FD 120

Card Cutter

MAINTENANCE MANUAL

SAFETY PRECAUTIONS

Always observe the cautions and warnings given below to prevent personal injury or property damage.

The degree of danger and damage that could occur is indicated on two levels by the following marks.

WARNING:

Ignoring this mark could result in the possibility of serious injury or even death.

CAUTION :

Ignoring this mark could result in the possibility of injury or physical damage

The following graphic symbols indicate the various types of action to be performed or avoided.

This graphic symbol indicates a forbidden action.

means “Do not disassemble.”

means “Do not touch.”

This graphic symbol indicates actions that must be performed.

means “Disconnect the power plug.”

Do not place metal objects or vessels containing liquids on top of the unit. The entry of any metal object or liquid could result in a fire or an electrical shock.

Do not insert any metal or easily‐combustible object inside this unit. This could result in a fire or an electrical shock.

Do not touch or insert foreign objects into any rotating part during operation. This could result in injury.

Do not remove the cover or back panel. This unit contains high‐voltage components that could cause an electrical shock.

Do not disassemble, modify or repair this unit. There is a danger of fire, electrical shock or injury. Contact your dealer when repairs are necessary.

Use only the power supply voltage specified on the main nameplate. Using other voltages could result in a fire or an electrical shock.

Keep this unit and the power cord away from heaters and heater vents. Excessive heat could melt the cover or power cord covering, and result in a fire or an electrical shock.

Do not use solvent inside or near the unit (e.g. when cleaning the unit). Such solvents may damage the rubber rollers and resin inside the unit, resulting in malfunctions.

Make sure that the combined power consumption of the appliances to be connected does not exceed the capacity rating of the power outlets or plug receptacles. Exceeding the capacity rating could cause the power outlets, plug receptacles, or power extension cords to overheat and catch a fire. Remove any dust that accumulates on the power plug prongs and the surface of the plug from which the prongs extend. Accumulated dust could result in a fire.

If any foreign object such as metal or liquid should enter this unit, immediately turn the unit off at the power switch and disconnect the power plug from the power outlet. Failure to do so could result in a fire or an electrical shock. Contact your dealer immediately.

Do not damage the power cord or power plug. (Do not scratch, alter, bend, twist, pull or place heavy objects on the power cord or power plug.) This could result in damage, a fire or an electrical shock.

Always grip the plug when disconnecting the power plug from the power outlet. Forcibly pulling on the power cord could cause damage, resulting in a fire or an electrical shock.

Do not handle the power plug with wet hands. This could result in an electrical shock.

Before cleaning this unit, turn the unit off at the power switch and disconnect the power plug from the power outlet. Accidental operation of the unit during cleaning could result in injury.

Do not touch the power switch with wet hands. Otherwise electric hazards may occur

Do not use flammable sprays inside or near the unit (e.g. when cleaning the unit). Such flammable gas may ignite and cause a fire or combustion.

Keep away long hair, ties, jewelry and loose clothing. This could result in injury.

Do not put fingers inside during operation. This could result in injury.

Always disconnect the power plug from the power outlet when the unit is not to be used for an extended period. Failure to do so could result in a fire due to leakage current if the insulation should deteriorate.

Install this unit on a level, stable stand or floor, with sufficient space around it. Failure to do so could result in the unit overturning and causing injury.

Do not install this unit in a location where there is excessive humidity or where contact with water is possible. Poor choice of location could result in deterioration of the insulation, a fire or an electrical shock.

Disconnect the power plug from the power outlet before attempting to move this unit. Failure to do so could result in power cord damage, a fire or an electrical shock.

Precautions in Maintenance and Handling

Repairs should be performed by qualified service personnel. WARNING: 2.1 To avoid the risk of electrical shock, disconnect the machine from the A.C. power source before performing any service procedure. The hardware used is METRIC. Replace hardware only with the same size as was originally used. Observe caution when cutting cable “tie‐wraps” so as not to damage the electrical wires. Note the routing of wiring harnesses, cables and the position of parts and assemblies before disassembly. They must be reassembled in the original configuration to avoid damage from moving components during operation. When using a tool generating heat such as soldering iron, take care not to damage the harnesses and cables.

Contents

1. Introduction ...................................................................................... 6
2. Specifications ..................................................................................... 6
3. Control Panel ...................................................................................... 6
4. Key Components ................................................................................ 8
5. Parts on Top of the Frame .................................................................. 10
6. Parts on Operating Side ...................................................................... 11
7. Parts on Non‐operating Side ............................................................. 12
8. Parts underneath the Frame .............................................................. 13
9. Electric PWB Assy. .............................................................................. 14
10. Electrical Wiring Diagram ................................................................. 17
11. Sensor Voltage Measurement .......................................................... 18
12. Replace Slitter .................................................................................. 19
13. Replace Cutting Knife ....................................................................... 20
14. Feeding Test and Permanent Count ................................................. 21
15. Calibration ........................................................................................ 22
16. Feed Tray Tension Adjustment ......................................................... 24
17. Feed Gap Adjustment ....................................................................... 25
18. Top Margin Parallel Adjustment ....................................................... 26
19. Self‐Diagnose for Malfunction ......................................................... 25
20. Error Message and Trouble Shouting ............................................... 26
21. Recommended Spare parts .............................................................. 27

1. Introduction

The FD 120 is designed to simplify business card, photo and post card cutting of paper printed by digital press, color laser printer or inkjet image printer.

2. SPECIFICATIONS

Paper Size Paper Weight Feeder Capacity Receiving Tray Speed Accuracy Dimension Net Weight Power

LT / Legal Size/ 9” x 14” (Max) 120gsm ~ 350gsm 75 sheets (200gsm) 500 business cards Up to 130 business cards per min ± 0.3 mm 13.8” (W) x 15.4” (D) x 13” (H) 60 lbs (27Kgs) 110/220V Selectable, 50/60Hz, 1.2A

3. CONTROL PANEL

Note: Depending on ƚŚĞŽƉĞƌĂƚŝŶŐmode, theŬĞLJƐĐĂŶŚĂǀĞdifferent functions. Standard Control Panel Dealer Control Panel

Start and Stop the cutter

Start and Stop the cutter

Clear paper jam in case of S3 error.

1. Clear paper jam in case of S3 error.
2. Increment settings by 0.1 mm when pressed.

Confirm job and batch count setting.

1. Confirm job and batch count setting.
2. Decrement settings by 0.1mm when pressed.

Rest error and counter.

4. KEY COMPONENTS

Index 4‐1‐01 4‐1‐02 4‐1‐03 4‐1‐04 4‐1‐05 4‐1‐06 4‐1‐07

Part Name Switch, Power Entry Key Pad Tray, Extension Knob, Center Alignment Side Guide, L Roller, Feed Cover, Top

Index 4‐1‐08 4‐1‐09 4‐1‐10 4‐1‐11 4‐1‐12 4‐1‐13 4‐1‐14 4‐1‐15

Part Name Waste Bin Tray, Stacking Cover, Safety, Rear Thumb Screw, Slitter Release Module, Slitter, 2” x 3.5” Roller, Ejection, Lower Roller, Ejection, Upper Belt, Slitting Transport

5. Parts on Top of the Frame

Tray, Extension, Feed Side Guide, L, Feed Knob, Cutting Center Alignment Roller, Feed Sensor, Paper Sensor, Paper Sensor, Mark Reader, White Key Pad Sensor, Paper, Black Separator, Feed

6. Parts on Operating Side

Asm, PWB, Logic Cable, 34 pin, 55cm, Driver Interface Cable, 34 pin, 37cm, Logic Interface Asm, PWB, Interface Asm, PWB, LCD Interface Cable, 16 pin, 47cm, LCD Interface Cable, 14 pin, Panel Interface Asm, PWB, Control Panel Switch, Interlock Display, LCD Switch, Interlock Sensor, Interrupter Belt, 0.08P, 102MXL Switch, Interlock

7. Parts on Non Operating Side

Asm, PWB, Power Belt, 0.08P, 132MXL Spring, Feed Tray Tension Motor, RD, 2.58V, 3A (replaced by 00M‐000‐0403) Motor, SQ, 2.58v, 3A

8. Parts underneath the Frame

Fan, DC, 12V Asm, Driver Box Asm, PWB, Driver, L298 Filter, AC Line Switch, 115/230V Selectable Transformer, 115/230V Motor, SQ, 2.58V, 3A Motor, RD, 2.58V, 3A (Replaced by 00M‐000‐0403) Motor, SQ, 2,8V, 1.7A (alternative 3.96V, 1.2A) Rectifier

9. Electric PWB Asm.

Asm, PWB, Logic Asm, PWB, Display, LCD Asm, PWB, Interface Asm, Driver Box Asm, PWB, Power Asm, PWB, Control Panel

Asm, PWB, LCD DISPLAY

ASM, PWB, INTERFACE

ASM, DRIVER BOX

9. 5 P/N 00A‐000‐1211 ASM, PWB, POWER

ASM, PWB, CONTROL PANEL

11. Sensor Voltage Measurement

Sensors play an important role in monitoring and tracking the flow of the media inside of machine. A majority of stall conditions could be sensor related. Therefore, a digital multi‐meter (DMM) is used for measuring the voltage reading of the sensors, and assuring proper alignment.

5.1 Set DMM to 20 at the DVC section. 5.2 Using the two probes of the DMM to get voltage, one probe placed at the chassis ground of the system, while the other one probe pin 1 of the sensor connector on the interface board. 5.3 Covering the sensor, the reading of DMM should be less than 0.2V. 5.4 Uncovering the sensor, the reading of DMM should be more than 4.5V. 5.5 Mark Reading Sensors

。Seeing paper 0.2V

。Seeing mark 1.8V

The range of sensor’s voltage reading is greater than 4.5V or less than 0.2V has the best state for the sensor to monitoring the media movement. The sensor connector on the sensor board has three pins. The first pin is for signal of sensor voltage reading measurement. The second pin is for VCC (5V). The third pin is for ground. Some sensors connector is 4‐pin, the 3 rd pin is empty; the 4 th pin will be common ground.

12. Replace Slitter

Open the rear cover

Rotate the thumb screw loosen the Slitter

Lay down the slitter and pull it out toward exit direction

• Note: The slitter assembly is replaced as a whole unit.

13. Replace Cutting Knife

Index 13‐7‐04 13‐7‐05

Knife, Upper Knife, Lower

14. Feeding Test and Permanent Count

The system provides view permanent count, mark and feeding testing without cutting features by:

Select Job #4 and set cutting mark to on by holding

for 5 seconds, “test mode 23" is displayed

On the lower right corner of the display will show xxxx. For example, if it shows 23 means the permanent count is 23,000

Press to feed paper, the cutting knife will be off without function to make sure feeder and mark reader is OK. This will save a lot of testing time and paper as well.

15. Calibrations

To calibrate cutting mark, cutting length, offset and top margin:

for 5 seconds. mark:50 length:50 offset:50 margin:50 is displayed.

to select the item you are going to calibrate.

to save when the calibration is done.

On Job #4, set it to without cutting mark mode, feed a piece of paper to cut the top margin, make sure the cut top margin is 12.7mm, if not calibrate the top margin first then do Length calibration. Select length:50. Feed a Letter Size sheet thru, the sheet will be cut into half which is 5.5”,

to adjust compare the 2 X 5.5”, if the 1 st half cut is shorter than the 2 nd half, tip on st nd until the 1 half and 2 half are exactly the same; If the first cut is greater than the 2 nd half,

to decrease the setting until the 2 half is equal. Each press on

represents 0.1mm increment or decrement

On job #4 to hold then tip on to set cutting mark, cut a printed sheet with mark, make sure the leading edge of the mark to cutting line is 3mm

Select mark:50, if the cut mark leading edge to cutting line is greater or smaller than 3mm,

to adjust. Each press represents 0.1mm increment or decrement.

After adjust the mark value, press to save the setting. Cut the mark again, if the cut mark is not within spec. repeat the calibration.

This is allowing calibrate the 5 th business card in a sheet which is possibly longer than the spec. Assume the 5 th card length is longer than the specification by 0.1mm. Under calibration mode select offset:50 to reduce the figure 50 to 49.

On job #4 without mark to cut the top margin, it should be 12.7mm. If the cut top margin

sample is greater or smaller than 12.7mm, select margin:50, tip on and to adjust until the top margin is within the spec. Each press represents 0.1mm increment or decrement.

16. Feed Tray Tension Adjustment

16. 1 Factory setting the spring position as shown below:

16.2 If feed hopper tension set to scale 4/Thin Paper, is still causing the paper to buckle, and not get into the 1 st set of transport roller, relocate the spring mounting hole to the right to reduce the tension.

16.3 If feed hopper tension set to scale 1/Thick Paper, still cannot feed the paper well and keep occurring misfeed, relocate the spring to the left to get more tension.

16.4 If the tension set tight still cannot feed well, replace the feed roller.

17. Feed Gap Adjustment

17.1 Loosen the Feed Ramp Mounting Screw on Both Sides

Ramp Adjustment Screw

Ramp Adjustment Screw

17.2 Press the feed ramp down to increase the gap, tilt it up to reduce the gap.

17.3 Place a 600gsm (2 x 300gsm) paper underneath the 2 side roller as shown below. Press the feed tray down and pull the paper to make sure the gap is right. It should not have too much drag.

17.4 Fasten the ramp mounting screw

18. Top Margin Parallel Adjustment

18.2 Remove the rear cover

18.3 Use a 300gsm or 14 pt. sheet as a gauge, hand feed it into and against registration roller firmed.

18.4 Underneath the feed tray has 5.5mm nut to hold the side guide, loosen the nut and align it against the paper to make it straight. Fasten the nut.

18.5 Feed a sheet to cut, measure the left and right of the top margin cut is 12.7mm +/‐ 0.1mm, if not re adjust the side guide.

19. Self‐diagnose for Malfunction

The system provides a unique feature to help service people pin point the sensor malfunction, detailed below:

Firmware Version: 01 Sensor Scan: OK 19.1 Hold then turn the power to on, is displayed 19.2 using a piece of paper to trigger the sensor, the sensor on the interface board connection are showing as below. Remove the trigger, the display will change to

Firmware Version: 01 Sensor Scan: OK

, If the display

Firmware Version: 01 Sensor Scan: I‐20

that sensor is bad.

S1 S2 S3 S4 Top cover Rear Cover Wast Bin

Feed Tray Sensor Input Sensor Paper Monitoring Sensor Mark Reading Sensor Safety Switch Safety Switch Safety Switch

Interface Board Interface Board Interface Board Interface Board Logic Board Logic Board Logic Board

Connector # I – 20 I – 21 I – 23 I – 22 L – 11 L – 14 L – 15

20. Error Message and Trouble Shooting

Jam in Sensor 2

Jam in Sensor 3

Check Top Cover Check Rear Cover Check Waste Bin Finish card not clean and neat

Finish card length uneven

Top margin not even left and right

Slitting not good No Power

1.Check S1 voltage 2.Check feed motor belt 3.Check pulley screw 4.Check motor detain torque, if no torque

5. Replace driver board 1.Check S2 2.Adjust the feed tray tension 3.Adjust the ramp

1. Check S3

2. check detain torque of transport motor, if no torque

3. Replace driver board

1. Check mark sensor voltage; see paper 0.2V

2. Seeing mark has to be greater than 1.8V

3. Change mark sensor and do mark, top margin calibration Check top cover interlock switch Check rear cover interlock switch Check waste bin interlock switch

1. Adjust the cutting knife guiding plate, if problem still

2. Replace cutting knife

1. Adjust the cutter Assy. frame mounting screw on the side plates

1. Turn the cutting knife crane plate, if no detain torque, replace driver box

2. Driving crane screw loose Adjust the side guide, make sure it is right angle to the first set of roller Rotate transport motor on the side frame, if no detain torque, replace driver box Replace the slitter

1. Check Fuse

2. Check power plug

21. Recommended Spare Parts List

Switch, Power Entry Fuse, Time Delay, 3.15 A, 250V Key Pad Module, Slitter, 2 x 3.5” Module, Perforator Module, Scoring Roller, Ejection, Lower Roller, Ejection, Upper Belt, Slitting Transport Roller, Feed Sensor, Paper Sensor, Mark Reader, White Sensor, Paper, Black Separator, Feed Asm, PWB, Logic Cable, 34 pin, 55cm, Driver Interface Cable, 34 pin, 37cm, Logic Interface Asm, PWB, Interface Asm, PWB, LCD Interface Cable, 16 pin, 47cm, LCD Interface Cable, 14 pin, Panel Interface Asm, PWB, Control Panel Switch, Interlock Display, LCD Switch, Interlock Sensor, Interrupter Belt, 0.08P, 102MXL Asm, PWB, Power Belt, 0.08P, 132MXL Spring, Feed Tray Tension Fan, DC, 12V Asm, Driver Box, L298 Asm, PWB, Driver, L298 Filter, AC Line Switch, 115/230V Selectable Motor, SQ, 2.58V, 3A Motor, SQ, 2,8V, 1.7A (Alternative 3.9V, 1.2A) Rectifier Knife, Upper Knife, Lower