 1 ware Kit


Kits
Assorted tapes Fuses

Item Qty. Item Qty.
K-200-027 - Grip Tape/Clamp 1 K-200787 - Fuse, 5x20mm 1A, 250V (QTY 5) 1
K-200-026-R - FB20/FB15xs/FB25 Series, Grip Tape, 1 K-560-002 - Fuse, 5x20mm, 2A 250V (QTY 5) 1
Roll K-560-003 - Fuse, 5x20mm, 5A 250V (QTY 5) 1
K-200-511-R - FB20/FB11/FB15/FB25 Series, Feed 1 K-560-011 - Fuse, 5x20mm, 10A 250V (QTY 5) 1
Bar Tape, Fiberglas/Teflon 1/2 ROLL ( 108’ )
Harness Harness
Item Qty. Item Qty.
K-208800 - Harness DC Power (PS to Main 1 K-208801 - Harness (Heater Control from 1
PCA) PS to Main PCA)

Kits
Harness Harness
Item Qty. Item Qty.
K-208802 - Harness (Chassis Sensors T1, 1
K-208803 - Harness (Book and Carriage 1
T2/T3, S3, S4, Smart, & IR) Sensors)
Harness Cable
Item Qty. Item Qty.
K-208804 - Harness (Main PCA to Motor K-208805 - Cable (Main PCA to Display 1
1-4) PCA)


Kits
Cleaning Solution Gloves

Item Qty. Item Qty.
K-212-001 - All, Cleaner 4 oz (1 box of 12 1 K-820-001 - Service Kit, Oven Glove (Pack 1
ea) of 5)
Level gauge Tape feed bar gauge

Item Qty. Item Qty.
K-825-002 - FB20/FB15/FB25 Series, Cool 1 K-825-003 - FB20/FB15/FB25 Series, Tape, 1
Platen Level Gauge Feed Bar Gauge


Kits
Interlock override tool Tape Feed Gauge

Item Qty. Item Qty.
K-820-008 - FB20/FB11 Series, Interlock 1 K-820-3576 - FB15/FB25/FB20 Series, 1
Override Tool Tape, Feed Gauge
Tong External Strip Guide

Item Qty. Item Qty.
K-208731 - FB20 Series, Tongs 1 K-208066 - FB20 Series, External Strip 1
Guide


Kits
K-208717 - Accessory Kit, Common Regional Kits

Item Qty. Item Qty.
Book Rest 1 K-208727 - Accessory Kit, Regional 1
Cooling Fins 3 K-208716 - Accessory Kit, Regional FB20E 1
User Manual 1
Brochure 1
Packaging Cooling Rack with Fins
Item Qty. Item Qty.

K-208718 - Service Kit, FB20, Outer Box, 1 K-A208054C - Cooling Rack Base w/Fins 1
Complete Packaging, Stay Clamp & Ac-
cessory box


Kits
Teflon Tapping Pad

Item Qty. Item Qty.
K-208559 - Service Kit, FB20 Series, Teflon 1 K-208076 - service kit, FB20 Series, Washer, Mica, 10
Tapping Pad .17” ID, .39” OD, .004” Thick
Item Qty. Item Qty.

K-208540 - Service Kit, FB20 Series, Cam, Restraint, 1 K-A208560 - Service Kit, FB20, Assembly, Shim, 1
Bar, with nut Rear, Backup Bar
K-A209012 - Service Kit, FB20, Assembly, Shim, 1
Rear, Backup Bar, International Only


Kits
Item Qty. Item Qty.

K-A208107 - Service Kit, FB20 Series, IR Board with 1
Bracket
Item Qty. Item Qty.
NOTE: ASSEMBLY DRAWINGS FOUND IN THE REAR OF THE MANUAL MAYBE USED TO LOOK UP PART NUMBERS. PLEASE
CONTACT TECH SERVICE FOR PART AVAILABLILITY. POWIS PARKER RESERVES THE RIGHT TO NOT SELL ALL PARTS INDI-
VIDUALLY AS SERVICE PARTS (SOME PARTS WILL ONLY BE SOLD IN ASSEMBLIES).

10 P a c k a g i n g P r o c e d u r e
10.1 PACK AGING PROCEDURE
TOOLS REQUIRED: Packaging Tape
10.1.1 Packaging Procedure
1. Open FB20 unit by inserting a screw driver into the access hole and pushing to release the lid assembly. Lift lid and latch in op
position
2. Rotate carriage belt to open the clamp, so that the small foams can placed in between the front and back clamps and the fron
and back “back up” bars.
* Note that the thinner piece will be at the bottom.
3. Install foam pieces and close lid by releasing the clip on the right inside.
Make sure the foam pieces line up with the book fence tabs. See the top view photos.

10 Packaging Procedure
10.1 PACK AGING PROCEDURE CONTINUED
10.1.1 Packaging Procedure Continued
4. Install the Stay Clamps. You may need to move the clamps up or down to line up the screw holes. Once the holes are
aligned make sure the thumb screws are fastened tightly.
Note: The stay clamps can be found in most machines near the front of the chassis. When installing the stay clamp
during machine operation make sure the the clamp is positioned between the cut out found on the cool platen. This
wil insure that the clamp does not cause any clearance issues with the clamps (Older models may have screws insert
oppisite side than pictures shows).
5. Now install the Left and Right side foams –Make sure the cooling rack block is in the slot on each of the side foams.
6. Insert the accessory box in the front of the left and right foams.

10 P a c k a g i n g P r o c e d u r e
10.1 PACK AGING PROCEDURE CONTINUED
10.1.1 Packaging Procedure Continued
7. Now place the top foam on top of the machine and put the common kit back in the empty slot.
8. Insert the unit back in the box with the rear of the unit toward the bottom on the box. Having it on top of a table
and sliding it back into the box is the easiest way.
9. Once inside the box set it back onto the floor insert the top reinforcement card board and seal the box up.

11 Assembly Drawings
11.1 ASSEMBLY DR AWINGS
11.1.1 Assembly Drawings
NOTE: ASSEMBLY DRAWINGS FOUND IN THE REAR OF THE MANUAL MAYBE USED TO LOOK UP PART NUMBERS. PLEASE
CONTACT TECH SERVICE FOR PART AVAILABLILITY. POWIS PARKER RESERVES THE RIGHT TO NOT SELL ALL PARTS INDI-
VIDUALLY AS SERVICE PARTS (SOME PARTS WILL ONLY BE SOLD IN ASSEMBLIES).
POWIS PARKER ALSO RESERVES THE RIGHT TO CHANGES DRAWING AT ANYTIME WITHOUT NOTIFACTION AND/OR WITH
OUT EXPLAINATION.

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Copyright Powis Parker Incorporated 2004

Page ii FB20 Service Manual, Rev.C 1/18/13

2.1 Main Components of the FB20

3 REQUIRED SERVICE TOOLS

4.1 Power Problems

5.1 Accessing the Service Menu

6. SERVICE AND CALIBRATION PROCEDURES

6.1 Covers 6.2 UI Board

8 SERVICE KIT LISTING

9 SERVICE KIT PICTURES

FB20 Service Manual, Rev.C 1/18/13 Page iii

THIS PAGE IS INTENTIONALLY LEFT BLANK

Page iv FB20 Service Manual, Rev.C 1/18/13

THE FASTBACK® BIND CYCLES

FB20 Service Manual, Rev.C 1/18/13 Page 1

2.1 MAIN COMPONENTS OF THE FB20

Cooling Rack Rest

Front Cover OPEN Button 4-Way Cursor Button BIND Button

Positioner Motor, Feed Motor, M2

Power Indicator Controller Latch Release

Page 2 FB20 Service Manual, Rev.C 1/18/13

2.1 MAIN COMPONENTS OF THE FB20 CONTINUED

Rotating Lifter Platen

Rotating Lifter Platen Gear Positioner Gear Assembly

Carriage Sensor Carriage Sensor

Strip Rejector Guide Tape Edge Sensor

Linkage Lifter Motor, M4

FB20 Service Manual, Rev.C 1/18/13 Page 3

2.1 MAIN COMPONENTS OF THE FB20 CONTINUED

Front Back-up Bar Clamp Springs

Back-up Bar Shoes

Rear Back-up Bar Linear Bearings

Interlock Power Switch

Support Strip Assy. Tape Feed Roller

Tape Feed Bar

Page 4 FB20 Service Manual, Rev.C 1/18/13

2.1 MAIN COMPONENTS OF THE FB20 CONTINUED

FB20 Service Manual, Rev.C 1/18/13 Page 5

2.2 USER MENU

Page 6 FB20 Service Manual, Rev.C 1/18/13

FB20 Service Manual, Rev.C 1/18/13 Page 7

2.3 SYSTEM BLOCK DIAGRAM CONTINUED

Page 8 FB20 Service Manual, Rev.C 1/18/13

Power Requirements: USA: 120V, 50-60 Hz, 10 Amps

EU: 230V, 50-60 Hz, 5 Amps

JAPANESE: 100V, 50-60 Hz, 10 Amps

100V 60Hz TBA Amps TBD Watts

Dimensions: 23.5”W x 9”H x 23”D (60 cmW x 23 cmH x 58 cmD

Spine Thickness: Narrow, Medium, Wide

Binding Capacity: 10 sheets to 350; 1.5” max. thickness (3.8 cm)

Page Sizes: Max. 12” (30.5cm) and Min. 5.5” (13.97cm)

Optimal Paper Weight: 20 lb standard (80 gsm) to 32 lb (120 gsm)

Safety Certifications: UL, CE, CUL

Packing & Unpacking Refer to the Section 10.

FB20 Service Manual, Rev.C 1/18/13 Page 9

THIS PAGE IS INTENTIONALLY LEFT BLANK

Page 10 FB20 Service Manual, Rev.C 1/18/13

2.5 GET TING THE BEST BIND QUALIT Y

FB20 Service Manual, Rev.C 1/18/13 Page 11

2.6 CONTAC TING TECHNICAL SUPPORT

Spare Parts Order

Machine and Controller Repair