Standard PS-P61 Punch Stapler

Service Manual

Provided By

SERVICE MANUAL

PS-P61 Punch Staple

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

FOREWORD

Punch Staple

Model PS-P61

This manual is designed to help you to keep the machine in a good operating condition. Read, study and keep this manual in a safe and convenient place.

Do not perform any maintenance until you read and understand the instructions in this manual.

If you have questions regarding maintenance or this publication, please contact our service division.

The machine design and specifications are subject to change without notice.

030701/PSP61/03E/DV

Safety Instruction

1. Read and understand all safety instructions with a signal WARNING, CAUTION. If safety instructions are ignored, personal injury will and result.
2. HORIZON INTERNATIONAL INC. cannot anticipate every possible situation that might involve a potential hazard. The instruction in this manual are therefore not all inclusive.
3. Be sure to unplug the power cord when replacing the parts or repairing the machine.
4. Take care with the rotating parts when the machine is operated with the covers being opened.
5. Use the original HORIZON spare parts when replacing the parts.

I Necessary Tool for Maintenance and Repair

Use the following tools for maintenance and repair.

Screw Driver Screw Driver Allen Wrenches Open-ended Wrench Box Wrench Snap-ring Expander

No. 2 6 to 7 mm 1.5, 2, 2.5, 3, 4, 5, and 6 mm 5.5 x 7 mm 8 x 10 13 x 17 5.5 mm

II Signs and Abbreviations in This Manual

1. The following signs in this manual represent wire color.
2. The following abbreviations in this manual represent electronic and electrical parts.

Brown Red Orange Yellow Green Blue Violet Gray White Black Transparent

CL BK SW mSW M LED VR RY

Clutch Brake Switch Microswitch Motor Light Emitted Diode Potentiometer Relay

Contents

FOREWORD .......................................................................................................................... I Safety Instruction ................................................................................................................... II I Necessary Tool for Maintenance and Repair ................................................................... III II Signs and Abbreviations in this manual ........................................................................... III

1. PS-P61 Specifications ...................................................................................................... 1
2. Operation Overview ........................................................................................................ 2
3. Sheet Flow ........................................................................................................................ 3
4. How to Remove Cover .................................................................................................... 4
5. Sensors and Electronic Parts Descriptions ................................................................... 5
6. Sensor Location and Descriptions ................................................................................. 6
7. Transport Belt Drive Descriptions ................................................................................ 7
8. Troubleshooting ............................................................................................................... 8
9. LED and ConnectorDescriptions on P.C.B. .................................................................. 11
10. Power & Signal Line Diagram ..................................................................................... 12
11. Panel Sensor Line Diagram .......................................................................................... 13
12. Staple Unit Inside Line Diagram ................................................................................. 14
13. Power Supply Line Diagram ........................................................................................ 15
14. Punch Unit and Sensor ................................................................................................. 16
15. Timing Chart 1 .............................................................................................................. 17
16. Timing Chart 2 .............................................................................................................. 18
17. Timing Chart 3 .............................................................................................................. 19
18. Check Mode ................................................................................................................... 20

1. PS-P61 Specifications

Staple and Punch Unit for QC-P8/P10

QC-P8, QC-P10

A4 : Corner Staple, Top Staple, and other Side Corner Staple A3: Corner Staple NOTE - Only corner staple can be done with optional punch.

• Two hole punch (option) can be performed only on A4 size.

Sheet Size with Operation Panel A4 and A3

NOTE - Sheet size must be within +,-0.5 mm.

Width : Maximum 298 mm (11.8") Minimum : 182 mm (7.2") Length : Maximum 432 mm (17") Minimum : 257 mm (10.2") NOTE - Other side corner staple and top staple are limited in size.

Stapling and Punching Thickness 10 Sheets of 135 gsm (36# Bond)

53 to 135 gsm (16# Bond to 36# Bond)

Optional Punch Capacity Up to 105 gsm of normal paper

25 Sets/min. (Corner Staple)

15 Sets/min. (Top Staple, Other Side Corner Staple and Staple with Punch)

Connecting Section : Roller Transport Producing Section : Belts Transport

Sheet Jam, No Staple, Door, Staple Trouble, Punch Trouble, and Full Tray (LEDs illuminate on operation panel.)

4 digits (For Maintenance)

DC Motor : 3 x 24 V DC Solenoid : 4 x 24 V/35 W

DC Motor : 1 x 24 V (with Punch)

100 V 50/60 Hz, 115 V 60 Hz, 230 V 50 Hz

Power Consumption 150 W

Machine Dimensions Tray Open : 1,115 x 562 x 582 mm (43.9" x 22.2" x 22.9") (WxDxH) Tray Close : 775 x 562 x 580 mm (30.6" x 22.2" x 22.9")

77 kg (170 lb)

2. Operation Overview

1. Pile sheets into bins and turn on power switch.

• Staple unit will be reset if staple unit is not at home position before power is on.
• LED conditions of operation panel Jog Guide Illuminates at the current position. Not illuminates when irregular sheets are used. Staple Mode Illuminates at the angled side staple position. Punch Not illuminates. Jog Time 1 time lamp illuminates.

2. Press option button on collator.

• Option LED illuminates.
• Gate in collator moves.

3. Set jog guides according to sheets.

• LED in the selected sheet size illuminates.

4. Select required mode with staple mode button.

• LED illuminates in different position as staple button is pressed. Staple unit moves to set position a few seconds after staple mode is selected.

NOTE

• In the case of other side corner staple or top staple, staple mode cannot be selected because of limited sheet size.
• In the case of staple with punch, staple mode cannot be selected because of limited sheet size.

5. Set receiving tray and receiving tray guide according to sheet size.
6. Press check button of collator twice. As collator starts, transport unit will transport a set of sheets. The set is stapled and/or punched and delivered to receiving tray.
7. Press start button of collator. Collator starts collating and sets of sheets are produced.

When miss/double or other troubles happen on collator, collating job stops with LED illuminated.

Collator's Error : Sheet jam, misfeed, and double feed are indicated on panel of collator. PS-P61's Error : QC-P10 : Option error message is indicated on collator. QC-P8 : Receiving tray lamp illuminates on collator. PS-P61 : Monitor lamp illuminates.

8. When preset counter reaches to set number, collating stops and then transport unit stops.

• In the case of the number of sets are not input in preset counter, collator stops because sheets run out, or because receiving tray of PS-P61 is full.

3. Sheet Flow

A. Corner Staple with A4 and A3 Sheet Size (8.5" x 11"/11" x 17")

1. A set of collated sheets are delivered to transport unit.

2. A set of sheets are transported by transport rollers and pass sheet feed detector.

3. Transport belt and forward roller transport a set of sheets to stopper.

4. Transport belt stops.

5. Jog solenoids is activated and jog sheets.

6. Stapler staples sheets.

7. Delivery roller lowers and transport belt delivers a set of sheets to receiving tray.

B. Top Staple with A4 Sheet Size (8.5" x 11")

Staple unit moves to top staple position and is ready to staple. The procedures 1 to 6 are the same as A.

7. Delivery roller lowers and transport belt delivers a set to the second staple position.

8. Jog solenoids is activated and jog sheets.

9. Stapler staples sheets.

10. Transport belt delivers a set of sheets to receiving tray.

C. Other Side Corner Staple with A4 Sheet Size (8.5" x 11")

Staple unit moves to the other side corner staple position and is ready to staple. The rest procedures are the same as A.

The procedures 1 to 6 are the same as A.

7. Punch punches sheets.
8. Delivery roller lowers and transport belt delivers a set to receiving tray.

5. Sensors and Electronic Parts Descriptions

S/N 001001 to 099001

S/N 002901 to 008917

Transport Unit Open Sensor

Power Supply Box (Switch, Power Supply (5 V and 24 V), Breakers)

Punch Unit (Motor and Reset Sensor)

Staple Unit (Motor, Reset Sensor and No Staple Sensor )

Door Open Sensor Switch

Full Tray (Receiver) P.C.B. (QPP-263A)

Full Tray (Projector) P.C.B.(QPP-263A)

From S/N 100001

6. Sensor Location and Descriptions

Jog Guide 1 Position Sensor

Staple Home Position Sensor

Jog Guide 2 Position Sensor

Sketch of Staple Cabinet

7. Transport Belt Drive Descriptions

(1) Applied Serial Number : S/N from 002901 to 008917

Sketch of Inside of Staple Unit

2. Applied Serial Number : S/N 001001 or up

8. Troubleshooting

A. Staple position (top staple) varies by more than 10 mm.

(Cause) Delivery roller does not lower enough and not deliver a set of sheets. Transport belt is dirty. Clearance between clutch and brake gets wider.

(Remedy 1) Adjust delivery roller so that it lowers enough.

• Adjust solenoid so that delivery roller touches transport belt and spring is compressed about 1 mm when solenoid activates.

(Remedy 2) Clean transport belt with alcohol soaked cloth.

(Remedy 3) Check the clearance between clutch and brake. Standard clearance is 0.15 (+,-0.05) in both clutch and brake. Applied Serial Number : S/N from 002901 to 008917

2. When sheet jam 1 lamp illuminates.

(Cause) (Remedy) Sheets are jammed in transport Open transport unit and remove jammed sheets. And unit or transport unit is open. close transport unit firmly.

3. When sheet jam 2 lamp/ sheet jam 3 lamp illuminates.

(Cause) Sheets are jammed in staple cabinet.

(Remedy 1) Press eject button.

(Remedy 2) Pull out staple cabinet and remove jammed sheets. In the case sheet jam 3 lamp illuminates, lift support guide unit and remove jammed sheets.

4. When punch trouble lamp flashes.

(Cause) Punch unit is locked.

Attention Punch Capability: up to 10 sheets of 105 gsm normal paper.

(Remedy) Turn off power switch of collator, then turn on again after a few seconds. Press eject button, open staple cabinet and remove jammed sheets.

8. Troubleshooting

E. When no staple/staple trouble lamp illuminates.

(Cause 1) Out of staples.

(Remedy 1) Refill staples.

(Cause 2) Staple unit head is not set on the proper position.

(Remedy 2) Press eject button to reset staple unit.

6. When no staple/staple trouble lamp flashes.

(Cause) (Remedy) Staple unit is locked because of Turn off power switch of collator, then open staple staple jam. cabinet and remove jammed sheets or staples. Close staple cabinet, turn on power switch of collator and press eject button. Staple unit will be reset. Check for proper stapling by collating several sets (7 to 8 sets).

7. When door lamp illuminates.

(Cause) Staple cabinet or rear cover is open.

(Remedy) Close staple cabinet or rear cover.

8. When receiving tray lamp illuminates.

(Cause) Receiving tray is full, or sheets are not delivered completely.

(Remedy) Remove sheets from receiving tray, or delivery area.

I. When sheets are delivered without stapling. (Collating Continues.)

(Cause) Staples are not fed to stapling position in staple unit.

(Remedy 1) Set unnecessary sheets on bin, and check for proper stapling by collating several sets (7 to 8 sets).

(Remedy 2) Open staple unit, pull up and release staple cartridge and clean staple feed roller with alcoholic soaked cloth.

8. Troubleshooting

J. When sheets are delivered without stapling. (Collating stops.)

(Cause) Collated sheets are not jogged neatly.

(Remedy 1) Open staple cabinet and check whether jog guide is positioned to sheet size properly.

(Remedy 2) Straighten curled sheets, and fan them well.

(Remedy 3) Press jog switch and select 2-time jog.

K. When circuit breaker trips.

(Remedy) Turn off power switch of collator. Check inside of collator for obvious problems such as jammed sheets. If there is a problem, remove the cause. Reset circuit breaker a few minutes after turning off power switch. Push two left breakers to reset. Push up two right breakers to reset.

9. LED and Connector Descriptions on P.C.B.

CON8

CON10

CON1

CON5

CON3

CON9

CON12

CON7

CON6

CON4

CON2

CON11

Control P.C.B. QPW457

Illuminates at the reset position.

Illuminates when staples remain in cartridge.

Illuminates at the home position.

Illuminates when PS-P61 cannot start.

Illuminates when punch is selected.

Illuminates at home position.

Transport Unit Open Sensor

Illuminates when no sheets under sensor.

Illuminates when no sheets over sensor.

Illuminates when no sheets over stopper.

Staple Cabinet Rear Cover Open

Illuminates when cover is open.

Illuminates when button is pressed.

Illuminates when button is pressed.

Illuminates when button is pressed.

Illuminates when button is pressed.

Illuminates when transport unit is closed.

CON1

CON7

CON2

To Sheet Size Sensor and Panel P.C.B.

CON8

To Connector which connects Collator

CON3

To Solenoids and Transport Motor

CON9

To Power Supply 5V 24V

CON4

CON10

To Panel P.C.B Switch

CON5

To Transport Roller Solenoid and B4 Stopper

CON11

CON6

To Indicate Panel P.C.B LED

CON12

To Staple Motor, Clutch, Blake and Pulse Sensor

CON7

CON3

CON5

CON6

CON4

CON2

CON1

QPW 457

CON7

CON8

CON1

CON5

CON3

CON9

Sheet Jog Solenoid 1

Staple Cabinet Rear Cover Open Sensor

Sheet Jog Solenoid 2

CON12

CON10

Full Tray Sensor (Receiver)

CON4

CON11

Staple Home Position Sensor

CON2

Transport Unit Open Sensor

QPW 457

Applied Serial Number : S/N from 002901 to 008917

Full Tray Sensor (Projector)

CON6

10. Power & Signal Line Diagram

CON7

CON3

CON5

CON4

CON6

CON2

CON1

QPW457

B4 Stopper Solenoied

Motor Driver P.C.B.

CON7

CON8

CON1

CON5

CON3

CON9

Sheet Jog Solenoid 1

CON12

Sheet Jog Solenoid 2

CON10

Staple Cabinet Rear Cover Open Sensor

CON6

CON4

CON11

Full Tray Sensor (Receiver)

Staple Home Position Sensor

CON2

Full Tray Sensor (projector)

QPW457

Power Sopply Unit

Applied Serial Number :

Sheet Feed Sensor

11. Power & Signal Line Diagram S/N 001001 or up

Staple Unit

B5 Longer Edge Size Sensor

B5 Shorter Edge Size Sensor

A4 Longer Edge Size Sensor

A4 Shorter Edge Size Sensor

B4 Longer Edge Size Sensor

B4 Shorter Edge Size Sensor

A3 Longer Edge Size Sensor

A3 Shorter Edge Size Sensor

12. Panel Sensor Line Diagram

To Control P.C.B. QPW457

CON7

CON3

CON5

CON4

CON6

CON2

CON1

13. Staple Unit Inside Line Diagram

No Staple

View from Arrow Mark (Leading Cable)

Side View of Staple Unit

14. Transport Belt Motor Driver Wiring

Function Select Switch

Applied Serial Number : S/N 001001 or up

CN2

CN1

To Transport Belt 1 Green

Black Blue Red Yellow White

CN2 S/N099999 or before To MotorTo Control P.C.B. 1 To Connector 4-10

2 To Connector 3-10 3 None 4 None 5 None 6 None 7 None 8 None 9 None 10 None 11 To Connector 3-9 12 To Connector 11-4

None To Connector 4-10 To Connector 3-10 None None None None None None To Connector 3-9 To Connector 11-4

The following list is shown the function select switch position in normal operation condition. The machines having S/N 007006 or up equip with ver. 3.03 rom.

Normal Position Another Position Normal Position Normal Position

1.Automatic Current Reducing Function

OFF

OFF

0.9゜ / stp

OFF

OFF

3.Input Pulse Select Switch

OFF

OFF

OFF

OFF

4.Power Voltage Select Switch ON

Noise Filter

SUP-B3G-ER

Receptacle

WCF1041B

G3NE-205T-DC5V

NRF110-2A

NRF-110-3A

Power Supply

Power Supply

+24V COM

+24V COM

5V COM

Remote +

Remote -

15. Power Supply Line Diagram

NRF1100-1A SD

NRF1100-3A AD

16. Punch Unit and Sensor

SMR-08V-B

Sheet Sensor EE-SPY-302 Stopper Sensor Y G B

SMR-03V-B

+5V OUT COM

Side Staple Correct Function

Unneatly Jogged Sheets / Option Error

Sheet Jog Solenoid 2

Unneatly Jogged Sheet Check

Sheet Jog Condition Check

Sheet Jog Solenoid 1

17. Timing Chart 1

Sheet Jog Solenoid 2

Sheet Jog Solenoid 1

Top Staple Correct Function

When staple lock timer is not reset in one second or punch is not reset in two seconds, each motor stops and nostaple monitor flashes.

No staple monitor illuminates.

Punch Lock / Option Error

The timig is different according to sheet size.

Sheet Jog Condition Check

18. Timing Chart 2

(Applied Serial Number : S/N from 002901 to 008917)

Top Staple Correct Function

The timing is different according to sheet size.

When staple lock timer is not reset in one second or punch is not reset in two seconds, each motor stops and nostaple monitor flashes.

No Staple monitor illuminates.

Punch Lock / Option Error

Sheet Jog Solenoid 2

Sheet Jog Condition Check

Sheet Jog Solenoid 1

For ROM ver. 3.21 or above, transport roller does not hold the sheets before second stitching.

19. Timing Chart 2

( Applied Serial Number : S/N 001001 or up )

20. Timing Chart 3

(Applied Serial Number : S/N from 002901 to 008917)

Sheet Jog Solenoid 1

Sheet Jog Solenoid 2

B4 Other Side Corner Staple Correct Function

21. Timing Chart 3

(Applied Serial Number : S/N 001001 or up )

Sheet Jog Condition Check

Sheet Jog Solenoid 1

Sheet Jog Solenoid 2

B4 Other Side Corner Staple Correct Function

22. Check Mode

1. Staple Unit Check Mode

• Turn on power with eject button pressed.
• Every time eject button is pressed, staple works.
• Lock sensor works during check mode. If staple lock continues for more than 1 second, staple motor stops and staple trouble lamp on monitor flashes

2. Punch Unit Check Mode

• Turn on power with eject button pressed.
• Press staple mode switch to select "corner staple 0˚".
• Every time eject button is pressed, punch works.

NOTE

• Operate punch unit with 3 to 4 seconds intervals. Otherwise, motor or controller may be broken. Lock sensor works during check mode. If punch lock continues for more than 2 seconds, punch motor stops and punch trouble lamp on monitor flashes.

3. Check on Complete Functions

• Turn on power with staple mode button and eject button pressed at the same time. And complete function of PS-P61 will work successively except punch.

NOTE

• Operating PS-P61 with staple cartridge in check mode may cause staple jam. When operating in check mode, remove staple cartridge or insert sheets into staple section.
• When each of monitor lamp flashes, PS-P61 does not work. Turn off power and turn on again.
• Check mode does not reset until power is turned off. Turn on again when collating job is started.