U.S. PAPER COUNTERS

COUNT-WISE 1, COUNT-WISE M & BANTAM

SECTION #1: WARRANTY …………………………………………………………………………………………..….3 & 4

SECTION #1: TECHNICAL DETAIL & INSTALLATION INSTRUCTIONS ……………………………………..…….5

INSTALLATION INSTRUCTIONS

MAX-BANTAM SHEET COUNTER ...................................................................................................................6 DIAGRAM-MAX-BANTAM …………………………………………………………………………..………..7 COUNT-WISE I SHEET COUNTER ……………………………………………………………………..……8 DIAGRAM-RECEPTACLE GUARD …………………………………………………………..………………9 COUNT-WISE M SHEET COUNTER ………………………………………………..………………………10 AIR FLOTATION SYSTEM …………………………………………………………………….…………….10 DIAGRAM- COUNT-WISE M …………………………………………………………………….………….11 COUNT-WISE 1, M & BANTAM TECHNICAL DETAILS SUCTION BLADE GUIDE FOR RANGE OF PAPER TO BE COUNTED …………………….……………12

SECTION #3: OPERATION INSTRUCTIONS & SEQUENCE OF EVENTS DURING OPERATION ………….…...13

OPERATING INSTRUCTIONS

DIAGRAM-BREATHERS …………………………………………………………………………………….14 BREATHERS …………………………………………………………………………………………………15 OPERATING INSTRUCTIONS……………………………………………………………………....……….16 DIAGRAM-SELF DIAGNOSTIC LEDS ……………………………………………………………………...17

SEQUENCE OF EVENTS-LOGIC BOARD S-3170 …………………………………………………………………18 DIAGRAM-LOGIC BOARD ………………………………………………………………………………….19

SECTION #4: COUNTING HEAD & MAINTENANCE SCHEDULE …………………………………………………...21

LOADING OF INSERT TAPE ………………………………………………………………………………………..22

DIAGRAM-TAPE LOADING ………………………………………………………………………………………...23 RESET ADJUSTMENT W/DIAGRAM …………………………………………………………………………...….24 COUNT ADJUSTMENT W/DIAGRAM ………………………………………….……………….………...………..24 COUNTING HEAD INSTALLATION AND ALIGNMENT ………………………………………………...….…..25 COUNTING HEAD REMOVAL ………………………………………………….……………………....…………..26 REMOVING COUNTING HEAD CENTER PLATE ……………………………………………….………...……...26 REPLACING COUNTING HEAD CENTERPLATE …………………………………………………………...……26 REPLACING COUNTING HEAD …………………………………………………………………………...……….26 COUNTING HEAD REMOVAL – PHOTO …………………………………………………………………………..27 HOW TO CHANGE A SUCTION BLADE ………………………………………………………………..…………28 SETTING VERTICAL RISE SWITCH ……………………………………………………………………..….……..28 SETTING THE COUNTER POISE SPRING ……………………………………………………………..…….…….28 DIAGRAM-ORBIT ADUSTMENT …………………………………………………………………….…………….29 ORBIT ADJUSTMENT ………………………………………………………………………………….……………30 DRAWING: COUNTING HEAD CENTER PLATE/TAPE CHUTE ………………………………..……………....31 HOW TO REMOVE A TAPE JAM …………………………………………………………………..……………….32 TAPE CHUTE REMOVAL ………………………………………………………………………….…………..........33 REPLACING TAPE CHUTE ……………………………………………………………………….…………………33 CHANGING THE TAPE SOLENOID ………………………………………………………………………………..34 REMOVAL OF KNIFE ASSEMBLY …………………………………………………………………………….…...34 REPLACING KNIFE ASSEMBLY …………………………………………………………………………………...34 PHOTO-COUNTING HEAD, RIGHT SIDE …………………………………………………………………………36

PHOTO-COUNTING HEAD, LEFT SIDE …………………………………………………………………………...37 MAINTENANCE SCHEDULE ……………………………………………………………………………………………….38 SECTION #5: TROUBLE SHOOTING …………………………………………………………………………....……39-45 CONTACT INFORMATION ……………………………………………………………………………….…………40 TROUBLE SHOOTING …………………………………………………………………………………………...41-45

SECTION #6: ELECTRICAL SYSTEM ………………………………………………………………………………….....47

LOGIC CONTROLLER ……………………………………………………………………………………………….48

PHOTO & PARTS LIST-REAR & TOP OF MACHINE ……………………………………………………...49 COUNT-WISE SPEED CONTROL 15DV PARTS PLACEMENT & LIST ………………………………...…50 PHOTO & PARTS LIST-FACEPLATE COUNTWISE-M …………………………………...……………….51 BANTAM CONTROL PANEL 2001 TO PRESENT …………………………………...…………………………….52 DIAGRAM OF MAX BANTAM CONTROL PANEL, 2001 & AFTER..............................................................53

SECTION #7: BASIC ADJUSTMENTS …………………………………………………………………………...………...55

VACUUM SYSTEM ……………………………………………………………………………………..……………56

PHOTO & PARTS LIST: POWER SUPPLY & VACUUM AREA ……………………………..…………….57 SETTING VACUUM SWITCHES ……………………………………………………………..……………...58 VACUUM SWITCH ADJUSTMENT ……………………………..…………………………………………..59 SPEED CONTROL ADJUSTMENT SEQUENCE ……………………………………..……………………..60 ACE MICRO CUSHION ADJUSTMENT …………………………………………..………………………...61

SECTION #8: WIRING DIAGRAMS …………………………………………………………….…………………………63

LOGIC BOARD WIRE CONNECTIONS ………………………………………………….…………………...…64-65 DIAGRAM-LOGIC BOARD PLUGS ………………………………………………………………………………...66 DIAGRAM-COUNTING HEAD ……………………………………………………………………………………...67 VERTICAL RISE MOTOR ……………………………………………………………………………………………68 DIAGRAM-LOGIC CONTROLLER …………………………………………………………………………...…….69 ELECTRONIC COUNTING UNIT (ECU) BASIC COMPONENTS ………………………………………………...71 ELECTRONIC COUNTING UNIT (ECU) ……………………………………………………………………......72-73 POWER SUPPLY ASSEMBLY ON ECU ………………………………………………………………....………….74 COMPUTER ECU ………………………………………………………...…………………………….…………76-77

SECTION #9: PARTS LISTS, PHOTOS & DIAGRAMS ………………………...………………………………………..79

TAPE RETAINING BLOCK ……………………………………………………...…………………………………..80 RECOMMENDED SPARE PARTS ……………………………………………...…………………………………...81 PHOTO-COUNTING HEAD …………………………………………………………...………………………….….82 PARTS LIST-COUNTING HEAD ………………………………………………...…………………………..83 PHOTO-FRONT VIEW COUNTING HEAD ………………………………………..……….………………84 PHOTO & PARTS LIST-PRE-SELECT & START SWITCH AREA ……………..….………………………..85 PHOTO & PARTS LIST-POWER SUPPLY & VACUUM AREA ………………...…………………………..86 PHOTO & PARTS LIST-INSIDE CONTROL PANEL ………………………...……………………………..87 LASER SYSTEM OPERATION, DIAGRAM & PARTS LIST …………………...…………………………....88

INDEX ………………………………………………………………………………………………………………...……..89-92

DIAGRAMS & PHOTO LISTINGS ……………………………………………………………...………………………93-94

NOTE: U.S. Paper Counters reserves the right to change the price, appearance, specifications or design of its products at any time without notice or incurring the obligation either to modify units previously manufactured or to furnish products with previously published specifications. Revised: February 2012.

SECTION #1: WARRANTY

MUST BE RETURNED WITHIN

10 DAYS AFTER RECEIPT OF MACHINE OR WARRANTY CAN BE DISPUTED

INSTALLATION INSTRUCTIONS

MAX-BANTAM SHEET COUNTER (REFER TO PAGE 7, DIAGRAM #1)

Remove carton containing mount bolts, table supports, insert tape, power cord, receptacle guard, bag of hardware and manual.

Place machine on workstation, or optional base cabinet.

Remove hex head screws from left and right sides of front panel and install table support brackets using same screws.

Place table onto brackets and into the “throat” of the counter.

Place the small silver hex-bolt through the table at the “point” nearest the throat of the counter. Tighten the bolt so that the table is approximately 1/32” above the table flap.

Install the remaining two (2) small silver hex-bolts through the table and the brackets. You may have to move the brackets into position.

Open back panel access door by pulling out, then lifting up. There are two (2) white plastic holders on the side panels that the access door slides into.

Remove all packing material from interior of machine. This includes:

1. cardboard under counting head; B) two rubber bands holding tape cover closed and counting head down; and C) white plastic wire ties holding counting head down.

Install receptacle guard to rear of machine (Refer to Diagram #2, Page 9).

Remove shipping bands from the counting head. Plug power cord securely into the socket located on the rear panel. MUST BE INSERTED FIRMLY.

NOTE: REAR BACK PANEL MUST BE CLOSED FOR MACHINE TO OPERATE.

• ****SEE OPERATING INSTRUCTIONS***** (Page 13)

(DIAGRAM #1 – MAX BANTAM)

Table Mounting Bolt

INSTALLATION INSTRUCTIONS

COUNT-WISE I SHEET COUNTER

1. Remove carton containing mount bolts, jogging plates, table supports, insert tape, breathers (wood inserts), power cord, receptacle guard, bag of hardware and manual.
2. Place machine on workstation, or optional base cabinet.

WARNING: PROPER ASSEMBLY OF COUNTER IS ESSENTIAL TO ELIMINATE TIPPING OF THE MACHINE.

3. Remove hex head screws from left and right sides of front panel and install table support brackets using same screws.

4. Place table onto brackets and into the “throat” of the counter.

5. Place the small silver hex-bolt through the table at the “point” nearest the throat of the counter. Tighten the bolt so that the table is approximately 1/32” above the table flap.

6. Install the remaining two (2) long silver hex-bolts through the table and the brackets. You may have to move the brackets into position so they support the table.

7. Open back panel access door.

8. Remove all packing material from interior of machine. This includes:

A) cardboard under counting head; B) two rubber bands holding tape cover closed and counting head down; and C) white plastic wire ties holding counting head down

9. Install receptacle guard to rear of machine (Refer to Diagram #2, Page 9).

10. Remove shipping bands from the counting head. Plug power cord securely into the socket located on the rear panel. MUST BE INSERTED FIRMLY.

NOTE: REAR BACK PANEL MUST BE CLOSED FOR MACHINE TO OPERATE.

• ****SEE OPERATING INSTRUCTIONS***** (Page 13)

INSTALLATION INSTRUCTIONS

COUNT-WISE M SHEET COUNTER (Diagram #3, Page 11)

1. Remove carton containing mount bolts, jogging plates, table supports, insert tape, breathers (wood inserts), power cord, receptacle guard, bag of hardware and manual.
2. Open wings on the cabinet until each wing wedges into its corner of the cabinet.
3. Lift counter and place it into the cups on the base cabinet. Slide the counter all the way forward into the wings.
4. Place table onto the wings and into the “throat” of the counter.
5. Place the small silver hex-bolt through the table at the “point” nearest the throat of the counter. Tighten the bolt so that the table is approximately 1/32” above the table flap.
6. Install the remaining four (4) long silver hex-bolts through the table and the wings. You may have to move the wings into position so they support the table.
7. Install the two (2) jogging plates (available on Count-Wise M only) insuring the plates are parallel with the throat of the machine.
8. Open back panel access door.
9. Remove all packing material from interior of machine. This includes: A) cardboard under counting head; B) two rubber bands holding tape cover closed and counting head down; and C) white plastic wire ties holding counting head down.
10. Install receptacle guard to rear of machine (Refer to Diagram #2, Page 9).
11. Remove shipping bands from the counting head. Plug power cord securely into the socket located on the rear panel. MUST BE INSERTED FIRMLY.

AIR FLOTATION SYSTEM

1. Connect the plug coming out of the top of the case to the receptacle coming out of the bottom of the machine.
2. Install the hose connector to the underside of the table. Connect the hose coming from the base cabinet to this connector and tighten.

NOTE: REAR BACK PANEL MUST BE CLOSED FOR MACHINE TO OPERATE.

• ****SEE OPERATING INSTRUCTIONS***** (Page 13)

(DIAGRAM #3 – COUNT-WISE M)

A. Jogging Plate

B. Table

C. Table Support

E. Table Mounting Bolt

F. Bumper Cups

G. Base Cabinet w/ Locking Storage Compartment

COUNT-WISE 1, M & BANTAM TECHNICAL DETAILS

DIMENSIONS

COUNT-WISE 1

COUNT-WISE M

MAX-BANTAM

Weight : Height: Width: Depth:

• Stack Size:

Table Dimensions:

185 lbs / 84 kg 30” / 75cm 38” / 95cm 54” / 135cm 8” / 20cm 27” X 27” 68cm X 68cm

275 lbs / 125 kg 55” / 138cm 42” / 105cm 56” / 140cm 8” / 20cm 32” X 32” 80cm X 80cm

160 lbs / 72 kg 28” / 70cm 18” / 45cm 36” / 90cm 6” / 15cm 15” X 18” 38cm X 45cm

SHEET SIZE:

Minimum:

Maximum:

• PAPER RANGE:

2 ¼” x 5” 2 ¼” x 5” 2 ¼” x 5” 5.5cm x 13cm 5.5cm x 13cm 5.5cm x 13cm Smaller sheets can be counted using optional coupon tray (2 ¼” x 2 ¾”) (57mm x 70mm) Limited only by size of table selected.

20 up to 250 G/M² 20 lb Book up to .010 Stock 4 lb Bond up to .010 Stock

SUCTION BLADE GUIDE FOR RANGE OF PAPER TO BE COUNTED

(Choice of 2 with the purchase of any of these three counters.)

Blade #70:

30 – 75 G/M² 20 – 50 lbs Books 8 – 20 lbs Bond

Blade #71:

50 – 90 G/M² 33 – 60 lbs Book 13 – 24 lbs Bond

Blade #72:

75 – 110 G/M² 50 – 73 lbs Book 20 – 30 lbs Bond

Blade #73:

110 – 220 G/M² 73 – 113 lbs Book 29 – 45 lbs Bond

Blade #74:

20 – 30 G/M² Tissue thru onion skin

• Blade #75:

110 up to 250 G/M² 006” up to .010

COUNTING SPEED:

• TAB INSERTION:

CW-1 & M: Variable up to 2500 sheets per minute according to texture of paper. Bantam: Variable up to 2000 sheets per minute according to texture of paper.

CW-1 & M: 3 TO 9999 Bantam: 5 TO 999

ELECTRICAL:

CE:

120v AC 60 Cycle, 15 Amps or 230V AC 15 Amps @50/60 Hz (If you cannot maintain a steady power source, please call us to purchase an optional line conditioner to insure accuracy.) Standards to which conformity is declared: CW-1 & M: EN 55022 Class A, EN 55024:1998 & EN 60950 (1992). BANTAM: EN 55011, EN 50082-1 & EN 60204-1.

• NOTE: DEPENDING UPON THE PAPER TO BE COUNTED, BREATHERS (WOOD INSERTS) MAY BE NECESSARY ON THE CW-1 OR CW-M (SEE PAGES 14 & 15). STACK SIZE AND COUNTING ABILITY MAY VARY DUE TO THE SUBSTANCE AND TEXTURE OF THE PAPER BEING COUNTED AND THE TABBING RANGE SELECTED. A CURL OF THE CORNER COUNTED IS TO BE EXPECTED DUE TO THE MECHANICAL OPERATION THAT SEPARATES THE SHEETS.

BREATHERS-WOOD INSERTS

(Refer to Diagram Page 14)

“Breathers” (wood inserts) are specially shaped lengths of wood inserted into the stack at intervals (as shown in figure on Page 14) to “loosen” the corner by creating an air space. This space allows the counting head to operate without damaging the paper or the machine.

The intervals at which breathers (wood inserts) should be inserted in the stack follow no hard and fast rule. Papers vary in weight, texture and finish which will effect the breather spacing. Through experience, it will be found that, while spacing at 3” (76mm) intervals for one type of paper gives excellent results, another type will require spacing at 4-6” (100-150mm), and yet another type will only be counted with the spacing closer at the bottom than at the top.

Overuse of breathers (wood inserts) must be avoided. An excessive number inserted in the stock will loosen the corner so much that the “FOLLOW-UP” of the counting head will bend them back and give erratic counting.

On thin paper, care should be taken not to damage the sheets when inserting breathers .

OPERATING INSTRUCTIONS

CAUTION:

PRE-SELECT SHOULD NEVER BE SET LOWER THAN 005 ON BANTAM AND 0003 ON COUNT-WISE!!! Check that reset on-off switch is in your desired position. In the “ON” position overage will be displayed on the electronic counting unit and will zero when Start Switch is pushed. In the “OFF” position display will maintain number from previous batch and continue from that number. Set Tape Length and Speed Control knobs to desired settings. Tape lengths should be between 2 ¼” and 2 ½”. Depending on speed of machine, length of tape may need to be adjusted.

NOTE: Batch and totalizer counters reset manually by pressing their individual buttons.

Counting head should be set up with a suction blade suitable for the paper. Suction blade chart located on Page 12. (Refer to Page 28 for how to change a suction blade.)

Be sure that “Emergency Stop Switch” is not activated (should be in “OUT” position).

Activate “Main Switch” at rear of machine to “ON” position.

Turn “Pre-Select” (tabbing selector) to the required number of tab insertions.

Load paper on table, locating it firmly against guides; insert breather (wood inserts) if necessary.

Press “Start Switch” when lit.

At completion of count, clamp will release. Remove paper; counters will reset automatically.

IMPORTANT

Count-Wise 1 & M: According to the height of the paper to be counted, “breathers” (wood inserts) may be necessary. (Page 14,15).

Stack size, counting speed and counting ability may vary due to the substance and texture of the paper being counted and the tabbing range selected.

A slight curl of the corner counted is normal. The thickness of the stock determines the amount of curl that is produced.

When increasing counting speed, tape length should be lowered by equal amounts.

When decreasing counting speed, tape length should be increased by the same.

SEQUENCE OF EVENTS LOGIC BOARD S-3170

Plug machine into AC service.

Turn main switch to “ON” position with cover down (Safety Switch engaged).

1. Power applied to all circuits.
2. Red Power LED activated on Logic Board.

Material inserted, green Table Sensor/Laser LED #7 activated, and Vacuum Pump turns “ON”. Green Vertical Rise Switch LED #8 needs to be on. Red Count Valve LED #5 activates momentarily to bleed vacuum off system.

Pressing Start Switch:

1. Green Start Switch LED #11 activates on Logic Board.
2. Red Clamp Valve LED #16 activates.
3. Red 24V DC Relay LED #1 activates.

Clamp comes down:

Red Vertical Rise LED #3 lights. Counting Head rises to meet paper. LED #10 lights. When Head tips off Vertical Rise Switch, RED Count Valve LED #5 activates and vacuum is applied to Suction Blade.

5. When vacuum reaches 19” HG, GREEN Motor Start Vacuum Switch LED #15 turns, activating the RED Speed Control LED #4; AC is applied to Speed Control via SSRI. Counting Head counts as long as a minimum of 20” HG is maintained.

At completion of count, vacuum breaks and AC is turned off to Speed Control. The Counting Head will rise 2” – 3” above the stack of paper and stop.

Removing paper from Table Sensor/Laser deactivates Pump Control Relay and the Counting Head lowers to bottom position.

Upon reaching bottom position, the Reset Circuit is energized; the RED Reset LED #2 activates until the Counting Head is in the reset position.

LOADING INSERT TAPE

(Video available on Web Site, “Service & Support)

CAUTION: Use extreme care when installing tape so as not to bend or distort the looper wire. After loading tape, make sure looper switch wire has not been distorted out of shape and that it is not rubbing against the tape reel cover when closed. Switch wire must operate freely for proper loop follow-up when tabbing, or the loop will not keep up and will cause a tape jam or no tape will come out.

NOTE: When back access door is open, power is automatically turned off.

Loading insert tape:

1. Be sure that tape roll is flat (not coned) and center cardboard core is not “egg shaped”. Spool must spin and float freely when cover is closed.
2. Place a roll of insert tape on the counting head, as shown in the illustration on Page 23.
3. Close magnetic tape cover.
4. Pull out a 12” to 14” length of tape.
5. Spread tape loop rollers using tape-loading lever.
6. Place tape between looper rollers.
7. Push end of tape through the chute until it exits the front of the counting head.
8. Open tape cover; place remaining loop inside. Close cover.

i. Close back access door; turn on power.

To cut the excess tape, press the Cut Tape button located on the front panel.

RESET ADJUSTMENT W/DIAGRAM #8A

Remove counting head from machine. (See instructions, page 26.) Remove both counting head covers. Place ohmmeter on #9 reset leads with Magnet, #8 away from switch. Meter should register closed. Position wiper pin #3 as shown above. Lossen allen screw #6, turn magnet carrier #7 until meter registers “open”. See Figure above. Tighten screw #6. Check tightness – allen screw #10

COUNT ADJUSTMENT W/ DIAGRAM #8B

Remove counting head from machine. (See instructions, page 26.) Remove both counting head covers. Place ohmmeter on #9 on count switch leands (with magnet (#8) away from switch, meter should register “open”. Position wiper pin #3 as shown above. Lossen allen screw #6, turn count magnet carrier #7 until meter registers “closed”. See Figure above. Tighten screw #6. Check tightness – allen screw #10

7. Verify meter readings after rotating counting head one full turn clockwise.

COUNTING HEAD INSTALLATION AND ALIGNMENT**

• *Refer to photos on Pages 27, 82, & 84

Raise carriage assembly approximately halfway. Loosen pivot block bolts (p.27, #4 & 9) from carriage base plate.

With a marker, indicate center of suction blade directly behind hole in suction blade.

Lower carriage assembly and stop when suction blade is level with tabletop surface.

Insert paper squarely into throat or jog of machine over suction blade.

Viewing from top of machine, adjust counting head until corner of paper is on centerline mark on blade and approximately 1/16” (1.59mm) from back edge of blade.

Move right pivot block 1/16 to 1/4 of an inch forward, causing right side of head to be closer to paper.

Raise counting head again approximately halfway and tighten pivot blocks to carriage base plate.

Hook counter poise (p.84, #2) spring to dash pot bracket.

Insert a 3/8” (9.54mm) spacer block between carriage base bracket and counting head base to level head.

Loosen set screw on dash pot assembly (setting to be a #5 or mid-range) and adjust dash pot plunger so that a 1/16” to 1/8” gap exists between the plunger and suction blade housing. Tighten nuts.

Remove 3/8” (9.54mm) spacer and lower counting head leveling bolt on rear of dash pot bracket to give approximately 1/16” (1.59mm) gap between dash pot plunger tip and base of suction blade housing. Tighten.

To set vertical rise setting: Turn mushroom cap bolt into vertical rise switch button until you hear a click. When it clicks, adjust approximately 1/16 th of a turn into vertical rise switch, hold and tighten.

Adjust counter poise spring tension to lightly pull counting head down. Approximately half the length of the bolt or less is satisfactory.

• *ADJUSTMENT IS CRITICAL FOR PROPER FOLLOW-UP THROUGH PAPER

COUNTING HEAD REMOVAL (Refer to Pages #27, 82, 84) (Video available on Web Site, “Service & Support”)

Pull off “Vacuum Hose” (p.27, #1).

Pull “15 Pin head Plug” (p. 27, #2)from counting head (NOTE: Grasp plug (not wires) when unplugging cable) and hook into white clip on side of counting head (p.82, #8).

Loosen wing nuts on left and right pivot blocks, and lift hinged top from bearing.

Remove Counter Poise Spring (p.84, #2) by unhooking ”S” clip (p.27, # 10) from dash pot bracket.

Grasp front of counting head by vacuum shaft housing and the back of counting head. Carefully lift head out.

REPLACING COUNTING HEAD

1. Place counting head into pivot blocks. Take care to position left side bearing squarely between guide pins located in left side housing. Close hinged top onto pivot bearing and tighten wing nuts.
2. Connect counter poise spring “S” clip into hole provided in rear of dash pot bracket.
3. Plug cable into counting head and reconnect vacuum hose.

REMOVING COUNTING HEAD CENTER PLATE

(Video available on Web Site, “Service & Support”)

Remove counting head from machine; remove counting head covers and insert tape.

Unscrew vacuum hose from suction blade housing.

Place screwdriver on the outer side top of 15-pin plug. Press down and in. Plug will disconnect from plate. (Plug should hang free inside counting head.)

Disconnect 3-pin motor plug.

Remove 2 allen screws from the bottom of Counting Head base plate connecting center plate. Carefully lift center plate out.

NOTE: When replacing center plate, position on steel guide pin and gently push into position. Take care that drive gears are properly meshed before tightening allen head screws.

COUNTING HEAD REMOVAL

PHOTO/DIAGRAM

1. Vacuum Hose (S-4033)
2. 15 Pin head plug (S-3032)
3. 3 Pin counting head motor plug (S-3037)
4. Left side pivot block (S-2221)
5. Tape reel cover (S-6162)
6. Down limit adjustment plate (S-2247)
7. Down limit switch (S-3112)
8. Counter poise spring adj. bolt. (S-6171)
9. Right side pivot block (S-2222)
10. “S” Clip (S-6174)

Note: Photo above shows counting head with center cover removed. Do not run machine without center cover installed.

HOW TO CHANGE A SUCTION BLADE**

(Video available on Web Site, “Service & Support)

1. Turn off power receptacle (main power, rear of machine) and disconnect cord.
2. Remove counting head from machine (refer to “Counting Head Removal”, page 26).
3. Holding the link arm, loosen the allen cap screw in the center of the blade and remove the blade from the holder.
4. Take the blade required, line up the locator pin with the slot in the holder, and install the blade.
5. Again, holding the link arm, tighten the allen cap screw in the blade.
6. Reinstall and connect counting head.
7. Reconnect cord and turn on power. The machine is ready to count.

SETTING VERTICAL RISE SWITCH**

With counting head in machine, loosen “locking nut” on vertical rise actuator.

Adjust the vertical rise actuator so it lifts off the vertical rise switch.

Screw the vertical rise actuator onto the vertical rise switch until you hear the switch click or switch close.

Turn the vertical rise actuator no more than 1/16” (1.59mm).

Tighten the “locking nut”.

SETTING THE COUNTER POISE SPRING**

Loosen wing nut on counter poise spring bolt.

Adjust tension of spring by turning the counter poise spring bolt so that there is sufficient tension on counter poise spring to ensure that the head of the vertical rise actuator will engage into the vertical rise switch.

Secure bolt by locking wing nut.

• *Refer to photos on Pages 82 & 84.

ORBIT ADJUSTMENT (REFER TO DIAGRAM ON PAGE #29)

CAUTION:

Read and understand all instructions before attempting this adjustment.

Remove counting head from machine. (Refer to procedures on Page 26.)

Remove both covers and tape spool.

Disconnect small vacuum line from suction blade housing, 15-pin plug from side plate and disconnect 3-pin motor plug.

Remove 2 screws from bottom of base connecting center plate and carefully lift plate out.

Loosen allen screw on small crank arm #1. Rotate and hold crank arm at maximum forward position so that allen screws are facing downward.

Loosen allen screw on large crank arm #2 and raise back edge of suction blade #5 approximately 2 degrees above level. Lightly tighten screw.

While holding small crank arm #1 at maximum forward position, rotate main shaft #9 until top of wiper pin #3 is flush and parallel with front surface of suction blade #5 and approximately 1/8” (3.18mm) away from front edge.

NOTE: Adjustment of push rod #8 may be required to obtain this setting. Loosen 2 screws #13 on orbitor assembly to adjust.

Lightly tighten all screws.

Continue rotating wiper pin #3 under suction blade #5 and around back edge. Set clearance of approximately 1/8” (3.18mm) between wiper pin #3 and back edge of suction blade #5 by loosening screw #14 and rotating rocker arm adjustor #15. Lightly tighten screw.

Continue rotating wiper pin #3 across top surface of suction blade #5 to achieve approximately 1/16” (1.59mm) clearance. Set this by adjusting push rod #8 length. (Refer to note in Step 7).

Rotate wiper pin #3 around suction blade #5 observing all clearances. Repeat procedures 5 through 10 if necessary to obtain uniform orbit.

Tighten all screws securely.

HOW TO REMOVE A TAPE JAM (REFER TO DIAGRAM ON PGS. 36 & 37) (Video available on Web Site, “Service & Support”)

Remove head from machine. (Refer to Counting Head Removal, Page 26 & 27).

Remove both head covers.

Push small knurled wheel against large knurled wheel and rotate the main shaft to “back-out” the jam in the chute.

NOTE: On 2000+ models, the internal size of the chute has been increased and the slot has been extended for easier removal of tape jam.

If step 3 doesn’t work, use a small pair of needle-nose pliers or tweezers, grasp the tape and pull the jam from the chute. Do not damage knurled wheels by “picking” at the tape with a screwdriver and be careful not to damage the tape chute by scoring or burring where the tape travels.

If step 4 did not work, removal of knife assembly is necessary. Do not pick at tape through knife or serious damage will result to knife assembly.

Unhook black Connecting Link Arm (R-11, S-6283) from teardrop (R-14) Loosen the #10-32 nut and remove #10-32 allen cap screw (#1). Carefully lift knife assembly (#13) from tape chute (#3). You will now see the tape protruding from end of chute. Grab tape with small needlenose pliers and pull out straight. While you have knife assembly out, this is an excellent time to internally clean the knife. Remove anvil from barrel and clean both pieces with a Q-tip and acetone. DO NOT OIL THIS ASSEMBLY. Reassemble knife and carefully place back onto tape chute. Replace #10-32 allen cap screw until it “bottoms out” in knife. DO NOT OVER TIGHTEN OR DAMAGE WILL RESULT TO END OF TAPE CHUTE. Adjust screw so the tape will exit from center of slot. Hold and tighten nut securely. Reattach connecting link S-6283.

If step 5 did not work, the tape chute will have to be removed (Tape Chute Removal, Page 33). Using a small torch, heat area of tape to “burn out” the tape jam. Pass a new piece of tape through the chute to clear or you may order a new Tape Chute, S-6056-1, if necessary.

TAPE CHUTE REMOVAL

(REFER TO DRAWING #10, PAGE 31)

1. Remove screw (#1).
2. Loosen nut (#2). DO NOT “REMOVE”.
3. Slide tape chute carefully out of knife assembly and “L” bracket (#14).

REPLACING TAPE CHUTE

Replace chute carefully into knife and “L” bracket (#14).

Replace screw #1- DO NOT TIGHTEN.

Insert tape into chute until tape comes through knife assembly smoothly. If restrictions are felt, move the chute out of the knife assembly slightly until the tape passes smoothly through the knife. Tighten nut (#2).

Re-insert tape into tape chute (#3) and push tape through to the tape chute slot(#15).

Position chute so that tape lightly brushes bottom knurled drive wheel (not shown) while passing over tape chute slot (#15).

CHANGING TAPE SOLENOID (S-3103)

These instructions reference photo and parts on Pages 36 & 37.

Remove center plate (Refer to instructions, Page 26). Remove tape drive (#R9) by removing 2 allen screws. Using ½” (12.7mm) socket, remove nut holding the tape solenoid to the center plate. Push back the sleeve over the solenoid wires and cut the wires. Take the wires of the new solenoid and solder them to the cut wires. Use shrink tube or electrical tape to cover solder connections. Replace the ½” nut that holds the solenoid to the center plate. Replace the tape drive with the 2 allen screws. Before tightening, make sure the gear of the top tape drive is engaged with the gear of the bottom tape drive. Push the top tape drive so that both knurled wheels touch. Turn the solenoid plunger into the solenoid while holding down the top tape drive until you feel the top tape drive being pushed away. At this point, turn the plunger one full turn away from the tape solenoid.

REMOVAL OF KNIFE ASSEMBLY (S-6285-1) –Refer to Page 36

Remove connecting link arm (#R11) from tear drop (#R14) of knife. Loosen locking nut and remove allen screw. Remove knife assembly from the end of tape chute and adjusting plate.

• *DO NOT USE OIL ON KNIFE ASSEMBLY**

REPLACING KNIFE ASSEMBLY (S-6285-1)

Position knife on tape chute. Turn allen head screw into knife adjusting plate until screw “bottoms out”. Attach knife Connecting Link Arm (#R11) to tear drop (#R14). Push tape through until it comes through the knife anvil. Tape must travel smoothly through anvil. Slightly turn the allen head screw clockwise or counter-clockwise until tape flows smoothly. Lock down the locking nut (#R15). Depress knife solenoid and ascertain knife blade completely passes over anvil slot with over travel not to exceed 1/32” (.79mm). This adjustment is made via the connecting link arm (#R11). Place counting head in a flat position. Push tape through chute until tape hits bottom of blade, approximately mid-way. Adjust the angle of the of the knife anvil using the allen head screw.

• *DO NOT USE OIL ON KNIFE ASSEMBLY**

COUNTING HEAD, CENTER PLATE – RIGHT SIDE

(PHOTO / DIAGRAM # 11)

R1- Vacuum Switch (S-3043-1) R2- Tape Loading Lever (Ass’y S-6045) R3- Looper Stop Switch (S-3105) R4- Looper Driver Motor (S-3106-1) R5- Looper Drive Belt (S-6062) R6- Knife Solenoid (S-3102) R7 – Reset Reed Switch (S-3107) R8- Tape On / Off Switch (S-3140)

R9 – Tape Drive (S-6250) R10- Knife Assembly (S-6285-1) R11- Connecting Link Arm (S-6283) R12- Allen Screw R13- Nut R14- Tear Drop R15 – Locking Nut (H-154) R16 - Knife Adjusting Plate (S-6287)

COUNTING HEAD CENTER PLATE LEFT SIDE

(PHOTO / DIAGRAM # 12)

L1- Low Tape Actuator (S-3110)

L5- Tape Chute (S-6056-1)

L2- Loop Drive Assembly (S-6040) (O-Ring = S-6054) L3- Looper Follower (S-6050)

6- Count Reed Switch (S-3108)

L7- Knurled Wheels (S6250-E, S-6021(plated)… not shown)

L4- Tape Solenoid (S-3103)

L8- Looper Stop Actuator (S-3105-A)

MAINTENANCE SCHEDULE

Filter assemblies (vacuum manifold and counting head): Remove jars and clean filters daily. Depending on dust and paper material, more frequent cleaning or replacement of filters may be necessary. Be sure jars are tight to avoid vacuum leaks.

Wiper pin bearing (critical): Due to the extreme load placed on the wiper pin assembly, it must be checked daily. For free spinning and no excessive up and down movement. To lubricate. Remove brass end cap using a large tipped flat screwdriver and push assembly through housing. Use either Teflon based oil, any high-grade motor oil or lithium or Teflon grease and place directly into bearings. It is not recommended to use multi-oil or light household oil because it will not adhere to the ball bearings. Lubricate weekly or every 40 hours of operation.

Knife assembly (critical): The knife assembly should be checked daily for free movement. If knife appears sluggish, use a high-pressure contact cleaner and spray directly into knife. Disassembling the knife may be required to clear barrels internally if sluggishness persists. Do not use any oil on knife assembly. This will attract dust and cause knife malfunction.

Tape Loop Drive (critical): To ensure proper tape loop and tabbing, the tape loop drive must always spin freely. Check that all o-rings are in place. If tape loop drive is binding, it may have to be disassembled and lubricated using a light oil. When reinstalling, do not sandwich pieces together tightly. Remember that it must move freely. Inspect and check monthly (every 30 days).

Counting blade: The wiper pin must orbit the blade without coming in contact with it. Any scoring of the blade can cause tearing, miscounts or marking of the stock being counted. If blade shows signs of wear, it must be replaced. If paper chips or dust becomes lodged in blade, it must be removed and cleaned. When reinstalling, make sure housing seat and bottom of suction blade are clean and be sure blade is tight to avoid vacuum leaks.

Additional lubrication points (lubricate weekly or every 40 hours of operation, using a light oil): Pivot bearings (on sides of head) Connecting link bearings (dog bone assembly) Rocker arm assembly (in head; remove covers) Tape drive assembly (in head; remove covers) Note: Do not spray lubricant inside mechanical parts on head. This can and will cause head failure. If you have any questions, contact the factory. (See page 40 for contact information.)

Inspect upper and lower knurled wheels and gears. (Refer to Diagram on Page #37) Check all mechanical and electrical connections for tightness.

Machine: General cleaning of machine may be done using a store bought glass cleaner or allpurpose cleaner.

Note: Remove any tabs from bottom of machine that could block the laser pick-up assembly.

CONTACT INFORMATION

CALL U.S. PAPER COUNTERS

SERVICE DEPARTMENT

PHONE: 518-622-2600

FROM 8:30 A.M. TO 5:00 P.M. EST.

MONDAY THRU FRIDAY

YOU CAN ALSO:

FAX TO: 518-622-2695

Shipping Address: 138 Elizabeth Terrace, Cairo, NY 12413

Mailing Address: P.O. Box 837, Cairo, NY 12413

TROUBLE SHOOTING

Power switch in off position

Turn power switch to on position

2. Power LED on logic not lit

a. Main power fuse blown.

b. Emergency Stop Switch not set/reset.

c. Bad interlock

a. Replace fuse.

b. Set Emergency Stop Switch to correct position.

c. Close rear cover, check Cover Safety Switch. Check AC pins 3 & 4 on interlock. If no AC, check plug 1 pins 8 & 9 on logic board.

d. Check for broken wire or replace logic board.

3. Vacuum Pump does not start.

b. LED #7 on logic board not lit

c. Solid state relay (SSR) on pump plate not turning on (LED #7 is lit).

d. Lower laser receiver bad.

4. Vacuum pump does not stop.

a. Obstruction (tabs) over lower laser receiver

b. Laser not aligned.

c. Laser dim or not lit.

d. Bad logic board.

5. Decade (overage) not lit.

a. F2 fuse blown.

b. No voltage going to ECU.

6. Counts fail to register while machine is running

b. Bad count reed switch

c. Vacuum switch out of adjustment or bad.

a. Check procedures for “No power” #1 above

b. Check plug on receiver.

c. Check for DC voltage on SSR pin 1 & 2. If you have voltage, jump relay or if no voltage, replace SSR

d. Replace receiver.

a. Clean lower laser of obstructions.

b. Check alignment.

c. Replace laser diode addembly (test with flashlight). Check DC voltage on plug 4 pins 6 & 7 on logic or replace logic board.

a. Replace fuse

b. Check ECU 9-pin plug, pins 8 & 9 for AC.

c. Replace ECU

a. Check continuity of coax cable from ECU 9-pin plug, pins 1 & 2 to head cable.

b. Replace switch

c. Check vacuum switch settings (17 ½”hg). Jump vacuum switch. If counts register, replace. With power on, jump between 9-pin plug on ECU pins 1 & 2 or replace ECU.

7. Count registers but no tabs in stack

a. Tape length too short

b. Knife sticking.

c. No tape loop.

b. Clean knife**

c. Check loop follow up, o-rings, looper switch and motor.

d. Loose connection on ECU/broken d. On 9-pin plug, check pin 3 & 6. wire.

e. Tape chute out of adjustment or

e. Adjust chute or clean. jammed.

f. Bad solenoid/ECU

f. Check continumity from ECU pins 3 & 6 to counting head cable. Jump pins 3 & 6. Listen for click from knife.

g. Bad totalizer board.

g. Replace ECU. Unplug totalizer board. If decade runs and tabs, replace total board.

h. Bad in-line fuse/blown F3 fuse.

h. Replace fuse.

8. Count registers but no knife or batch counts

a. Sticky knife.

b. Loose connection of ECU

c. Broken wire.

d. Bad ECU

Refer to steps under “Count registers, but no tabs in stack” (#7 above).

9. Decade and batch counter register but no knife.

b. Check connections of white/brown wire in head cable.

c. Check knife linkage from knife to solenoid.

c. Broken knife linkage

a-c. Replace parts as needed.

10. Tape and/or knife operate continuously

Replace ECU. (May need to replace solenoid.)

a. Refer to counting blade chart for correct blade.

b. Test count reed switch for proper function. Replace if needed.

c. Vacuum switch bad, clogged or

c. Clean, adjust or replace vacuum out of adjustment switch.

d. Bad pre-select.

d. Test 4 corner of the stack without tabbing. If all corners are the same, replace pre-select.

e. Vertical rise out of adjustment

e. Check VR switch settings.

• *USE A NON-RESIDUE ELECTRONIC CLEANER (DO NOT USE A SILICONE SPRAY)

11. Miscounts, undercounts or overcounts.

a. Wrong suction blade for stock being counted.

b. Bad count reed switch

12. Decade fails to reset

a. Reset switch in “Off” position.

b. Broken wire on “Start Switch”.

a. Move switch to correct position or replace.

b. Test blue wire from start switch to reset switch.

13. Insert tape not entering stack or falling out.

a. Tape length too short.

a. Adjust tape to 2 ¼” to 2 ½” length.

14. Knife partial cutting or half cuts

a. Clean knife and linkage**

b. Linkage sticking

c. Weak pulse from ECU

d. Bad ECU

e. Bad cutting edge on knife

b. Check for binding or worn parts.

c. Adjust “K” pot on ECU

d. Replace ECU

e. Replace knife.

a. Laser out of alignment or blocked by tables

b. Vertical rise switch out of adjustment.

c. Bad start switch

15. Clamp not lowering

b. Set VR switch.

c. If LED #11 does not light when start switch is pressed, replace switch.

d. Replace F3 fuse on logic board. Refer to Sequence of Events Page 18.

16. Clamp lowers as soon as paper is placed in throat of counter.

a. Bad start switch

b. Bad clamp valve.

c. Bad logic board.

Replace parts as needed.

17. Counting head does not rise.

a. If logic board was replaced, check VR jumper settings on board.

b. VR switch out of adjustment.

a. Move jumpers to match VR motor in machine.

b. LED #8 on logic must be lit. Check and adjust VR switch

c. Check fuses; replace if needed.

d. Led #1 should be lit when relay is energized. Replace if needed.

d. Tighten setscrew or replace roll pin. Replace logic board.

c. Blow F1 or F3 fuse.

d. Bad 24 VDC directional relay.

e. VR sprocket loose.

f. Bad logic board.

• *USE A NON-RESIDUE ELECTRONIC CLEANER (DO NOT USE A SILICONE SPRAY)

18. Counting head does not lower.

a. Laser obstructed, out of alignment or dim.

b. Down limit switch out of adjustment.

c. Blown F1 fuse.

19. Counting head fails to stop after counting is complete.

20. Counting head fails to start counting

a. Filters, counting head or vacuum lines clogged.

b. Motor start vacuum switch out of adjustment or bad.

c. Bad logic board.

a. Vacuum pressure too low (min. 22”hg on gauge needed to start).

b. Vacuum leak.

c. Motor start vacuum switch out of adjustment or bad.

d. Blown F4 or F5 fuse.

e. Speed control set to off.

f. Bad counting head motor.

g. Wrong suction blade for stock.

21. Counting head stops counting before counting is complete.

b. Check 24 VDC relay on logic board. Check LED #10 on logic. Must be in up position (adjust switch).

c. Replace fuse.

a. Clean vacuum filters, head and line.

b. Check switch settings.

c. Replace logic board.

a. Adjust vacuum relief valve.

b. Check for vacuum leak (filters, lines, etc.)

c. Set vacuum switch to 19”hg or replace.

d. Replace fuse(s)

e. Increase speed.

f. Check voltage at counting head motor. Replace if needed.

g. Install correct suction blade. Refer to “Suction Blade Guide” Page 12.

a. Wrong suction blade.

a. Check suction blade chart (Page

12) for correct blade.

b. Stack being counted is not jogged properly.

c. Stack too loose.

b. Check jog of paper.

d. Speed too fast or too slow.

e. VR switch travel not set correctly.

f. Counter poise spring not adjusted correctly.

22. Continuous reverse rotation of wiper pin for reset.

a. Clear, adjust or replace

a. Bad reset switch.

b. Weak magnet or magnet broken or missing.

c. Bad logic board.

c. Check spring blade and blade stop for proper adjustment.

d. Adjust counting speed.

e. Adjust VR switch and counter poise spring.

f. Adjust counter poise spring.

a. Test reed switch and replace if needed.

b. Check magnet and replace if needed.

c. Move reset speed jumper on logic board or replace logic board.

22. Counting head fails to reset after counting.

24. Tearing or chipping of corners.

b. Bad counting head motor.

a. Check LED #2. IF NOT FLASHING REPLACE LOGIC.

b. If it is flashing, check voltage at motor. If there is voltage at the motor, replace motor.

a. Orbit out of adjustment

b. Wiper pin not spinning freely or bad wiper pin bearings.

c. Bent wiper pin.

d. Incorrect suction blade

e. Counting speed set too fast for stock being counted.

f. Vertical rise (VR) switch not set properly.

g. Depth of corner off.

h. Bad spring blade or blade stop set to wrong angle.

a. Bad logic board.

c. Replace wiper pin and bearings.

d. Install correct suction blade.

e. Reduce counting speed.

f. Set VR switch.

i. Stack too high for quantity tabbing in.

g. Set depth of corner.

h. Adjust spring blade stop (stop should have slight downward bend) or replace spring blade. i. Shorten stack height or insert “breathers” Page 15.

a. Orbit out of adjustment

b. Bad wiper pin bearings or wiper pin (pin needs to spin freely)

c. Depth of corner off.

a. Reset orbit

b. Replace bearings and/or wiper pin.

c. Set depth of corner.

26. Erratic tape lengths.

a. No tape loop or not keeping tape loop.

a. Set actuator wire on looper switch. Check and replace drive orings if needed.

b. Check for AC at pins 7 & 9 on head cable. If voltage is present, check looper switch for continuity.

c. Replace F2 fuse.

d. Adjust tape chute.

b. Bad looper motor or bad looper stop switch.

c. F2 fuse blown

d. Tape chute out of alignment

ELECTRICAL SYSTEM

LOGIC CONTROLLER

24 DC RELAY

De-energized switches vertical rise motor leads to “down” position.

Energized switches vertical rise motor leads to “up” position.

SSR1

Supplies 120V AC ± 5% to speed control.

SSR2

Supplies 120V AC ± 5% to vertical rise motor via 24V DC relay.

Fuses for counter function

• **Also see Page 19***

PHOTO - REAR TOP OF MACHINE

(PHOTO / DIAGRAM #13)

Logic Controller (S-3170) C Upper Laser System (S-3079-U) D Down Limit Switch (S-3112) Clamp Plate (S-1025-∗) F0 – F5 Fuses F0 – *A & *B Fuse 10Amp.5X20mm – Mains (*16 Amp with air table) F1 – .75 Vertical Rise Motor for Dayton Motors 2Amp. SLO/BLO for Bodine Motor F2 – 1Amp. ECU / Looper F3 – 3Amp. + 42V DC F4 – 5Amp. Speed Control AC In F5 – 5Amp. Speed Control AC Out

∗ - Different styles available depending on machine

FACEPLATE COUNT-WISE M

(PHOTO / DIAGRAM #15)

A Emergency Stop (EMO) (S-3188) H Tape Cut Switch (S-3119) B Low Tape Indicator (S-3111-A) Tape Length (S-3048) C Batch Counter (S-3062-∗) J Blower On / Off (S-3058) D Reset On / Off Switch (S-3056) K Speed Control (S-3047-∗) E Totalizer w/ Memory (S-3062-∗) L Pre-Select (S-3065-∗) F LED Display (S-3067) G Start / Stop Switch Ass’y (S-3049-∗) Start / Stop Switch (S-3049-∗) ∗ - Different styles available depending on machine

CONTROL PANEL KEY – MAX BANTAM 2001 TO PRESENT

FACEPLATE LED DISPLAY Displays paper count PRE-SELECT Displays batch number selected by user LOW-TAPE DC voltage supplied by the electronic counting unit via INDICATOR (S-3111the low-tape switch located in the counting head, behind A) the tape reel. RESET-ON/OFF “ON” position: overage display on the electronic SWITCH (S-3056) counting unit will zero when start switch is pushed. “OFF” position: display will maintain number from previous batch and continue from that number. TAPE LENGTH 500K with ON/OFF switch. Controls length of tape as it POTENTIOMETER is being inserted into pile. “OFF” disconnects power to (S-3048) tape and knife solenoids, low-tape indicator and batch counter. START SWITCH Supplies 5 volts DC to the logic controller START SWITCH 5 volts DC supplied from laser sensor LAMP (CALL FOR PART NUMBERS) N/A N/A RUBBER FEET Supports faceplate against chassis N/A N/A BATCH COUNTER Function: counts tabs inserted. Powered from electronic counting unit; knife pulse 42V DC. Will not operate with tape length potentiometer in “OFF” position. Reset accomplished with button on “batch counter”. TOTALIZER WITH Voltage supplied by 42V DC power supply; count input MEMORY from count proximity and count vacuum switch located in counting head, via coax cable. Reset accomplished with button “Totalizer”. COUNT SPEED Supplies up to 90V DC to counting head motor. Speed CONTROL control is supplied from output of SSR1. NOTE: Speed control can be turned “OFF” for circuit testing. KEY LOCKS (S-1017) Secures face plate (keys included). TAPE CUT (S-3119) Manual tape cut (after changing roll of tabbing paper). EMERGENCY STOP Emergency stop switch. Push to cease operation and stop (EMO) (S-3118) Power to the machine.

VACUUM SYSTEM

VACUUM PUMP

“E” 110 (S-3004-3B) 220 (S-3004-4B)

CLAMP VALVE

(S-3041-1) (Not Shown) COUNT VALVE “I” (S-3042) START VACUUM SWITCH “H” (S-3043-1)

COUNT CONTROL

VACUUM SWITCH (S-3043-1) (Also refer to Page 34, KEY #R1)

Manufactured by Thomas Industries; standard voltage 120 AC or 220/240 V AC, 50/60 Hz. Maximum output 29 ½” HG. NOTE: Vacuum may vary due to altitude and barometric pressure. Four-way vacuum valve, operates clamp cylinder.

Applies vacuum to suction blade when counting head tips off vertical rise micro switch. Valve de-energizes when clamping circuits are released. Manually adjusted to operate at 19” HG. When hole on suction blade is exposed to atmosphere, counting head vacuum switch opens, breaking circuit to counting head.

(Refer to Page 58 “Setting Vacuum Switches”) Manually adjusted to operate at 17 ½” HG. Wired series with count reed switch. Assures the accuracy of the count. Opens when last sheet is counted.

(Refer to Page 58 “Setting Vacuum Switches”)

PHOTO - POWER SUPPLY & VACUUM AREA

(PHOTO/ DIAGRAM #17)

A Power Supply Assembly (S-3008-1)

G Filter Housing Assembly (S-4018)

Glass Jar (S-4006) Plastic Rivet (S-4018-A) Filter Stem (S-4018-B) Filter Element 2 (S-4019)

B Vacuum Pump Cut-off (S-3132-2) H Vacuum Switch (3043-1) Vacuum Pump Cut-Off w/ Air (S-3132-∗) C Vertical Rise Motor (S-3005-∗) I Count Vacuum Valve (S-3042) D Starting Cap. V/R Motor (S-3007) J Cover Safety Switch (S-3165) E Vacuum Pump 110 (S-3004-3) K Lower Laser System (S-3079-L) Vacuum Pump 220 (S-3004-4) F Vertical Rise Switch (S-3114) ∗ - Different styles available depending on machine

SETTING VACUUM SWITCHES

Adjusting your vacuum switches does not change the output of vacuum from your pump. Adjustment occurs when the switch closes. For instance, setting the count control vacuum switch to 17 ½” Hg allows the machine to register a count when this vacuum is achieved.

FOR MORE INFORMATION,

AND BEFORE ATTEMPTING

THIS PROCEDURE,

PLEASE CALL

U.S. PAPER COUNTERS

(DIAGRAM #18: VACUUM SWITCH)

• *FOR REFERENCE ONLY**)

Turn allen screw clockwise; this will increase vacuum required to activate

(DIAGRAM #19: SPEED CONTROL ADJUSTMENT SEQUENCE)

1. Turn speed control knob to “0” on faceplate. (Do not attempt to tab at this time. Turn tape pot “Off”.)
2. Bottom out the center pot (B) by turning it completely counter-clockwise.
3. Set the slow speed pot (C) to “Off” position by turning it completely counter-clockwise.
4. Insert a stack of paper into the machine. Press the “Start” switch and turn pot (C) Clockwise until counting starts; then back off until it stops.
5. Turn “Speed Control Knob” on face plate to full “On” position. Insert a stack of paper into The throat of the machine and press the “Start” switch. Using a stopwatch, counter should read 425 in 15 seconds. Adjustment of pot (A) may be required to obtain this.

(DIAGRAM #20: ACE MICRO CUSHION ADJUSTMENT)

Proper adjustment is important to the efficient operation of the ACE Micro Cushion. All units are preset at the factory at 50°. To adjust deceleration, loosen the lock screw located in the adjustment knob at rear of shock absorber with hex wrench. (.050 inch or 1.27mm). Turn towards “0” for more cushioning. When desired setting has been determined, tighten lock screw. The shock absorber is now ready for use.

LOGIC BOARD WIRE CONNECTIONS

PLUG 1

COLOR CODE

Green/Yellow White/Green Orange Black/Green White/Gray White/Blue Green White or Blue Black or Brown White/Brown Blue White/Orange White/Black Red Black White/Red White Gray

DESCRIPTION

Earth ground VR switch signal input

• N/C VR switch DC ground VR switch for light paper applications (left column switch) Down limit switch signal input Down limit switch DC ground AC neutral in AC line in VR motor capacitor VR motor Laser input DC ground VR motor VR motor +42 VDC AC neutral out AC line out

PLUG 2

COLOR CODE

White/Purple

Blue White/Orange Black/Orange White Brown/White White/Black White/Red Black

DESCRIPTION

+5 VDC out to start switch

• N/C (+) speed control ECU mode ECU mode
• N/C
• N/C, DC ground
• N/C
• N/C
• N/C Start switch signal input Start switch *N/C internally (-) speed control output Neutral to speed control ECU Switched AC to speed control DC ground +42 VDC AC line to ECU (On old version with interface board. ECU gets power from looper motor on Plug 3)

PLUG 3

COLOR CODE

White/Red White/Black

Green/Yellow White/Gray

White/Gray Black/Green Brown/White Brown/White Black/Orange

DESCRIPTION

Laser Laser

• N/C
• N/C
• N/C
• N/C
• N/C, (Internal neutral to looper motor)
• N/C, (Internal line to looper motor)
• N/C Earth ground Reset proximity switch
• N/C
• N/C Reset proximity switch (+) to counting motor Looper motor Looper motor (-) to counting motor

PLUG 4

COLOR CODE

1. 2. 3. 4. 5. 6. Red 7. Black 8. 9.

10. Black

11. Black/Yellow

12. Black/Orange

13. Black 14.

15. Black/Green

16. White/Gray

17. Black/Orange 18.

• No Connection

DESCRIPTION

• N/C
• N/C (+42 VDC internal) (+) speed control output
• N/C
• N/C Laser Laser ground
• N/C
• N/C ground Clamp valve (-) to TIP41C open collector Clamp valve (+42 VDC) Count valve (+42 VDC) Count valve (-) to TIP41C open collector
• N/C Start count vacuum switch signal input Start count vacuum switch ground Start count switch
• N/C ground

VERTICAL RISE MOTOR

The Logic Controller (S-3170) is compatible with either the Bodines or Dayton Vertical Rise Motor.

The board has 2 jumpers that determine which motor the board will drive. Refer to the picture (Page 69) to determine the proper jumper position

COUNT-WISE ECU HEADER PINOUT

9-PIN HEADER ON MAIN ECU BOARD

Count Input Count Ground Ground Reset +42V DC Tape Knife Line Neutral

Coax Shield White/Black White/Blue White/Orange White/Green White/Brown Brown/White White

5-PIN HEADER ON MAIN ECU BOARD

External Tape Pot External Tape Pot Ground Ground Ground

Orange Orange White/Black

• N/C
• N/C

ADJUSTMENT POTS

“T” “KD” “K”

=Internal Tape Adjustment =Knife Delay =Knife Adjustment

Center pot on board is equal input delay. Set adjuster pointer towards transformer.

DO NOT TURN ANY OF THESE POTS TO THE FULL END OF THEIR ROTATIONAL TRAVEL, AS THIS WOULD CAUSE AN OPEN CONDITION.

(DIAGRAM #23: WIRING DIAGRAM-LOGIC CONTROLLER)

Baldor VR Motor

Bodine VR Motor

Jumper position

COMPUTER ECU

11-PIN HEADER ON MAIN ECU BOARD

Count Input Count Ground Ground Reset 24V DC Tape Knife Line Neutral 12V DC Ground

Coax Shield White/Black White/Blue White/Orange White/Green White/Brown Brown/White White White/Red White/Black

NOTE:

Pin 3 and Pin 11 are connected. 12V DC comes from own main ECU.

5-PIN HEADER ON MAIN ECU BOARD

External Tape Pot External Tape Pot Ground Ground Ground

Orange Orange White/Black

• N/C
• N/C

AUTOSTOP ECU BOARD

10-PIN HEADER ON AUTO-STOP ECU BOARD

+5V DC Start switch

• N/C Autostop Relay Board
• N/C
• N/C
• N/C
• N/C Logic Ground
• N/C Batch signal

NOTE:

J8 & J10 come from the total and batch board.

RECOMMENDED SPARE PARTS

PART # S-3105 S-3043-1 S-6062 S-6054 S-3108 S-6236-2

QUANTITY

PART DESCRIPTION

Looper Stop Spring Switch Vacuum Switch-New Type Drive Belt O-Ring Looper Drive O-Ring Count Reed Switch Assembly Wiper Pin W/Bearings (Includes wiper pin, 2 open bearings, large & small spacers & E-clip) Open Bearing Counter Poise Spring Filter & Muffler Element Vertical Rise Switch K-H Relay (24V) Sm (Dir.VR) Test Kit Complete-New Assorted Nuts & Bolts Suction Blade (*most commonly used) Tape Solenoid Knife Solenoid Adj. Connecting & Link Arm Tape On/Off Switch Felt Filter Assorted Fuse Pack Start Switch (*Depends on type of machine)

PARTS LIST-COUNTING HEAD

KEY #

PART # S-6045 S-6269 S-6132 S-6135 S-6133 S-627* S-6234 S-6236-2

PART DESCRIPTION

Tape Loading Lever Assembly Suction Blade House Assembly

• Seals-Suction Blade (2)
• Bearings-Suction Blade & Orbitor Suction Blade Shaft Suction Blade (#70-#75- See Page 12 “Suction Blade Guide’) Wiper Pin Assembly Complete Wiper Pin W/Bearings (includes wiper pin, 2 open bearings large & small spacers & E-clip) Wiper Pin Housing
• End Cap
• Small Spacer (not shown)
• Large Spacer (not shown)
• Wiper Pin Bearing (2) (not shown)
• Snap Ring Clip Hose Barb Connector Cable Clamp-Black Plastic (not shown in this photo) Lock Buttons, Relieved Pivot Bearing Receptacle 15-pin Mainshaft Bearing Retainer (2) Mainshaft Bearing Snap-Ring (2) Mainshaft Snap-Ring (2) (not shown) Orbitor Bearing (not shown) Orbitor Bearing Retainer (not shown) Orbitor Bearing Housing (not shown) Push Rod Count Vacuum Switch

FRONT VIEW COUNTING HEAD

(PHOTO / DIAGRAM #30)

1- Counting Head Motor (S-3100-B) 2- Counter Poise Spring (S-6173) 3- Vertical Rise Actuator (S-6175) 4- Magnet Carrier Count Reed (S-6316) 5- Connecting Link Arm (S-6100) 6- Counting Head Filter (S-4062) 7- Drive/Timing Belt (S-6011)

8- Orbitor (S-6230) 9- Magnet Carrier Reset Reed (S-6316) 10- Lower Tape Drive Ass’y (S-6020) 11- Suction / Counting Blade (S-627--) 12- Wiper Pin w/bearings (S-6236-2) 12a- Wiper Pint w/housing (S-6234) 13- Tape Retaining Block (S-6290)

PRE-SELECT & START SWITCH AREA

(PHOTO/DIAGRAM #31)

Pre-Select Assembly (S-3065-∗) Speed Control Pot (S-3047-∗) Tape Length Pot (S-3048)

G Reset On / Off (S-3056) H Batch Counter (S-3062-∗) Emergency Stop Switch (EMO) Assembly (S-3188)

Includes: Contact Block (S-3188-A) Red Stop Switch (S-3188-C) Terminal Protector (S-3188-C)

D Tape-Cut Switch (S-3119) E Main Blower Switch (S-3058) F Start Switch Assembly (S-3049-∗)

Includes: Start Switch (S-3049-∗) Splash Guard (S-3049-2D) Lamp (S-3050-∗) Lens Cap (S-3051-∗)

Speed Control (S-3047-∗) Totalizer Counter (S-3062-∗) Decade Board (S-3067) Totalizer / Batch Driver P.C. Board (S-3145-∗)

∗ - Different styles available depending on machine

PHOTO - POWER SUPPLY & VACUUM AREA

(PHOTO/ DIAGRAM #17)

A Power Supply Assembly (S-3008-1)

G Filter Housing Assembly (S-4018)

Plastic Rivet (S-4018-A) Filter Stem (S-4018-B) Filter Element 2 (S-4019)

B Vacuum Pump Cut-off (S-3132-2) H Vacuum Switch (3043-1) Vacuum Pump Cut-Off w/ Air (S-3132-∗) C Vertical Rise Motor (S-3005-∗) I Count Vacuum Valve (S-3042) D Starting Cap. V/R Motor (S-3007) J Cover Safety Switch (S-3165) E Vacuum Pump 110 (S-3004-3) K Lower Laser System (S-3079-L) Vacuum Pump 220 (S-3004-4) F Vertical Rise Switch (S-3114) ∗ - Different styles available depending on machine

INSIDE CONTROL PANEL

(PHOTO / DIAGRAM #33)

14 Pin Ribbon Cable (S-3066-1) 24 Pin Ribbon Cable (S-3068)

Clamp Cylinder (S-4023-∗) Electronic Control Unit (ECU) (S-3064) ∗ - Different styles available depending on machine

DIAGRAM/PHOTO #34: LASER SYSTEM OPERATION WITH PARTS LIST

The upper laser system contains a laser diode, which projects a light down on the lower laser system receiver. When the laser beam is broken, a signal is sent to the S-3170 Logic Controller, which activates the vacuum pump and enables the start switch. This will allow the clamp to lower and the paper to be counted when the”Start” switch is depressed.

The laser beam must fall on the lens cap located on the lower laser receiver. Adjustments to the lens position can be made by loosening the left to right or front adjustment screws located on the upper laser system. The laser mounting bracket can now be moved, so that the beam is in the correct position, and the screws re-tightened.

Laser mounting bracket Laser mounting block Cellomating lens Upper laser system (above 3 items + laser diode) Lower laser system

INDEX

A Ace Micro Cushion …………………………………………………………...………………………….61 Adjustments ………………………………………………...……………………………………...…55-61 Air Flotation ……………………………………………………………………………………...………10

B Batch Counter Face Plate (Photo) ………………………………………………………………..…….51 Breathers ………………………………………………………………………………………….…14, 15

C CE Certification ………………………………………………………………………………….….…..12 Center Plate: Removal ………………………………………………………………….……….…...….26 Center Plate: Drawing with Tape Chute …………………………………………………..…………...31 Center Plate, Right Side: Photo ………………………………………………………………….…......36 Center Plate, Left Side: Photo …………………………………………………………………..………37 Clamp Cylinder ……………………………………………………………………………….…………87 Clamp Plate …………………………………………………………………………………………..…..49 Computer ECU ……………………………………………………………………………………….….76 Computer ECU Board ……………………………………………………………………………….….77 Connecting Arm Link …………………………………………………………………………….…36, 81 Count Adjustment w/Diagram ……………………………………………………………….…………24 Count Reed Switch – Photo Reference ………………………………………………………………... 37 Counter Poise Spring, Setting …………………………………………………………………………..28 Counter Poise Spring, Photo ………………………………………………….. …………….……..27, 84 Counting Head: Photo & Parts List …………………………………………...…………………..82 - 84 Counting /Suction Blade Guide …………………………………………………………………………12 Counting Head: Photo, Front View & Parts List ………………………………...……………………84 Counting Head: Installation & Alignment ………………………………………...…………………...25 Counting Head Motor ……………………………………………………………..………………….....84 Counting Head: Removal & Replacing …………………………………………..………………..26, 27 Counting Head: Wiring Diagram ………………………………………………..……………………..67 Counting Speed ………………………………………………………………….. ……………………...12 Count Vacuum Switch (Photo)………………………………………………………………………….82 Count-Wise 1: Installation ………………………………………………………………………………..8 Count-Wise M: Diagram ………………………………………………………………………..………11 Count-Wise M: Installation …………………………………………………………………..…………10 Cover Safety Switch …………………………………………………………….……….…………...57,86

D Decade Board ……………………………………………………………………………….……41-43, 85 Down Limit Switch ………………………………………………………………………….…………...49 Drive/Timing Belt ………………………………………………………………………………………..84

E Electronic Counting Unit (ECU) Wiring Diagrams ……………………...………………..………72-74 Electronic Counting Unit (ECU) Basic Components ………………………………………………….71 Electronic Counting Unit (ECU) Power Supply Assembly ……………...………………………....…74 Electrical …………………………………………………………………………………………..……..12 Emergency Stop Switch …………………………………………………………………………..…52, 85

F Filter, Counting Head …………………………………………………………...………………………81 Filter Housing Assembly ………………………………………………………...…………….…...……57 Filter Jar, Glass ………………………………………………………………...….……………….…....57 Filter Element

• Stem ………………………………………………………...…………………………….……….….....57 Fuses …………………………………………………………………………...…………………….…...49

Insert Tape: Loading Diagram ……………………………………..………………….……….…..22, 23 Insert Tape: Removing a Tape Jam ……………………………..……………………………….….…32 Installation ……………………………………………………..……………………………...….……5-11 Max Bantam……………………………………………………………………………………….6 Count-Wise 1………………………………………………………………………………………8 Count-Wise M…………………………………………………………………………………….10

K Knife Assembly: Maintenance Schedule …………………………………..……………………...……38 Knife Assembly: Removal/Replacement & Diagram ………………………..……………….……34, 36 Knife Solenoid ……………………………………………………………….…………...………………36 Knurled Wheels …………………………………………………………….……………………..…31, 37

L Laser System: Operation, Diagram & Parts List …………………………………...…………………88 Laser System – Lower ………………………………………………………………...………..……57, 88 Laser System – Upper ……………………………………………………………..…………………49,88 LEDS: Self-Diagnostic Diagram ……………………………………………..…………………………17 Logic Board: Sequence of Events & Diagram ……………………………..……………………....18, 19 Logic Board Wire Connections ……………………………………………..……………….………64-66 Logic Controller ……………………………………………………………………….….….….48, 49, 69 Looper Driver Motor ……………………………………………………………….…………………...36 Looper Stop Switch: Photo Reference ……………………………………………..……………...…...36 Looper Stop Actuator ……………………………………………………………………….…………..37 Low Tape Indicator ………………………………………………………………………….…………..51 Low Tape Actuator ……………………………………………………………………………………...37 Lower Tape drive Assembly: Photo ……………………………………………………………………84

M Maintenance Schedule …………………………………………………………………………………..38 Max-Bantam Control Panel 2001 & After …………………………………………………………52, 53

Max-Bantam: Diagram …………………………………………………………………………………...7 Max-Bantam: Installation ………………………………………………………………………………..6

O Operating Instructions…………………………………………………………………...………………13 Orbit Adjustment & Diagram …………………………………………………………………...….29, 30

P Paper Range ……………………………………………………………………………………………..12 Parts Lists, Photos & Diagrams ………………………………………...……………………………...79 Parts: Recommended Spare Parts List …………………………………………………...……………81 Photos & Drawings ………………………………………………………………..…………………79-88 Pivot Blocks …………………………………………………………………………………………..26,27 Power Supply Assembly ………………………………………………………………………………...86 Pre-Select ……………………………………………………………………………………….……51, 85

R Receptacle Guard …………………………………………………………………………………………9 Reset Adjustment w/Diagram …………………………………………………………..………………24 Reset On/Off Switch ……………………………………………………………………………………..51 Reset Reed Switch ……………………………………………………………………………………….36 Ribbon Cable (14 & 24 Pin) …………………………………………………………………………….87

S S Clip …………………………………………………………………………………………………26, 27 Service ……………………………………………………………………………………………………40 Spare Parts, Recommended …………………………………………………………………………….81 Speed Control Adjustment Sequence ………………………………………….……………………….60 Speed Control, Count-Wise ………………………………………………………………..………..50,.51 Speed Control, Pot ……………………………………………………………………………………….85 Start/Stop Switch ………………………………………………………………………………...………51 Start Switch Assembly …………………………………………………………………………………..85 Suction Blade: How to Change …………………………………………………………………………28 Suction Blade Guide …………………………………………………………………………….……….12

T Tape Chute: Diagram & Photos………………………………………………………….…...…31,33,37 Tape Cut Switch ……………………………………………………………………………………..51,85 Tape Drive ……………………………………………………………………………………………… 36 Tape Jam: Tape Chute Removal/Replacement ………………………………………………….…32,33 Tape Length …………………………………………………………………………...…………………51 Tape Loading Lever: Photo Reference ………………………………………………………………...36 Tape Reel Cover …………………………………………………………………………………………27 Tape Retaining Block ………………………………………………………………………………….. 84 Tape Solenoid: Photo ……………………………………………………………………………………37

Tape Solenoid: Changing ……………………………………………………………………………….34 Tearing or Chipping of Corners ………………………………………………………………………..45 Technical Details: Count-Wise 1, M & Max-Bantam …………………………………………………12 Totalizer ………………………………………………………………………………………………….51 Trouble-Shooting ………………………………………………………………………...…………..41-45

Vacuum Pump …………………………………….………………………………………..……41, 56, 57 Vacuum Switch Adjustment …………………………………………………………………………….59 Vacuum Switch (Photo)………………………………………………………………………………….82 Vacuum Switches: Setting ……………………………...…………………………………………….....58 Vacuum System………………………………………………………………………………..……. 56, 57

Vertical Rise Motor …………………………………………………………………………..……..57, 61 Vertical Rise Switch …………………………………………………………………………………28, 57

W Warranty ………………………………………………………………………………………………..3, 4 Wiper Pin Bearing: Maintenance ………………………………………………………………………38 Wiper Pin w/Bearings & Housing: Photo ………………………………………………...……………84 Wiring Diagrams ……………………………………………………………………………..………63-77

DIAGRAMS & PHOTOS FOR REFERENCE

DESCRIPTION

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ACE MICRO CUSHION ADJUSTMENT

BREATHERS COMPUTER ECU BOARD COUNT ADJUSTMENT COUNTING HEAD-FRONT VIEW COUNTING HEAD-PHOTO COUNTING HEAD-CENTER PLATE & TAPE CHUTE COUNTING HEAD-CENTER PLATE-RIGHT COUNTING HEAD-CENTER PLATE-LEFT COUNTING HEAD REMOVAL COUNT-WISE M ELECTRONIC COUNTING UNIT (ECU) BASIC COMPONENTS FACE PLATE-COUNT-WISE M INSIDE CONTROL PANEL LASER SYSTEM OPERATION & DIAGRAM LOADING INSERT TAPE LOGIC BOARD MAX-BANTAM MAX-BANTAM CONTROL PANEL-2001 & AFTER ORBIT ADJUSTMENT POWER SUPPLY & VACUUM AREA POWER SUPPLY ASSEMBLY ON ECU PRE-SELECT & START SWITCH AREA REAR-TOP OF MACHINE-AMPS & FUSES RECEPTACLE GUARD RESET ADJUSTMENT SELF DIAGNOSTIC LEDS SPEED CONTROL-COUNT-WISE 15DV-PARTS PLACEMENT & LIST SPEED CONTROL ADJUSTMENT SEQUENCE TAPE RETAINING BLOCK VACUUM SWITCH ADJUSTMENT WIRING DIAGRAM-COUNTING HEAD WIRING DIAGRAM-ELECTRONIC COUNTING UNIT (ECU) WIRING DIAGRAM-LOGIC BOARD PLUGS WIRING DIAGRAM-LOGIC CONTROLLER

DESCRIPTION

(SORTED BY PAGE & DIAGRAM #)

MAX-BANTAM

RECEPTACLE GUARD COUNT-WISE M BREATHERS SELF DIAGNOSTIC LEDS LOGIC BOARD LOADING INSERT TAPE COUNT ADJUSTMENT RESET ADJUSTMENT COUNTING HEAD REMOVAL ORBIT ADJUSTMENT COUNTING HEAD-CENTER PLATE & TAPE CHUTE COUNTING HEAD-CENTER PLATE-RIGHT COUNTING HEAD-CENTER PLATE-LEFT REAR-TOP OF MACHINE-AMPS & FUSES SPEED CONTROL-COUNT-WISE 15DV-PARTS PLACEMENT & LIST FACE PLATE-COUNT-WISE M MAX-BANTAM CONTROL PANEL-2001 & AFTER POWER SUPPLY & VACUUM AREA VACUUM SWITCH ADJUSTMENT SPEED CONTROL ADJUSTMENT SEQUENCE ACE MICRO CUSHION ADJUSTMENT WIRING DIAGRAM-LOGIC BOARD PLUGS WIRING DIAGRAM-COUNTING HEAD WIRING DIAGRAM-LOGIC CONTROLLER ELECTRONIC COUNTING UNIT (ECU) BASIC COMPONENTS WIRING DIAGRAM-ELECTRONIC COUNTING UNIT (ECU) POWER SUPPLY ASSEMBLY ON ECU COMPUTER ECU BOARD TAPE RETAINING BLOCK COUNTING HEAD-PHOTO COUNTING HEAD-FRONT VIEW PRE-SELECT & START SWITCH AREA INSIDE CONTROL PANEL LASER SYSTEM OPERATION & DIAGRAM

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