JBI Docupunch P33 Automatic Punch

JBI Docupunch P33 Automatic Punch Instruction Manual Provided By http://www.mybinding.com http://www.mybindingblog.com

TABLE OF CONTENTS SECTION I: INSTALLATION & TESTING: 1) Uncrating, Inspection & removal from skid... 1 2) Initial Testing... 2 SECTION II: OPERATION: 1) Explanation of controls... 4 2) Tool Changing... 6 3) Machine setup... 6 4) Operator Troubleshooting... 7 5) Cleaning & Maintenance... 9 SECTION III: MECHANICAL: 1) Calibration of side guides... 10 2) Feeder... 18 3) Reception... 21 4) Pincher... 21 SECTION IV: ELECTRICAL: 1) Fuses... 22 2) Safety Circuit... 23 3) Sensors... 24 4) Encoder... 24 5) Solenoids... 25 6) Stepper Motor... 25 SECTION V: TIMING: 1) Mechanical... 26 2) Electrical... 27 SECTION III: TROUBLESHOOTING: 1) General... 28 2) Fault Lights... 29 3) Electrical Diagrams... 30

SECTION I: INSTALLATION & TESTING 1) Uncrating & Removal from Skid a) Remove the lag screws from around the bottom of the crate. b) Disassemble the crate by loosening the catches on the top and sides. c) Carefully remove all wrapping from the machine, and inspect machine for exterior damage. d) Remove the four nuts that secure the hold down brackets to the skid. e) Remove the wooden spacer blocks under the hold down brackets by carefully tilting the machine upwards. f) Once the machine is set on its wheels, remove the hold down brackets from the feet. g) Place the end of one of the sides on the lower lip of the skid to create a ramp and stock the other side on top of it for strength. h) With help from another person, very carefully roll the machine down the ramp and onto the floor. i) Roll the machine into place. Page 1

2) Initial Inspection & Testing a) Before connecting to the 120V supply, remove the cover from the electrical cabinet and visually inspect the panel for signs of shipping damage. b) Remove the power cord from inside the confetti bin and connect it to a grounded 120 VAC supply. c) Complete the initial testing by switching the machine on, installing the die and punching approximately 1 ream of paper. Make sure that the holes are centered on the sheet and that the registration is accurate. *If the holes are not centered on the paper, follow the instructions for calibrating the side guides in the mechanical section of this manual (pgs. 11-12). *If the holes are not registered properly, follow the instructions in the troubleshooting section of this manual (pg. 30). *If the machine will not start, refer to the troubleshooting section of this manual (pg. 29). Page 2

SECTION II: OPERATION Page 3

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2) Tool Changing: a) Press Tool Down b) Open cover on back side of die. It will support itself in place. c) Pull and hold the retaining latch out of the notch in the rear of the die. Slide the die out of the machine by pulling on the handle. d) To install the die slide it into the machine and lock the retaining latch onto the correct notch for the number of holes you will be punching (odd or even number). e) To disable punch pins for standard paper, pull out the two pin pulls for that size. f) Close back cover. 3) Machine Set Up: a) Using the hand wheel on the side of the machine, open the feeder guides enough to fit the paper between them. b) Place a small stack (about 2 thick) of paper onto the feeder, and set the side guides so that there is about 1/16 clearance at each end of the paper. *It may be necessary to re-adjust the side guides when the feed table is at the top. c) Press and hold the start button until the machine begins to cycle very slowly. The machine will pull 1 lift, then stop when the paper is in the die and ready to be punched. d) Adjust the side joggers, by turning hand wheel, so that they are tight against the ends of the paper, without it being buckled. e) To adjust the foot-stops loosen the locking handle on the side of the upper belt carriage. Set the foot-stops so that the paper buckles slightly. f) To punch through the paper press and hold the start button until the machine begins to cycle. It will punch the paper that is in the die and one more lift after that. g) Loosen the two thumb wheels to set the top reception guide so that it is approximately ½ above the top of the paper. h) Punch the rest of the test paper, and check the registration and centralization of the holes. If both are correct, the machine is now ready to run. If one or both are not correct, refer to the Operator Troubleshooting section of this manual (pg. 8). Page 6

4) Operator Troubleshooting: If, after following the instructions in this section, the operator is unable to make the machine run correctly, it will be necessary to place a service call with whomever the machines was purchased from. A) If the machine jams with pins in paper, hold Stop key to reverse motor and clear the jam. (If pins are already up, nothing will happen when you press the stop key). B) If the machine will not turn on and/or run, check the following: 1) Are any of the LEDs on the control panel lit? If yes, see below. If not, see number 2 of this section. Electronic Fault: Make sure the emergency stop switch is pulled out. Make sure all of the covers are closed. Paper Jam: Make sure there is no paper caught anywhere in the machine. Make sure the sensors and the reflectors are clean. Confetti Tray: Make sure the confetti bin is empty. Make sure the sensor and the reflector are clean. Cover Open: Make sure all of the covers are closed. 2) Make sure the power cord is connected to both the machine and the 110V supply and that the main switch is in the ON position. 3) Make sure there is 110VAC present at the supply outlet. C) The machine will not feed paper: 1) With the machine running, make sure the stabber is moving in and out, and the pincher is moving up and down. 2) Make sure the belts are turning. 3) Make sure the backstop on the feeder is against the pile. Page 7

D) The machine jams repeatedly: 1) Make sure there are no obstructions in the paper path or the die. 2) Make sure the paper is within the operating specifications indicated in this manual on Page 5. 3) Make sure the machine is set up correctly for the size paper you are trying to punch. E) The ends of the paper are getting nicked : 1) Make sure the pin pulls for that size are pulled out. If there are no pin pulls for the size being punched, it may be necessary to disassemble the die and remove two pins. 2) Make sure the die is in the correct position as indicated by the instructions for tool changing on Page 7. F) The holes are not registering properly on the paper.: 1) Make sure all of the paper is the same size. 2) Follow the instructions for Machine Set Up on Page 7 to ensure the joggers are set correctly. G) The paper jams repeatedly at the reception: 1) Make sure the top reception guide is properly adjusted. 2) Make sure there is nothing to prevent the paper from falling into the reception properly. Page 8

5) Cleaning & Maintenance Daily Maintenance Confetti tray should be emptied as needed. To empty confetti tray: Pull the confetti tray towards you Empty the tray Re-position it and insert tray until it stops Weekly Maintenance Using a soft, clean rag: Wipe down the machine. Clean the lens of the cell located at the confetti tray level, the one under the tool and another under the reflector. Annual Maintenance (at the rate of 600,000 strokes) See the counter located inside the electric box Have a general inspection performed on the unit by a factory trained technician. *Routine maintenance is not covered under the warranty. Please note: If your tool reaches a million strokes or its perforations do not meet your requirements in terms of quality, feel free to contact James Burn International or your local dealer to sharpen or make a diagnostic check of this tool. Page 9

SECTION III: MECHANICAL 1) Calibration of the Side Guides: It will be necessary to calibrate the side guides and joggers if: The holes are being punched off center on the paper. The linkage that controls the side guides and joggers is disassembled for any reason. The belt that links the side joggers to the feed and reception guides is broken or removed. The side guides on the feeder and the reception must be set in relation to the lateral joggers, which in turn are set in relation to the die. To calibrate the side guides and joggers, follow the steps listed below. (Note: Make sure the timing is correct first. See pg. 27.) a) Install a die into the machine. b) Remove the right side cover, feeder guides, the front plate, reception guides, reception jogger, and the rear plate. c) Tighten the timing belt on the right side. d) Loosen the set screws on the two timing pulleys for the feeder guides and the reception guides. (Leave the screws on the lateral jog pulley tight.) e) Loosen the set screws on the locking collar in Figure 1 (pg. 13). f) Center the lateral joggers with the die by turning the threaded shafts independently of each other. (Use the hand wheel to adjust the right side jogger.) g) Once centered, tighten the set screws on the locking collar. Make certain that the lateral joggers are correct before setting the feed and reception guides. h) Make sure the joggers are in the open position. Measure from the inside of the right hand plate to the inside of the right hand lateral jogger. Using the hand wheel on the right side, set the jogger so that it is 3 from the plate (Figure 2, pg. 14). i) Loosen the set screws on the locking collar (Figure 3, pg. 15). Page 10

j) By turning the threaded shaft, set the right side feeder guide so that there is 3.25 from the inside of the right side plate to the inside of the feeder guide mounting block (Figure 4, pg. 16) k) Tighten the set screws on the timing pulley for the feed guides. l) Loosen the set screws on the locking collar (Figure 5, pg. 17). m) Set the right side reception guide mounting block (this will be on the left side as you face the reception) using the threaded shaft so that it is 1.625 from the inside of the mounting block to the inside of the side plate (Figure 6, pg. 18). n) Tighten the set screws on the reception pulley. o) Follow these same procedures to set the left side guides for the feeder and reception. p) Tighten the set screws on all of the locking collars. * Double-check all of the settings. Page 11

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2) Feeder: The feeder tray on the DocuPunch uses a stepper motor to raise and lower the table. There is a micro switch at each end of the left assembly. The top switch sends a signal to the PLC when the tray reaches the top of its cycle. This tells the PLC that the tray is empty. The bottom switch tells the PLC when the tray has reached the end of its downward travel. The complete feeder assembly, including the micro switches and adjusting screws, is pictured on page 21. A) Adjusting the Top Micro Switch: *The top micro switch must be adjusted so that the machine does not stop cycling until it picks up the last sheet of paper. However, it must stop the machine before the feeder reaches its mechanical limit. 1) With the power on, press the Start button until the feeder begins to rise. When the machine begins to cycle, press the Stop button. 2) Turn the power off and remove the left side cover from the machine. 3) Turn the pulley on the top of the feeder to raise the feed tray, and stop when the top of the tray is about 1/16 higher than the tip of the stabber. 4) Loosen the lock nut on the actuating screw, and set the screw so that it just actuates the switch. 5) Tighten the lock nut. B) Adjusting the bottom micro switch: *The bottom micro switch must be adjusted so that the feeder cannot cycle down to its mechanical limit. 1) With the power on, press the feeder down button and allow the tray to cycle to the bottom. 2) Switch off the power and remove the left side cover. 3) Turn the timing pulley on the top of the feed assembly until the feeder reaches its mechanical limit. 4) Turn the pulley four turns in the opposite direction to raise the tray slightly. 5) Loosen the lock nut on the bottom actuating screw. 6) Adjust the screw so that it just actuates the switch and tighten the lock nut. Page 18

*To test, switch the power on and press the feeder down button. The feeder should cycle down and stop before it reaches its mechanical limit. Place a small amount of paper on the feeder, press the start button and punch the paper. The machine should cycle approximately 5 8 times after it lifts the last sheet of paper. Page 19

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3) Reception: A 24 VDC motor is used to move the reception tray up and down. The motor is controlled by the 24V relay card (see the electrical section of this manual). There is a microswitch at the bottom of the guide track that limits the downward motion of the tray. A sensor mounted at the top limits the upward movement and also sends a signal to the PLC as the tray fills with paper. 4) Pincher: The pincher is controlled by a solenoid, which gets a signal from the 24V relay card. The grip of the pincher must be adjusted properly in order for it to work correctly (the pincher must bottom out before the solenoid does). The procedure for adjusting the grip is as follows. a) Remove the left side cover from the machine. b) Loosen the clamping screw on the pincher shaft. c) Hold the pincher down against the BEC. d) Press the solenoid down until it bottoms out, then allow it to come back up approximately 1/64 1/32. e) Tighten the clamping screw. Page 21

SECTION IV: ELECTRICAL 1) Fuses: QF1 Main supply 16A Circuit Breaker Upper Right in Electrical Panel F2 T1 SUPPLY 6.3A 5mm X 20mm (2 Fuses) Upper Right in Electrical Panel F4 Inverter Supply 10A 5mm X 20mm (2 Fuses) Upper Right in Electrical Panel FC1 24V Card (Supply) 16A 5mm X 20mm (2 Fuses) 24 V Relay Card FC2 PLC Supply 6A 5mm X 20mm 24 V Relay Card FC3 Foot Solenoid 3.15A 5mm X 20mm 24V Relay Card FC4 Counter 3.15A 5mm X 20mm 24V Relay Card FC5 Pincher Solenoid 3.15A 5mm X 20mm 24V Relay Card FC6 Feed Motor.25A 5mm X 20mm 24V Relay Card FC7 Fan 7.5A 5mm X 20mm 24V Relay Card FC8 Not used FC9 Reception Motor 5A 5mm X 20mm 24V Relay Card Page 22

2) Safety Circuit: The safety circuit consists of a relay that monitors the condition of the safety switches. When all of the switches are closed the relay will latch. This will send a signal to the PLC and also energize the main contractor. Below is a list of the switches and their locations. 1) Emergency Stop----------------------------------- Right side cover 2) Top Perspex Guard------------------------------- Under Left Cover 3) Tool Guard------------------------------------------ Under Left Cover 4) Tool Lock-------------------------------------------- Under Tool Guard 5) Tool Present -------------------------------------- Under Tool Guard If the emergency stop switch is pressed the Electronic Fault light on the control panel will come on. The guard switches each have two contacts (1 normally open and one normally closed). When a guard is opened, the N.C. contact will open the circuit to the safety relay, and the Electronic Fault light will come on. The N.O. contact will close to turn on the Cover Open light. The tool lock switch functions the same as the guard switches, except that the N.O. contact turns on the tool light on the control panel instead of the cover open light. The tool present switch functions the same, except that the contacts are reserved (the N.O. contact is in the relay circuit and the N.C. contact turns on the tool light). *To bypass the safety circuit, place a jumper wire between wire #601 & 204 on the safety relay. Page 23

3) Sensors: a) Feeder: (Input X5) This sensor is located under the right side cover. It sends a beam across the feed tray to read the top of the pile. b) Confetti tray: (Input X11) This sensor is located under the left side cover and sends a beam across the top of the tray to a reflector located under the right side cover. When this beam is blocked the confetti full light will come on. c) Paper Jam: (Input X7) This sensor is located directly in front of the die. It sends a beam down to a reflector to detect a paper jam. ** When adjusting the above sensors, you must position them so that the orange and green lights on them are lit. (The red light must not be lit.) d) Reception: (Input X10) This sensor is inductive and is located on the back of the rear cover. As the tray fills and the jogger is forced back a metal tab on the back of the jogger activates the sensor. 4) Encoder: The encoder monitors the position of the machine. It is supplied with 24VDC and sends information to the PLC via three channels. The supply can be checked by measuring voltage between the brown (+) and white (-) wires. Channels A & B can be checked by measuring between the green (Channel A, XO on PLC) or yellow (Channel B, X1 on PLC) and the white (-) wire. As the machine is turned the voltage will switch between channels as the encoder counts. The zero signal is sent via the gray wire. To check this signal, measure between the gray and white wires. Voltage should only be present when the encoder is at absolute zero. Page 24

5) Solenoids: There are two solenoids on the DocuPunch; one controls the pincher and the other controls the footstops. Both solenoids are identical and operate on 24 VDC. To check whether or not the solenoid is good, you must use an OHM meter to measure the resistance through the coil. You must first disconnect the solenoid, then measure between the two wires. The correct value of this measurement is 24 OHMS.(+ 2 OHMS) 6) Stepper Motor: The DocuPunch uses a stepper motor on the feeder to accurately control the amount of paper it lifts with each cycle. The motor is a 3AMP stepper with 1.8 degree steps. To check the stepper motor, cycle the feeder up to the top, then back down to the bottom. The motion should be very fluid, with no dead spots or jerky movements. Another check is to measure the resistance in the two windings on the motor. There should be 1.3 OHMS between the yellow and red wires, and also between the blue and orange wires. The motor is controlled by a stepper drive card. To check the card, measure the voltage between the four wires on the motor connector and wire #600 when the feeder is sitting idol. There should be 1.2 VDC at the yellow and orange wires, and 2.2 VDC at the red and blue wires. An output signal from the PLC is what tells the driver to run the motor. When output Y-0 is activated, the feeder should go up, and when both outputs Y-0 & Y-1 are activated, the feeder should go down. Page 25

SECTION V: TIMING There are two types of timing on the DocuPunch: Mechanical timing, which is adjusted by moving a series of cams and a timing belt, and electrical timing, which is adjusted by moving the position of the encoder on its shaft. Below is a list of the different functions, with the correct timing for each one. 1) 0 Degrees ------------The input light X-2on the PLC should be on. 2) 226 Degrees ---------The headstop should have just reached its down position. 3) 254 Degrees ---------The reception jogger should be all the way up. 4) 259 Degrees ---------The belt carriage should just start moving up. The stabber should just stop moving out. 5) 298 Degrees ---------The lateral joggers should have just reached the closed position. If any of these settings are not correct, it will be necessary to adjust the timing. The procedure for setting the timing is as follows: 1) Mechanical Timing: 1) Remove the left side cover, feeder guides, front plate, reception guides, reception jogger and rear plate. 2) Using a 6mm hex key, turn the main pulley counter clockwise until the 259* mark is lined up with the left edge of the index tab. 3) Loosen the timing belt tensioner, and remove the belt from the stabber pulley. 4) Turn the stabber pulley counter clockwise and stop the instant that the stabber stops its outward motion. 5) Replace and tighten the timing belt. Be sure that neither the stabber pulley, or the main pulley lose their position as you tighten the belt. 6) Turn the main pulley counter clockwise until the 298* mark is lined up with the index tab. 7) Loosen the set screws on the stabber pulley. 8) Turn the top shaft counter clockwise until the lateral joggers just reach the closed position. 9) Tighten the set screws on the stabber pulley. 10) Turn the main pulley until the 226* mark lines up with the index tab. 11) Loosen the set screws on the headstop cam* and turn it counter clockwise and stop the instant the headstop reaches the down position. Page 26

12) Tighten the set screws on the cam. 13) Turn the main pulley until the 254* mark lines up with the index tab. 14) Loosen the set screws on the cam for the reception jogger and turn it counter clockwise. Stop when the follower arm reaches the top dead center of the cam. 15) Tighten the set screws. 16) Turn the main pulley until the 259* mark lines up with the index tab. 17) Loosen the four mounting screws from the belt carriage cam *. 18) Position the cam so that the belt carriage is at the very beginning of its upward motion. 19) Tighten the four mounting screws. *Please note: The cams for the headstop and belt carriage are mounted to the same sleeve. Once one is set correctly they both should be correct (unless one has been moved on the sleeve). 2) Electrical Timing: *The mechanical timing must be correct before setting the electrical timing. 1) Turn the main shaft counter clockwise until the 0* mark lines up with the index tab. 2) Loosen the set screws on the encoder collar. 3) Slowly turn the collar clockwise and stop when the input light X-2 comes on (this is the zero position on the encoder). 4) Tighten the screws on the encoder ensuring that the input light X-2 remains on. Double check this setting by turning the main pulley counter clockwise until the 0* mark is lined up with the index. At this point the input light for X-2 should be on. Page 27

SECTION VI TROUBLESHOOTING: 1) See Operator Troubleshooting (pgs. 9 10) before following these steps. The machine will not feed paper: A) Is the BEC moving in and out? If it is, move on to the next step. If not, check the following: 1) Check the timing belt. 2) Check the set screws on the pulley. B) Is the pincher solenoid working? If it is, make sure it is adjusted properly then move on to Step C. If not, check the following: 1) Check the solenoid. 2) Check to see if it is getting voltage from the relay card. 3) Check if the relay card is getting a signal from the PLC. C) Is the feed table moving up? If it is, move on to Step D. If not, check the following: 1) Check the stepper motor. 2) Check the stepper drive. 3) Check to see if the PLC is sending a signal to the stepper drive. Foot jogger will not operate: A) Check the solenoid. B) Check the jam sensor. C) Check the relay card. D) Check the output from the PLC. Machine will not run: A) Check the start button (Input X4). B) Check the inverter input from the PLC. C) Check the inverter supply. D) Check for fault lights on the control panel. Feeder will not come up: A) Check the sensor and reflector. B) Check the top microswitch. C) Check the stepper motor. D) Check the stepper drive. E) Check the relay card. F) Check the output from the PLC. Page 28

The feeder will not go down: A) Check the button. B) Check the bottom micro switch. C) Check the stepper motor. D) Check the stepper drive. E) Check the output from the PLC. The reception will not come up: A) Check the sensor and reflector. B) Check the output from the PLC. C) Check the output from the relay card. D) Check the motor. If the reception will not go down: A) Check the bottom micro switch. B) Check the output from the relay card. C) Check the output from the PLC. D) Check the motor. 2) Fault Lights: A) Electronic Fault: 1) Check the safety switches. 2) Check the die switches. 3) Check the emergency stop switch. 4) Check the safety relay. 5) Check the transformer. B) Paper Jam: 1) Check the sensor and reflector. 2) Check the PLC. C) Confetti Tray: 1) Check the sensor and reflector. 2) Check the PLC. D) Cover Open: 1) Check the safety switches. 2) Check the safety relay. E) Tool Light (machine will not start) 1) Check the die switches. Page 29

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OUTPUT LIST/PLC Y0 Pulses for stepper motor of feeder 24 Vcc Y1 Motor way on the feeder (coming down) 24 Vcc Y2 Counter + foot jogger 24 Vcc Y3 Pincher Solenoid 707 24 Vcc Y4 Reception motor 707 24 Vcc Y5 To reverse the motor 709 24 Vcc Y6 Reverse rotation: jam punching Inverter Y7 1 st Speed (punching unit) Inverter Y10 2 nd Speed (punching unit) Inverter Y11 To validate rotation (+) Inverter Y12 Red LED : 3,5 V Jamming Y13 Red LED : 3,5 V Confetti Tray Y14 Green LED : 3,5 V Tool low position Y15 Green LED : 3,5 V Not Used Page 31

INPUT LIST/PLC X0 X1 X2 Encoder Way A Encoder Way B Encoder Zero Point X3 <<Stop>> Button B8 (605) X4 <<Start>> Button B1 (606) X5 Feeder Sensor C1 X6 <<Tool changeover>> Button BCO (608) X7 Detection at Tool Entry C2 X10 Detection Level Reception C4 X11 Confetti Tray C8 (611) X12 Inverter Alarm Switch Contact A et C X13 <<Going Down>> Button BRR (613) X14 Feeder High Position 601 C10 614 X15 Feeder Low Position 601 C11 615 X16 Full Table Tray (reception) R2 X17 Emergency Stop Button Page 32

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