GERA LadyBird I, Service Manual

Page 1: ...LadyBird I Folder Service Manual D860101X March 2014...

Page 2: ...RES III SECTION 2 REPAIR ANALYSIS PROCEDURE III SECTION 3 FOLD QUALITY III SECTION 4 REPAIR AND ADJUSTMENT III SECTION 5 PARTS LIST III SECTION 6 GENERAL PROCEDURES III SECTION 7 WIRING DATA III OTHER...

Page 3: ...iar with the use of any special tools that are required to service this product Service Documentation Revisions This service documentation may be subject to periodic revision in order to reflect any c...

Page 4: ...eneral Procedures This section contains procedures and Information of a general nature that apply to the machine The General Procedures subsection contains frequently used procedures that relate to th...

Page 5: ...are commonly found In GERA equipment These symbols are included as an aid to understanding the representations used in the Circuit Diagrams CDs AC and DC Voltage References The expected AC and DC volt...

Page 6: ...that is closed Switch relay contacts with momentary contacts shown normally open Switch relay contacts with momentary contacts shown normally closed Connectors numbering This symbol indicates the num...

Page 7: ...entire drawing was the configuration before being changed by the tag number within the circle Signal Nomenclature The signal is named to imply the condition of the machine when the signal is available...

Page 8: ...rch 2014 Service Manual 1 1 SERVICE CALL PROCEDURE 1 Service Call Procedure 1 SERVICE CALL PROCEDURE 1 1 SERVICE CALL PROCEDURES 1 2 INITIAL ACTION 1 2 FOLDER REGISTRATION 1 3 SYSTEM CHECKOUT 1 3 CSE...

Page 9: ...lassify the folder problem by using RAP and Fold Quality Section Perform RAP REP ADJ Final Actions FOLD QUALITY PROBLEMS Section 3 Fold Quality FOLD QUALITY SELECTION INDICATION Go to the Generic RAP...

Page 10: ...e delivered to the output tray Y N Refer to the Initial Action in order to classify the problem and begin your repairs Evaluate the print folding The folding quality is acceptable Y N Go to Section 3...

Page 11: ...2 2 Sensor default status chart 2 2 STATUS MESSAGE RAPS 2 1 TWO GREEN LED LIT ON TOGETHER 2 1 FAN FOLDER UPPER POCKET SENSOR COVERED RAP ALL 2 1 FAN FOLDER LOWER POCKET SENSOR COVERED RAP ALL 2 2 ala...

Page 12: ...o locate it count number of beeps ERROR Message RED LED FLASHIG Beeps every 30 sec ENTRY ALARM 1 Beep FAN ALARM 2 Beeps CROSS ALARM 3 Beeps SENSOR DEFAULT STATUS CHART Since the folder has many sensor...

Page 13: ...Control Panel red Led flashing and emitting 4 beeps The default sensor Led status is light on To locate Upper Pocket Sensor C3 refer to Electric Diagram Procedure The folder sensor C3 led should on i...

Page 14: ...ROBLEM_REPORT_FORM_ladybird pdf ALARM STATUS RAPS FOLDER ENTRANCE ALARM RAP ALL Use this RAP when the folder stops and the red led is flashing and 1 beep This occurs when the print jams at folder entr...

Page 15: ...on the Electric Diagram for missed input voltage 12Vdc or sensor signal sent to main Controller PWB Is sensor operating correctly Y N Replace sensors Please check Sensor C2 C3 and relative RAP if pape...

Page 16: ...er does not work open after the Power Supply replacement call to Gera Service Team by filling Problem Report Form available at http www gera it wp content uploads report_form PROBLEM_REPORT_FORM_ladyb...

Page 17: ...ce Manual 3 1 FOLDING QUALITY 3 Folding Quality INITIALIZATION PROCEDURE 3 2 FOLD DEFECTS 3 2 FOLD QUALITY DEFINITION 3 2 FOLD QUALITY RAPS 3 3 FQ 1 FOLD SKEW 3 3 FQ 2 FOLD DAMAGE 3 3 FQ 3 FOLD DIMENS...

Page 18: ...at cause media damage before attempting to fix fold quality problems Some media damage problems can cause fold quality problems To fix folding quality problems 1 Compare the fold defect to the Fold Qu...

Page 19: ...ly the Cross Folding infeed referring the quick guide Stair and or Skew effect A Wrong Folder and Printer Alignment A Perform Front Rule Adj 1 3 FQ 2 FOLD DAMAGE Defect Probable Cause Corrective actio...

Page 20: ...fold setup A Cross Trim Adjust panel 2B Print exits unfolded from the fan folder A sensor does not detect the print correctly B NO FOLD program selected A Perform Fold selector position B Check curren...

Page 21: ...OLDER ADJUSTMENTS 4 5 ADJ 1 1 Mobile Roller Right Side 4 5 ADJ 1 2 Mobile Roller Left Side 4 5 ADJ 1 3 FRONT RULE 4 6 ADJ 1 4 INFEED GROUP PARALLELISM 4 6 3 PROGRAM ADJUSTMENT PROCEDURE 4 7 ADJ 1 1 PR...

Page 22: ...Overturn down the Assembly carefully until to horizontal position Figure 4 1 Upper Infeed Group Overturn REP 1 2 LEFT COVER REMOVAL 1 Switch off the folder 2 Perform Rep 1 1 In feed Group Overturn 3...

Page 23: ...t Cover Figure 4 3 Right Cover Reamoval REP 1 4 POWER SUPPLY FRONT COVER REMOVAL Before open the Power Supply Front Cover that s advisable to lift up the mobile blue collector to avoid it obstacles th...

Page 24: ...Manual 4 4 REPAIR AND ADJUSTMENTS REP 1 5 POWER SUPPLY REAR COVER REMOVAL 1 Switch off the folder and disconnect the Plug 2 Remove the Plate showed below by unscrewing the two fixing screws Figure 4 5...

Page 25: ...left side Adjustment Figure 4 7 Mobile roller left side Adjust the Mobile Roller distance between the folding rollers Screw clockwise increase the distance Unscrew anticlockwise decrease the distance...

Page 26: ...ent 1 3 check the parallelism between the infeed group both side and the printer exit Adjustment Perform the parallelism adjustment Acting firstly on left attaching bracket to obtain equal distance fr...

Page 27: ...both for program P1 210 mm fan and program P2 190 mm fan LONG PLOT Panel mm Address 1A 210 Ad2 2A 210 Ad1 ADJ 1 2 PROGRAM P3 305 and P4 297 CROSS Program P3 305 mm Cross Fold Size Panel Mm Address A1...

Page 28: ...Ladybird Folder March 2014 SPARE PARTS LIST Service Manual 5 Spare Parts List PL 0 1 SENSORS 5 2 PL 0 2 ELECTRONIC PARTS 5 3 PL 0 3 MOTORS 5 4 PL 0 4 KIT 5 5...

Page 29: ...d Frontal Sensor 3 7 8 C695419X Barrier Sensor 4 C850405X Datalogic Lateral Sensor ITEM DESCRIPTION 1 Start toothed rollers Sensor 2 No Corss Sensor 3 Start Feeding Sensor 4 Advancing Sensor 5 Start M...

Page 30: ...nual 5 3 SPARE PARTS LIST PL 0 2 ELECTRONIC PARTS ITEM CODE DESCRIPTION 1 C940403R POWER SUPPLY 230v 2 C340418X RELAY 24VDC 3 C960423R PWB MAIN CONTROLLER REV 3 4 C960403R DRIVE CONTROLLER 5 C940405R...

Page 31: ...Ladybird Folder March 2014 Service Manual 5 4 SPARE PARTS LIST PL 0 3 MOTORS ITEM CODE DESCRIPTION 1 FEDING MOTOR 2 C860405X FLAP MOTOR 3 CONVEY MOTOR 4 MAIN MOTOR 5 E1 SOLENOIDE 4 M3 5 1 M1 2 MT 3 M2...

Page 32: ...Ladybird Folder March 2014 Service Manual 5 5 SPARE PARTS LIST PL 0 4 KIT CODE DESCRIPTION CARE PACK...

Page 33: ...860 SERVICE MANUAL 5 SPARE PARTS...

Page 34: ...specifications 6 2 CONTROL PANEL 6 3 Folding Programs 6 3 ELECTRONIC PWB 6 4 Main Controller PWB 6 4 Drive Controller PWB 6 4 JC 11 CONNECTOR 6 5 DIAGNOSTIC 6 6 Input Output Test 6 6 MAINTENANCE 6 7 F...

Page 35: ...ge Requirements 115V 2A 60Hz 230V 1A 50Hz Audible Noise Average Continuous 58dbA max run NEGLIGIBLE Stand by Environmental Relative Humidity 35 to 85 Temperature 60 to 90 Fahrenheit 15 to 32 Celsius P...

Page 36: ...market the folder is intended for Selection Key PRESS TO SELECT THE FOLD OUTPUT PACKAGE FOR PRINT INTRODUCED MANUALLY Press to perform Manual Eject and clear the folder jams Reset Key Performs RESET F...

Page 37: ...from Power Supply AMP 2x1 Drive Controller PWB The PWB Drive Controller is located inside the lower panel of the folder It contains the CPU and firmware that controls the stepper motor Main Fan Folde...

Page 38: ...er into the Folder through the Connector JC11 is for the information necessary between Folder and Printer stop the Printer with Folder Alarm Cut Signal and Starting Folding Process ITEM on JC11 DESCRI...

Page 39: ...nload the GERA UTILITY 2 5 from GERA web site and install it Download Utility Rel 2 5 Download the zipped file who contains defaults values ini file parameters and firmware Firmware Parameter and Ini...

Page 40: ...Poor print transportation lack of pressure Rubber rollers Poor print transportation Sensors Poor print sensing resulting in lower fold quality Every 15000 meters folded Maintenance activities Check C...

Page 41: ...Switch off on the folder If one green LED is lit on the upgrading was successfully done If two LED is lit on do the upgrading procedure again Folder Adjustment Connect the USB serial cable to the P5...

Page 42: ...made increase the folder safety O Optional If the modification is not necessary and can be installed by CSE choice The serial number of the folders that mount the modification MFG SERIAL N The TAG nam...

Page 43: ...Ladybird Folder 03 Mar 2014 Service Manual 6 10 GENERAL PROCEDURE...

Page 44: ...Ladybird Folder March 2014 Service Manual 7 1 WIRING DATA 7 Wiring Data 1 FOLDER WIRING DATA 7 2 BSD 1 1 ELECTRICAL MAIN DIAGRAM 7 2...

Page 45: ...Ladybird Folder March 2014 Service Manual 7 2 WIRING DATA 1 FOLDER WIRING DATA BSD 1 1 ELECTRICAL MAIN DIAGRAM...