continued - Ernst Nagel GmbH

2S Trimmer 

Service Manual 

Nagel 2S Trimmer

PAGE INTENTIONALLY BLANK 

© Ernst Nagel GmbH 2S Trimmer Service Manual en.doc Rev.1.0. 20.07.2011 

2

Contents 

TITLE PAGE 

CONTENTS ....................................................................................................................................................... 3 

1. SAFETY ..................................................................................................................................................... 5 

2. GENERAL.................................................................................................................................................. 6 

2.1 BASIC INFORMATION ................................................................................................................................... 6 

2.1.1 Basic Information............................................................................................................................... 6 

2.1.1 Type of machine and TAG ................................................................................................................ 7 

2.2 GETTING TO KNOW THE STR....................................................................................................................... 8 

2.2.1 Main components overview............................................................................................................... 8 

2.2.2 Components overview Inside ............................................................................................................ 9 

2.2.2 Components overview Inside .......................................................................................................... 10 

2.2.3 Components overview Interlock breaker & Safety block for knife beam......................................... 13 

2.2.4 Components overview I-CAN plug & Mode Selection plug............................................................. 14 

2.2.5 Rollers and Belts ............................................................................................................................. 15 

2.2.6 Interface signals explanation........................................................................................................... 18 

3. GLOBAL FUNCTIONALITY DESCRIPTION .......................................................................................... 19 

3.1 BYPASS MODE.......................................................................................................................................... 20 

3.2 TRIMMING MODE....................................................................................................................................... 24 

4. COVERS .................................................................................................................................................. 29 

4.1 FRONT COVER ......................................................................................................................................... 29 

4.2 REAR COVER ........................................................................................................................................... 30 

4.3 UPPER INFEED COVER.............................................................................................................................. 31 

4.4 LOWER INFEED COVER ............................................................................................................................. 32 

4.5 UPPER OUTFEED COVER .......................................................................................................................... 33 

4.6 LOWER OUTFEED COVER.......................................................................................................................... 34 

4.7 BASE PLATE COVER ................................................................................................................................. 35 

4.8 USER INTERFACE COVER.......................................................................................................................... 36 

5. TROUBLESHOOTING............................................................................................................................. 37 

5.1 SERVICE PROGRAM MODE......................................................................................................................... 37 

5.1.1 Software Version ............................................................................................................................. 38 

5.1.2 Diagnostics...................................................................................................................................... 39 

5.1.3 Motors.............................................................................................................................................. 40 

5.1.4 Solenoids......................................................................................................................................... 41 

5.1.5 Sensors and Switches..................................................................................................................... 42 

5.1.6 Voltmeters ....................................................................................................................................... 43 

5.1.7 Non Volatile Memory (NVM)............................................................................................................ 44 

5.1.8 Dead cycle....................................................................................................................................... 45 

5.1.9 Calibration ....................................................................................................................................... 46 

5.2 FAULT CODE DESCRIPTIONS ..................................................................................................................... 47 

5.3 FAULT CODE SOLUTIONS .......................................................................................................................... 49 

6. DEFAULT / BASIC ADJUSTMENTS...................................................................................................... 80 

6.1 REPLACING KNIVES .................................................................................................................................. 80 

6.1.1 Preparation...................................................................................................................................... 80 

6.1.2 Removal Upper Knife ...................................................................................................................... 81 

6.1.3 Removal Lower Knife ...................................................................................................................... 82 

6.1.4 Placement Lower Knife ................................................................................................................... 83 

6.1.5 Placement Upper Knife ................................................................................................................... 84 

6.1.6 Adjustment Upper Knife .................................................................................................................. 85 

6.1.7 Adjustment Lower Knife .................................................................................................................. 86 


3

6.1.8 Spine Support Knives...................................................................................................................... 88 

6.1.9 Testing / Finishing Adjustments ...................................................................................................... 89 

6.2 ADJUSTING BOOKLET QUALITY................................................................................................................... 90 

6.2.1 Trapezium / Diamond Shape........................................................................................................... 91 

6.2.2 Side Trim (Finished Size) ................................................................................................................ 95 

6.3 SENSORS AND SWITCHES ......................................................................................................................... 96 

6.3.1 Replace Photo Sensors................................................................................................................... 96 

6.3.2 Adjusting Photo Sensors................................................................................................................. 99 

6.3.3 Replace Switches.......................................................................................................................... 102 

6.3.4 Adjusting Switches ........................................................................................................................ 103 

6.4 REPLACING / PREPARING SIDE JOGGERS................................................................................................. 108 

6.5 ADJUSTING SIDE JOGGERS ..................................................................................................................... 110 

6.6 ADJUSTING CHAINS AND SPROCKETS ...................................................................................................... 112 

6.7 MOTOR AND ENCODER POSITIONS........................................................................................................... 115 

6.8 TAPPING TRANSFORMER AND BLOWN FUSE CONDITIONS........................................................................... 116 

6.9 ADJUSTING THICKNESS DETECTION ......................................................................................................... 118 

7. PCB’S .................................................................................................................................................... 119 

7.1 SOFTWARE DOWNLOAD........................................................................................................................... 119 

7.1.1 PCB1 MD6DC ............................................................................................................................... 119 

7.1.2 PCB5 MD6DC ............................................................................................................................... 120 

7.1.3 PCB6 CPU..................................................................................................................................... 121 

7.1.4 PCB8 ............................................................................................................................................. 122 

7.2 LED’S & TEST POINTS........................................................................................................................ 123 

7.2.1 Motor Drive (MD6DC) PCB1 & PCB5 ........................................................................................... 123 

7.2.2 CPU PCB6 & PCB7....................................................................................................................... 124 

7.2.3 Softstart PCB4............................................................................................................................... 124 

7.2.4 Interlock PCB3 .............................................................................................................................. 125 

8. NVM VALUES........................................................................................................................................ 125 

8.1 CURRENT NVM VALUES ......................................................................................................................... 126 

8.2 ADJUSTING NVM VALUES ....................................................................................................................... 127 

8.2.1 NVM Booklet width correction ....................................................................................................... 128 

8.2.2 NVM Side Jogger correction ......................................................................................................... 129 

8.2.3 NVM Centering correction............................................................................................................. 131 

8.2.4 NVM Stop if booklet too thick ........................................................................................................ 132 

8.3 RESET NVM VALUES.............................................................................................................................. 133 

9. MAINTENANCE..................................................................................................................................... 134 

9.1 PREVENTIVE MAINTENANCE TABLE........................................................................................................... 134 

9.2 SCHEMATICS .......................................................................................................................................... 135 

9.2.1 DTEO-0000-0121-0000................................................................................................................. 135 

9.2.2 DTEO-0000-0142-0000................................................................................................................. 135 

9.2.3 DTEO-0000-0143-0000................................................................................................................. 135 

10. TECHNICAL INFORMATION................................................................................................................ 136 


4

1. Safety 

RoHS 

compliant 


5 

Contents 

- The 2-Side Trimmer may only be plugged in to an approved and by circuit breakers 

protected electrical installation, that is secured with a maximum of 16A. 

- The outlet socket shall be installed near the equipment and shall be easily accessible. 

- Never put your hands, other body parts or anything else then booklets within trimming 

specifications in the infeed or outfeed of the 2-Side Trimmer. 

- Before cleaning, maintenance or repairs, always be sure to switch off the power switch and 

disconnect the appropriate power cord. 

- Always follow all warnings marked on or supplied with the equipment. 

- The equipment should only be placed on a solid surface with adequate strength to hold the 

extra weight of the machine besides the usual maximum load. 

- Always exercise care while moving or relocating the equipment. 

- Keep magnets and all devices with a strong magnetic field away from the machine. 

- Never attempt to perform maintenance or repairs other than described in this manual. 

- Never remove covers or guards that are fastened with screws. 

- Never install the equipment near a radiator or any other heat source. 

- Never override or bypass electrical or mechanical interlock devices. 

- In case of unusual sounds or noises, abnormal surface temperature or odours disconnect the 

equipments power source immediately and consult a qualified technician. 

The manufacturer cannot be held responsible for arbitrary changes in the machine and the 

originated damage. 

Make sure the 2-Side Trimmer is NOT powered during installation or service activities. 

This is a Class A product. In a domestic environment this machine may cause radio 

interference. In which case the user may be required to take adequate measures. 

Note: A domestic environment is an environment in which one a radio and television receivers 

can be expected inside a range of 10 meters of the concerning machines. 

The 2-Side Trimmer is RoHS compliant. 

ONLY use RoHS compliant replacement parts ordered from SDD.

2. General 

2.1 Basic Information 

2.1.1 Basic Information 


6 

Contents 

With the addition of the 2-Side Trimmer STR to the SDD product range, a cost effective full-bleed solution is 

available which has a small footprint and is easily to operate. This machine is designed with high reliability in 

mind, which means that it has been designed for long run production without any operator intervention. 

The main goal of the 2-Side Trimmer, further referred to as STR, is that it can be used for trimming the bleed 

off booklet. Booklets with a maximum up to 25 sheets 80g/m2 (100 pages) can be trimmed from 2mm to 

35mm on each short edge of the booklet, to a minimum of 200mm and a maximum of 320mm finished size. 

Thereby it is also possible to trim asymmetrical. All actions concerning operating the STR and adjusting the 

trim settings can easily be done by using the User Interface (UI) on STR 

For example, in the schedule mentioned below (Fig. 2.1) is schematically rendered some results which are 

possible with the STR by using a different Centre Offset (symmetrical or asymmetrical): 

Finished Size: 

260.0mm 

Fig. 2.1 

3,5mm Waste 

Centre Offset: 

-15mm 

33,5mm Waste 

33,5mm Waste 


15mm 

18,5mm Waste 


0mm 

3,5mm Waste 18,5mm Waste 

Infeed Size: 

297.0mm

2. General (continued) 

2.1 Basic Information (continued) 


7 

Contents 

2.1.1 Type of machine and TAG 

It is important to identify the type of machine and state (TAG) of it before carry out servicing activities. 

At the Rear cover there is a label which refers to the Type of machine and serial Nr. (Fig. 1.1 & 1.2). 

Fig. 1.1 Fig. 1.2 

To find out if it is a TAG0, TAG1 or a TAG2 etc. Machine, find the Yellow Square label (Fig. 2.2 & 2.3). 

The number that is marked on this label (Fig. 2.4) indicates the type (TAG) of the machine. 

If nothing is marked, the type of machine is a TAG0. 

Use only the appropriate settings/procedure for the type of machine! 

Fig. 2.2 Fig. 2.3 

Fig. 2.4 

XX XX XX


2.2 Getting to know the STR 

2.2.1 Main components overview 

The pictures of the STR in this document can be different than the actual machine! 

See the picture below to get familiar with the components of the STR (Fig. 2.5). 

All direction are seen from the paper flow direction. 

1 

6 

4 

Fig. 2.5 

Rear 

No. Action 

1 Top Cover 

2 Booklet Infeed 

3 Trim Waste Bin 

4 Power switch (inside) 

5 User Interface (UI) 

6 Booklet Outfeed 

Front 


8 

5 

Right 

3 

Left 

Bottom 

Top 

2 

Contents


2.2 Getting to know the STR (continued) 

2.2.2 Components overview Inside 

Motor3 

J4/P4 

J9/P9 

FC3 

J-Motor3 


9 

Contents 

Infeed Outfeed 

S12 

J3/P3 

PCB5 

PCB6 

S7 

Front-view 

Motor4 

J7/P7 

FC1 

J-Motor4 

S2 

S1 

J5/P5 

Motor6 

Fig. 2.7 

PCB = print board J-Motorx = Motor conn. Position Sx = Switch position 

Jx/Px = Connector position FCx = Sensor position Motorx = Motor position 

S8 

S9




PCB8 

PCB7 

Motor1 

J6/P6 

FC1 

J-Motor1 


10 

Contents 

Front-view 

Outfeed Infeed 

S10 

PCB1 

PCB3 

Motor5 

TR13 

PCB4 

FC7 

FC4 

Motor2 

J4/P4 

J9/P9 

FC3 

J-Motor2 

PCB2 

TR1 

DB1 

J1/P1 

J2/P2 

Trafo1 

C1 

K1+K2 

Fig. 2.8 

PCBx = Printboard position J-Motorx = Motor conn. Position TRx = Terminal Rail 

Jx/Px = Connector position FCx = Sensor position DBx = Rectifier position 

Sx = Switch position Motorx = Motor position Cx = Capacitor postion 

Trafox = Transformer position Kx = Relais position




C1 

K2 

K1 

J6/P6 

J6/P6 

J9/P9 

J4/P4 

FC6 

FC3 

J7/P7 

J11 

J12 


11 

Contents 


J3/P3 

M1 

Motor8 

U1 U2 

J10 

1 

2 

3 

Top-view 

PCB4 

TR13 

S11 

Motor7 

FC2 

S100 

CNT1 

S19 

S3 

S4 

J8/P8 

FC1 

S1 

S2 

S13 

Fig. 2.9 

J-Motorx = Motor conn. Position PCBx = Printboard position 1 = Docking Bracket 

Jx/Px = Connector position Kx = Relais position 2 = Trimmer/Paper Stop 

Sx = Switch position Cx = Capacitor position 3 = Transport Belts 

Motorx = Motor position S100 = Power switch position 

U1 = Netfilter connector CNT1 = Counter position 

U2 = Power Outlet connector M1 = Solenoid position 

FCx = Sensor position



2.2.2 Components overview Inside (continued) 

J6/P6 

J-Motor2 

Motor2 

Motor7 


12 

Contents 


Motor8 

Motor3 

S12 

J-Motor3 

J7/P7 

Knife Blocks Top-view 

J-Motor1 

S11 

S10 

Motor1 

Side 

Knife 

Knife 

Side 

Motor4 

S13 

J-Motor4 

Fig. 2.10 

J-Motorx = Motor conn. Position Sx = Switch position Motorx = Motor position 

Jx/Px = Connector position




13 

Contents 

2.2.3 Components overview Interlock breaker & Safety block for knife beam 

Use the Interlock breaker (Fig. 2.13) to override the Interlock switch (Fig. 2.14) for running the system with 

open top covers only when an override is really needed. 

Use the Safety block for knife beam (Fig. 2.15) to support the Upper Knife Beam for protection in case of 

adjusting or replacing Knives. 

Use Chapter 4.1 Front Cover or 4.2 Rear cover to remove the cover. 

Caution!!! Overriding the Interlock circuit is dangerous! This should only be done by a trained 

Service Engineer when no other solutions are possible! 

Fig. 2.12 Fig. 2.13 

Fig. 2.14 Fig. 2.15



2.2.4 Components overview I-CAN plug & Mode Selection plug 

Attention!!! Make sure the I-CAN Termination plug [6P3] (Fig. 2.16 & 2.17) is present. 

Otherwise communication problems can arise. 

Fig. 2.16 Fig. 2.17 

Attention!!! Make sure the Mode Selection plug [6P13] (Fig. 2.18 & 2.19) is present. 

Otherwise communication problems can arise. 


14 

6P3 

Fig. 2.18 Fig. 2.19 

Contents 

6P13



2.2.5 Rollers and Belts 

Infeed / Outfeed 

D 

C 

Rollers 

No. Description Article code 

A Conveyor Roller 2 Cpl.(A) OGMO-0000-0272-0000 

B Conveyor Roller 2 Cpl.(A) OGMO-0000-0272-0000 

C Conveyor Roller 1 Cpl. OGMO-0000-0052-0000 

D Thickness Measurement System OGMO-0000-0737-0000 

Belts 


1 3X Belt (Flat) UU20U 1521-6%x30mm ( ) OMRE-0000-0055-0000 


15 

Contents 


Fig. 2.20 

A 

1 (3x) 

B



2.2.5 Rollers and Belts (continued) 

Infeed / Outfeed 

G 

Rollers 


E Conveyor Roller 2 Cpl.(A) OGMO-0000-0272-0000 

F Conveyor Roller 4 L=40mm OGMO-0000-0274-0000 

G Conveyor Roller 3 Cpl.(B) OGMO-0000-0273-0000 

H Conveyor Roller 1 Cpl. OGMO-0000-0052-0000 

Belts 





16 

Contents 


1 

H 

E 

Fig. 2.21 

F 

F 

2 

F



2.2.5 Rollers and Belts (continued) 

Control Board 

1 

Belts 


1 1X Tooth Belt T5 107510 L=1075 ( ) OMRT-0000-0002-0000 

2 1X Tooth Belt T5 42010 L=420 ( ) OMRT-0000-0003-0000 


17 

2 

Contents



2.2.6 Interface signals explanation 


18 

Contents 

INPUT 

It is possible that the STR is connected to a previous machine with a 9Sub-D cable. 

Through this cable, the STR communicate with the part of the system before the STR, using the X-can. 

Signal name Direction Purpose 

X Can 

(High / Low) 

Start In 

(High / Low) 

Bidirectional bus between 

machines in the system 

From previous machine (there 

called Exit-H/L) -> STR 

Carries all communication between 

the modules in the system. 

Used during system start-up to assign 

node numbers for the Can bus. 

OUTPUT 

It is possible that the STR is connected to a next machine with a 9Sub-D cable. 

Through this cable, the STR communicate with the part of the system after the STR, using the X-can. 


X Can 

(High / Low) 

Exit Out 

(High / Low) 

Bidirectional bus between 

machines in the system 

From STR -> next machine 

(there called Start-H/L) 

Carries all communication between 

the modules in the system Exit-H/L. 

Used during system start-up to assign 

node numbers for the Can bus. 

INPUT 

It is possible that the STR is connected to a previous machine with a 15Sub-D cable. 

Through this cable, the STR communicate with the part of the system before the STR. 


Alternate Interface 

Start 

From previous machine -> STR To start the STR externally. 


Ready / Not ready 

From STR -> previous machine To give the status from the STR to 

the previous machine. 

OUTPUT 

It is possible that the STR is connected to a next machine with a 15Sub-D cable. 

Through this cable, the STR transmit the communication between the machine after the STR to the machine 

in front of the STR. 



Ready / Not ready 

From previous machine -> next 

machine. 

To give the status from the machine 

after the STR to the machine in front.

3. Global functionality description 

Bypass mode: Trimming mode: 

The Bypass mode transports the booklet from the 

infeed inside the 2-Side Trimmer, aligns the booklet, 

and transport it to the outfeed. 

Go to Bypass mode by continue chapter: 

3.1 Bypass mode 


19 

Contents 

The Trimming mode transports the booklet from the 

infeed inside the 2-Side Trimmer, aligns the booklet, 

trimmes the top and bottom side of booklet, and 

transport it to the outfeed. 

Go to Trimming mode by continue chapter: 

3.2 Trimming mode 

On the following pages both operating modes are explained in more detailed steps.

3. Global functionality description (continued) 

3.1 Bypass mode 

I) A booklet is sent from the previous machine. 

With every booklet that leaves the previous machine a ‘start’ 

signal is sent to the STR, the belt propulsion motor (Motor5) 

starts. 

When FC4 or FC7 are active, the STR will give an error 

STR107. Empty the Trim Waste Bin. 

When the booklet arrives inside the STR it will be 

transported to the output side up to the Paper-stop. 

II) The infeed sensor (FC3) is active. 

The time between the ‘start’ signal and sensor (FC3) 

activation should be less than 1 second, after that the 

STR will give an error STR101. 

To check if the booklet has arrived in the STR correctly. 

III) The infeed sensor (FC3) is inactive. 

Sensor (FC3) activation should be less than 1 second, 

after that the STR will give an error STR102. 

To check that the booklet have transported into the STR. 


20 

FC3 

FC3 

Contents 

� 

Motor5


3.1 Bypass mode (continued) 

IV) When the booklet arrived at the Paper-stop, sensor (FC2) is 

active and the belt propulsion motor (Motor5) stops. 

The time between sensor FC3 and FC2 should be less 

than 3 seconds, after that the STR will give an error STR103. 

To check if the booklet has arrived at the Paper-stop 

correctly. 

V) The Side Joggers start to move (Motor7 and Motor8) and 

deactivates Switch S11 and Switch S13. 

The Side Joggers aligning the booklet. 

VI) When the Side Joggers are reaching the absolute position 

(adjusted Side Trim size) the Side Joggers will stop. 


21 

FC3 

FC2 

Contents 

� 

Motor5 

� S11 

Motor8 

� 

Motor8 

S13 

� 

Motor7 

� 

Motor7



VII) Both Side Joggers return to their ‘home position’. 

VIII) When S11 and S13 are activated, Motor7 and Motor8 stops. 

IX) The solenoid M1 will be activated and the Paper-stop is 

going down. 

The belt propulsion motor (Motor5) starts. 

The booklet is transported to the output side of the STR. 


22 

� 

Motor8 

Contents 

S13 

� S11 

Motor8 

M1 

� 

Motor7 

� 

Motor7 

� 

Motor5



X) Sensor FC2 is inactive. 

Sensor FC2 activation should be less than 2 seconds, 


To check if the booklet was transported from the Paper-stop 

to the outfeed. 

Solenoid M1 is deactivated and the Paper-stop is closing. 

XI) Outfeed Sensor FC1 is active. 

The time between sensor FC2 and FC1 should be less than 1 

second, after that the STR will give an error STR105. 

To check if the booklet has arrived at the outfeed correctly. 

XII) Sensor FC1 is inactive. 

The time when FC1 is activated should be less than 2 

seconds, after that the STR will give an error STR106. 

To check if the booklet was transported out of the STR 

correctly. 

The belt propulsion motor (Motor5) stops. 

The booklet is transported out of the STR. 

3 Global functionality description (continued) 


23 

FC2 

FC2 

FC1 

FC1 

M1 

Contents 

� 

Motor5 

Contents 

� 

Motor5

3.2 Trimming mode 

I) A booklet is sent from the previous machine. 

With every booklet that leaves the previous machine a ‘start’ 

signal is sent to the STR, the belt propulsion motor (Motor5) 

starts. 

When FC4 or FC7 are active, the STR will give an error 

STR107. Empty the Trim Waste Bin. 

When the booklet arrives inside the STR it will be 

transported to the output side up to the Paper-stop. 

II) The infeed sensor (FC3) is active. 

The time between the ‘start’ signal and sensor (FC3) 

activation should be less than 1 second, after that the 


To check if the booklet has arrived in the STR correctly. 

III) The infeed sensor (FC3) is inactive. 

Sensor (FC3) activation should be less than 1 second, 


To check that the booklet have transported into the STR. 

Booklet is checked on thickness (FC6). 


24 

FC3 

FC3 

FC6 

� 

Motor5


3.2 Trimming mode (continued) 

IV) When the booklet arrived at the Paper-stop, sensor (FC2) is 

active and the belt propulsion motor (Motor5) stops. 

The time between sensor FC3 and FC2 should be less 

than 3 seconds, after that the STR will give an error STR103. 

To check if the booklet has arrived at the Paper-stop 

correctly. 

When booklet is to thick it will aboard the trimming mode. 

V) The Side Joggers start to move (Motor7 and Motor8) and 

deactivates Switch S11 and Switch S13. 

The Side Joggers aligning the booklet. 

VI) When the Side Joggers are reaching the absolute position 

(adjusted Side Trim size) the Side Joggers will stop. 


25 

FC3 

FC2 

Contents 

� 

Motor5 

� S11 

Motor8 

� 

Motor8 

S13 

� 

Motor7 

� 

Motor7



VII) Both Side Joggers return to their ‘home position’. 

VIII) When S11 and S13 are activated, Motor7 and Motor8 

stop. 

IX) The knife motors (Motor 1, 2, 3 and 4) will be activated, the 

booklet is trimmed to the desired ‘Finished Size’. 

Knife home switch S10 and S12 are deactivated. 

The counter (CNT1) adds 1 Trim-cycle to the total. 


26 

� 

3 Global functionality description (continued) 

FC4 

� 

Motor8 

CNT 

0001 

� 

Motor3 

� 

Contents 

� S11 

Motor8 

Motor1 

FC7 

Motor2 

� 

Motor7 

S13 

� 

Motor7 

� 

Motor4 

Contents 

S10 

S12


X) The cutting waste falls down into the Trim waste bin. 

Sensor Waste drawer full FC4 and FC7 detects for a very 

short time (< 1sec.) the cutting waste when it falls down. 

The short time is used to check if the cutting waste actually 

falls down in the Trim waste bin. 

Sensor Waste drawer full FC4 or FC7 activation should be 

less than 5 seconds for more than 10 booklets, after that the 


Empty the Trim Waste Bin. 

XI) When the knife home switches S10 and S12 are activated the 

knife motors will be deactivated. 

XII) Solenoid M1 will be activated and the Paper-stop is going 

down. 

The belt propulsion motor (Motor5) starts. 

The booklet is transported to the output side of the STR. 


27 

FC4 

FC7 

� � 

� 

Motor1 

FC4 

FC7 

Motor3 

M1 

Motor2 

� 

Motor4 

S10 

S12 

� 

Motor5



XIII) Sensor FC2 is inactive. 

Sensor FC2 activation should be less than 2 seconds, 


To check if the booklet was transported from the Paper-stop 

to the outfeed. 

Solenoid M1 is deactivated and the Paper-stop is closing. 

XIV) Outfeed Sensor FC1 is active. 

The time between sensor FC2 and FC1 should be less than 1 

second, after that the STR will give an error STR105. 

To check if the booklet has arrived at the outfeed correctly. 

XV) Sensor FC1 is inactive. 

The time when FC1 is activated should be less than 2 

seconds, after that the STR will give an error STR106. 

To check if the booklet was transported out of the STR 

correctly. 

The belt propulsion motor (Motor5) stops. 

The booklet is transported out of the STR. 


28 

FC2 

FC2 

FC1 

FC1 

M1 

Contents 

� 

Motor5 

� 

Motor5

4. Covers 

4.1 Front Cover 

Fig. 4.1 Fig. 4.2 

Fig. 4.3 Fig. 4.4 

Removal 

No. Action Remarks 

1 Open the Top cover. (See Fig. 4.1) 

2 Switch off the main power switch and disconnect the power cord. 

3 Remove Screw (A) (See Fig. 4.2) 

4 Lift the Front cover upwards to unhook the cover at the lower end. (See Fig. 4.3 & 4.4) 

5 Disconnect the Ground wire 

6 Remove the Front cover 

Installation 


1 For installation follow the Removal procedure in reversed order. 


29 

Contents 

A

4. Covers (continued) 

4.2 Rear Cover 

Fig. 4.5 Fig. 4.6 

Fig. 4.7 Fig. 4.8 

Removal 


1 Open the Top cover. (See Fig. 4.5) 


3 Remove Screw (A) (See Fig. 4.6) 

4 Close the Top cover. 

5 Lift Rear cover upwards to unhook the cover at the lower end. (See Fig. 4.7 & 4.8) 

6 Disconnect the Ground wire 

7 Remove the Rear cover 

Installation 




30 

A 

Contents


4.3 Upper Infeed Cover 

Fig. 4.9 

A 

Fig. 4.10 Fig. 4.11 

Removal 


1 Remove the Front & Rear Cover (See Chap. 4.1 & 4.2) 


3 Remove Screws [A] & [B] on both sides of the STR (See Fig. 4.10 & 4.11) 

4 Remove the Upper Infeed cover from the machine. (See Fig. 4.9) 

Installation 




31 

B 

Contents


4.4 Lower Infeed Cover 

Fig. 4.12 

C 

Fig. 4.13 Fig. 4.14 

Removal 




3 Remove Screws [C] & [D] on both sides of the STR (See Fig. 4.13 & 4.14) 

4 Remove the Lower Infeed cover from the machine. (See Fig. 4.12) 

Installation 




32 

D 

Contents


4.5 Upper Outfeed Cover 

Fig. 4.15 

E F 

Fig. 4.16 Fig. 4.17 

Removal 




3 Remove Screws [E] & [F] on both sides of the STR (See Fig. 4.16 & 4.17) 

4 Remove the Upper Outfeed cover from the machine. (See Fig. 4.15) 

Installation 




33 

Contents


4.6 Lower Outfeed Cover 

Fig. 4.18 

G H 

Fig. 4.19 Fig. 4.20 

Removal 




3 Remove Screws [G] & [H] on both sides of the STR (See Fig. 4.19 & 4.20) 

4 Remove the Lower Outfeed cover from the machine. (See Fig. 4.18) 

Installation 




34 

Contents


4.7 Base Plate Cover 

J 

K 

Fig. 4.21 Fig 4.22 

Removal 



2 Remove Screws [J] & [K] on the back of Base STR (See Fig. 4.21) 

3 Remove Base Plate cover from the machine. (See Fig. 4.22) 

Installation 




35 

Contents


4.8 User Interface Cover 

L 

M 

Fig. 4.23 Fig 4.24 

Removal 



2 Remove Screws [L] & [M] on the back of the User Interface (See Fig. 4.23) 

3 Remove User Interface cover from the machine. (See Fig. 4.24) 

Installation 




36 

Contents

5. Troubleshooting 

5.1 Service Program mode 


37 

Contents 

The Service Program mode (SP) can be used to check electrical data, electrical components and adjust 

values. This Service Program mode is provided and controlled by the UI (User Interface) on the STR or 

Booklet Maker. Peripheral units are embedded in this service program. Where applicable, a sub menu 

appears after a function is selected listing the peripherals. 

Entering and Exiting the SP mode 

There are two ways to enter the Service Program mode either from the operator mode [1] or directly from 

switched off machine [2]. 

Fig. 5.1 Fig. 5.2 

Fig. 5.3 Fig. 5.4 

[1] 

No. Action 

1 Press the ‘Admin’ button. (Note: Insert the Interlock cheater, otherwise some functions do not work!) 

2 Use the ‘▲ / ▼ buttons’ to select ‘Service’ and press the ‘Enter’ button. 

3 Enter the standard access code: 1974 or 1983 (by using the ‘◄ / ►’ and ‘+ / -‘ buttons) and press 

the ‘Enter’ button. 

4 Use the ‘▲ / ▼ buttons’ to select the Target that need to be checked and press the ‘Enter’ button. 

5 Press the ‘ ’ button to exit the Service Program mode and enter the Operator mode. 

[2] 

No. Action 

1 Press and hold the lower button on the UI. 

2 Switch on the main Power Switch. 

3 Release the lower button on the UI after the Service Access Code menu appears. 

4 Enter the access code: 1974 or 1983 (by using the ‘◄ / ►’ and ‘+ / -‘ buttons) and press the ‘Enter’ 

button. 

5 Use the ‘▲ / ▼ buttons’ to select the Target that need to be checked and press the ‘Enter’ button. 

6 Press the ‘ ’ button to exit the Service Program mode and enter the Operator mode.

5. Troubleshooting (continued) 

5.1 Service program mode (continued) 

5.1.1 Software Version 

Fig. 5.5 Fig. 5.6 

No. Action 

1 Enter the Service Program mode [see Chapter 5.1] 

2 Use the ‘▲ / ▼ buttons’ to select ‘Software version’ and press the ‘Enter’ button. 

3 Check the Software version of the CPU(PCB6), MD6DC(PCB1) and MD6DC(PCB5). 



38 

Contents



5.1.2 Diagnostics 

Throughout the diagnostics operation of the machine all functions and 

components are monitored. Should an error occur, a fault code is 

displayed (see Fig. 5.7). With a text message, such as 

”ST_MOTOR1_OPEN_CIRCUIT” many faults can simply be corrected by 

the Service engineer. If the text message ”Malfunction” is displayed, the 

fault can also be corrected by the Service engineer but requires more 

service research. All messages regardless of nature are always connected 

with a fault code. 

The main self-diagnostic mode, Diagnostics checks the voltages, the 

sensors, solenoids and the motors. If a fault is found it will be displayed 

as a fault code. This manual lists all fault codes. To correct the fault, 

go to chapter: 5.2 Fault Code Descriptions. 

NOTE: It is normal to receive the code ‘Fault Code 00034’ [STR034] if 

no Stacker is connected to the STR. 

Fig. 5.8 Fig. 5.9 

No. Action 


2 Use the ‘▲ / ▼’ buttons to select ‘Diagnostics’ and press the ‘Enter’ button. 


39 

Contents 

3 Press the ‘Start’ button to start the self diagnostic mode and press ‘Stop’ to end the self diagnostic 

mode. 


Fig. 5.7



5.1.3 Motors 

To check if the motors are functioning correctly by operating them separately. 

Always ‘Unlock’ the selected Motor before changing the status of functionality. 

Functionality: CW = moving in (clockwise) 

CCW = moving out (counter clockwise) 

Cycle 1 = moving 1 complete cycle 

Attention: Do not use ‘CW’ or ‘CCW’ more than 1 time!!! 

Fig. 5.10 Fig. 5.11 

Fig. 5.12 Fig. 5.13 

No. Action 


2 Use the ‘▲ / ▼’ buttons to select ‘Motors’ and press the ‘Enter’ button (Fig. 5.10). 


40 

Contents 

3 Use the ‘▲ / ▼’ buttons to select the Motor that need to be checked and press the ‘Enter’ button 

(Fig. 5.11). 

4 For Knife-motors only press the ‘Unlock’ button to change the status of the Motor (Fig. 5.12). 

5 Press the ‘CW / CCW / Cycle 1’ buttons to check the functionality of the selected Motor (differs per 

motor) 

6 After checking press the ‘OFF’ buttons to change the Status of the Motor back in the ‘normal’ 

situation. 




5.1.4 Solenoids 

To check if the Solenoid(s) are functioning correctly. 

Fig. 5.15 Fig. 5.16 

Fig. 5.17 

No. Action 


2 Use the ‘▲ / ▼’ buttons to select ‘Solenoids’ and press the ‘Enter’ button. 


41 

Contents 

3 Use the ‘▲ / ▼’ buttons to select the Solenoid that need to be checked and press the ‘Enter’ button. 

4 Press the ‘ON / OFF’ buttons to check the functionality of the selected Solenoid. 

5 After checking press the ‘OFF’ buttons to change the Status of the Solenoid back in the ‘normal’ 

situation. 




5.1.5 Sensors and Switches 

To check if the Sensors and Switches are functioning correctly. 

Fig. 5.18 Fig. 5.19 

Fig. 5.20 


42 

Contents 

All sensors and switches can individually be checked by blocking/unblocking sensors. 

While blocking/unblocking, view the display for response. Displayed is the state by :0 / ’Low’ (unblocked / not 

activated) :1 / ’High’ (= blocked / activated). 

Which state corresponding to blocked/unblocked is depending on whether the sensor or switch has inverted 

function or not. For status definition, see Service Program Mode Tables 5.1.2. 

No. Action 


2 Use the ‘▲ / ▼’ buttons to select ‘Sensors’ and press the ‘Enter’ button. 

3 Use the ‘▲ / ▼’ buttons to select the Sensor or Switch that need to be checked and press the ‘Enter’ 

button. 

Pay attention! In the Sensors menu there are more pages available. 

Use the ‘Next’ button to view the other pages. 

4 Check the Value : When :0/‘Low’ the sensor is not activated, when :1/‘High’ the sensor is activated. 




5.1.6 Voltmeters 

To check if the Electrical boards (prints) have the right voltage. 

Fig. 5.21 Fig. 5.22 

Fig. 5.23 

No. Action 


2 Use the ‘▲ / ▼’ buttons to select ‘Voltmeters’ and press the ‘Enter’ button. 


43 

Contents 

3 Use the ‘▲ / ▼’ buttons to select the Voltmeter that need to be checked and press the ‘Enter’ button. 

4 Check the Value. 


Voltage at Analogue 

Value 

Unregulated In 23-43V Unregulated 36V(before interlock PCB3) from Power supply in STR measured 

on Interlock PCB3 

Unregulated Out 23-43V Unregulated 36V(after interlock PCB3 before K1) measured on Interlock PCB3 

24V 16-30V Regulated 24V distributed from interlock PCB measured on Interlock PCB3 

Unregulated PCB1 23-43V Unregulated 36V (after interlock PCB3, after K1) measured on PCB1. 

Voltage supplies: M1 Knife 1 

M2 Knife 1 

M5 Int Transport 

M7 Side Jogger 

M Stacker 

Unregulated PCB5 23-43V Unregulated 36V (after interlock PCB3, after K1) measured on PCB5. 

Voltage supplies: M3 Knife 2 

M4 Knife 2 

M6 Width adjust 

M8 Side Jogger



5.1.7 Non Volatile Memory (NVM) 

NVM values (non volatile memory) are different address locations within the EE-prom. 

Each address reflects timing,calibration,counter or function in the system. 

Fig. 5.24 Fig. 25 

Fig. 5.26 

No. Action 


2 Use the ‘▲ / ▼’ buttons to select ‘NVM’ and press the ‘Enter’ button. 


44 

Contents 

3 Use the ‘▲ / ▼’ buttons to select the NVM setting that need to be checked or changed and press the 

‘ ’ or ‘Change’ button. 

4 Use the ‘+ / -‘ buttons to set a NewValue(Dec) and press the ‘OK’ button. 

5 Press the ‘ESC’ or ‘ ’ button to exit the Service Program mode and enter the Operator mode.



5.1.8 Dead cycle 

To make one complete Trim cycle. 

Dead cycling is a modified machine cycle. All functions in the machine are run such 

as motors and solenoids. The program is basically made for factory testing, but can 

be of some use when trouble shooting. 

Fig. 5.27 Fig. 5.28 

No. Action 


2 Use the ‘▲ / ▼’ buttons to select ‘Dead cycle’ and press the ‘Enter’ button. 


45 

Contents 

3 Use the ‘Start’ button to select the start the Dead cycle and the ‘Stop’ button to end the Dead cycle. 




5.1.9 Calibration 

Can be used for adjusting the Side Jogger correction. 

See chapter 8.2.2 NVM Side Jogger correction. 

Fig. 5.29 


46 

Contents


5.2 Fault Code Descriptions 

Before continue using the Fault Code Descriptions please make sure that all connectors are 

connected. 


47 

Contents 

Fault Item Fault Description Page 

code No. No. 

STR 001 STR M1 Motor1 Cycle Timeout 49 

STR 002 STR M1 Motor1 Short Circuit 49 

STR 003 STR M1 Motor1 Open Circuit 49 










STR 013 STR M5 Motor5 Pulse Timeout 55 
















STR 029 STR MAG1 Magnet1 Open Circuit 62 

STR 030 STR MAG1 Magnet1 Short Circuit 63 

STR 032 ST M1 Stacker Motor1 Open Circuit 63 

STR 033 ST M1 Stacker Motor1 Short Circuit 64 

STR 041 STR JOG1 Jogger1 Not Home 64 

STR 042 STR JOG2 Jogger2 Not Home 65 

STR 043 STR M6 Motor6 Home to high 65 

STR 045 STR PCB1 No response from MD6DC PCB1 66 

STR 046 STR PCB5 No response from MD6DC PCB5 67


5.2 Fault Code Descriptions (continued) 


48 

Contents 

STR 051 STR FC1 FC1 Faulty 68 



STR 054 STR FC4 FC4 or FC7 Faulty 69 

STR 055 STR ENC5 ENC5 Faulty 70 





STR 061 STR S1 S1 Faulty 71 


STR 063 STR K2 Interlock Circuit Faulty 71 

STR 064 STR S3,4,7,8 S3 S4 S7 S8 or K2 Faulty 72 








STR 080 36V INPUT 36V input Low 75 

STR 081 36V INPUT 36V input High 76 

STR 082 36V OUTPUT 36V output Low 76 

STR 083 36V OUTPUT 36V output High 76 

STR 084 24V OUTPUT 24V Low 76 

STR 085 24V OUTPUT 24V High 76 

STR 086 36V M6DC1 36V M6DC PCB1 Low 76 

STR 087 36V M6DC1 36V M6DC PCB1 High 77 

STR 088 36V M6DC5 36V M6DC PCB5 Low 77 

STR 089 36V M6DC5 36V M6DC PCB5 High 77 

STR 101 JAM FC3 Not Covered 78 

STR 102 JAM FC3 Not Uncovered 78 





STR 107 JAM FC4 or FC7 Trim Waste Bin Full 79


5.3 Fault Code Solutions 

Before continue using the Fault Code Descriptions please make sure that all connectors are 

connected. 

STR 001 Motor1 Cycle Timeout 

• See STR 004 Motor2 Cycle Timeout 

STR 002 Motor1 Short Circuit 

Procedure 

Disconnect the Motor plug M1. Run the diagnostics. Fault code STR 003(Open Circuit) is displayed? 

Y N 

Disconnect connector J6. Check wires for Short Circuit across leads. (Red1 & Black8) 

Is there a short Circuit? 

Y N 

Disconnect plug 1P3 from PCB1. Check wires for Short Circuit across leads. (Red2 & Black3) 

Is there a Short Circuit? 

Y N 

Replace PCB1 

Replace wire harness 


Replace motor STR-M1 

STR 003 Motor1 Open Circuit 


49 

Contents 

Procedure 

Disconnect the motor plug M1. Enter service mode, unlock and start the Motor M1. Measure between the Red and Black wire. The 

voltage is approximately 12VDC? 

Y N 

Disconnect connector J6 and cycle Motor M1. Measure between the Red and Black wire. (Red1&Black8). The voltage is 

approximately 12VDC? 

Y N 

Disconnect plug 1P3 from PCB1 and cycle Motor M1. Measure between points 2 and 3. 

The voltage is approximately 12VDC? 

Y N 

Replace PCB1 



Replace Motor M1


5.3 Fault Code Solutions (continued) 



50 

Contents 

Procedure 

Enter the Service mode and select Trimmer Knife home position (STR S10) in Switches. The switch indicates: 1 when activated, 

and: 2 when not activated? 

Y N 

Go to STR 066 – S10 Faulty 

Disconnect Motor2 (STR M2), enter the Service mode and select Motor1 (STR M1) in motors, unlock and start Motor1 (STR M1) The 

motor energizes? 

Y N 

Go to STR 003 – Motor 1 Open Circuit 

Connect Motor2 (STR M2) Disconnect Motor1 (STR M1), enter the Service mode and select Motor2 (STR M2) in motors, unlock and 

start Motor2 (STR M2) The motor energizes? 

Y N 


1. Make sure that nothing interferes with the mechanical movement. 

2. Lubricate where needed.




Procedure 

Disconnect the Motor plug M2. Run the diagnostics. Fault code STR 005(Short Circuit) is displayed? 

Y N 

Replace motor STR-M2. 

Disconnect J-CNT1. Run the diagnostics. Fault code STR 006(Open Circuit) is displayed? 

Y N 



Y N 


51 

Contents 

Disconnect plug 1P3 from PCB1 Check wires for Short Circuit across leads. (Red6 & Black7) Is there a Short 

Circuit? 

Y N 

Disconnect connector J8. Check wires for Short Circuit across leads. (Orange3 & Violet6) Is there a 

Short Circuit? 

Y N 

Disconnect connector J9. Check wires for Short Circuit across leads. (Orange3 & Violet6) Is 

there a Short Circuit? 

Y N 

Check connector 1P3 wires for Short circuit across leads. (Orange5 & Violet8) Is there 

a Short Circuit? 

Y N 

Replace STR-PCB1 






Replace Counter STR-CNT1





52 

Contents 

Procedure 

Disconnect the motor plug M2. Enter service mode, unlock and cycle the Motor M2. Measure between the Red and Black wire. The 


Y N 



Y N 



Y N 

Replace PCB1 



Replace Motor M2 


• See STR 010 Motor4 Cycle Timeout 


Procedure 


Y N 



Y N 

Disconnect plug 5P3 from PCB5 Check wires for Short Circuit across leads. (Red2 & Black3) 


Y N 

Replace PCB5 



Replace motor STR-M3





53 

Contents 

Procedure 

Disconnect the motor plug M3. Enter service mode, unlock and start the Motor M3. Measure between the Red and Black wire. The 


Y N 



Y N 



Y N 

Replace PCB5 





Procedure 

Enter the Service mode and select Trimmer Knife home position (STR S12) in Switches. The switch indicates: 1 when activated, 

and: 2 when not activated? 

Y N 

Go to STR 068 – S10 Faulty 

Disconnect Motor4 (STR M4), enter the Service mode and select Motor3 (STR M3) in motors, unlock and start Motor3 (STR M3) The 

motor energizes? 

Y N 


Connect Motor4 (STR M4) Disconnect Motor3 (STR M3), enter the Service mode and select Motor4 (STR M4) in motors, unlock and 

start Motor4 (STR M4) The motor energizes? 

Y N 


1. Make sure that nothing interferes with the mechanical movement. 

2. Lubricate where needed.




Procedure 


Y N 



Y N 

Disconnect plug 5P3 from PCB5 Check wires for Short Circuit across leads. (Red6 & Black7) 


Y N 

Replace PCB5 






54 

Contents 

Procedure 

Disconnect the motor plug M4. Enter service mode and cycle the Motor M4. Measure between the Red and Black wire. The voltage 

is approximately 22VDC? 

Y N 



Y N 



Y N 

Replace PCB5 



Replace Motor M4



STR 013 Motor5 Pulse Timeout 

Procedure 


• Go to STR 016 – Motor5 Open Circuit. 


Procedure 


55 

Contents 

Enter the Service mode and select Motor5 encoder in sensors. Slowly rotate the motor by hand and check the value on the display. 

Value toggles between “0” and “1”? 

Y N 

Disconnect the sensor plug to Motor5 (STR-Motor5). Measure between the two wires for the sensor (5V and Signal ground). 


Y N 

Replace Sensor 

Check wires for damage. Are the wires damaged? 

Y N 

Go to STR 015 Motor Short Circuit 

Replace wire Harness 

Enter service mode and start Motor5. The motor starts? 

Y N 

Go to STR 016 Motor 5 Open Circuit 

Check for obstructions 

Disconnect the wires from Motor M5. Run the diagnostics. Fault code STR 016(Open Circuit) is displayed? 

Y N 

Disconnect plug 1P2 from PCB1 Check wires for Short Circuit across leads. (Orange4 & Violet11) 


Y N 

Replace PCB1 


Replace motor STR-M5





56 

Contents 

Procedure 

Disconnect the motor plug M5. Enter service mode and cycle the Motor M5. Measure between the Orange and Violet wire. The 


Y N 



Y N 

Replace PCB1 




Procedure 

Enter the Service mode and select Motor6 encoder in sensors. Slowly rotate the motor by hand and check the value on the display. 


Y N 



Y N 



Y N 

Go to STR 019 Motor6 Short Circuit 



Y N 


Check for obstructions 


• Go to STR 020 – Motor6 Open Circuit




Fault code STR 019 indicates that Motor6 (STR-M6) has a Short Circuit 

Initial Actions 

• Check Fuse F15 on transformer 

Procedure 


Y N 

Disconnect connector J5. Check wires for Short Circuit across leads. (Orange1 & Violet4) 


Y N 


57 

Contents 

Disconnect plug 5P2 from PCB5 Check wires for Short Circuit across leads. (Orange4 & Violet 11) Is there a 

Short Circuit? 

Y N 

Replace PCB5 





Procedure 



Y N 

Disconnect connector J5 and cycle Motor M6. Measure between the Orange and Violet wire. (Orange1&Violet4). The 


Y N 



Y N 

Replace PCB5 



Replace Motor M6




Procedure 


• Go to STR 024 – Motor7 Open Circuit 


58 

Contents 

Warning : Fault code STR021 can be caused by a NVM 2 Infeed Position that is to high. 

Enter the Service mode and select Motor7 encoder A in sensors. Slowly rotate the motor by hand and check the value on the display. 


Y N 



Y N 



Y N 

Go to STR 023 Motor 7 Short Circuit 


Enter the Service mode and select Motor7 encoder B in sensors. Slowly rotate the motor by hand and check the value on the display. 


Y N 



Y N 



Y N 




Y N 


Check for obstructions




Procedure 


Y N 



Y N 


59 

Contents 

Disconnect plug 1P2 from PCB1 Check wires for Short Circuit across leads. (Orange2 & Violet9) Is there a Short 

Circuit? 

Y N 

Replace PCB1 





Procedure 



Y N 



Y N 



Y N 

Replace PCB1 



Replace Motor M7




Procedure 


• Go to STR 027 – Motor8 Open Circuit 


60 

Contents 

Warning : Fault code STR025 can be caused by a NVM 4 Infeed Position that is to high. 

Enter the Service mode and select Motor8 encoder A in sensors. Slowly rotate the motor by hand and check the value on the display. 


Y N 



Y N 



Y N 



Enter the Service mode and select Motor8 encoder B in sensors. Slowly rotate the motor by hand and check the value on the display. 


Y N 



Y N 



Y N 




Y N 


Check for obstructions




Procedure 


Y N 



Y N 


61 

Contents 

Disconnect plug 5P2 from PCB5 Check wires for Short Circuit across leads. (Orange2 & Violet9) Is there a Short 

Circuit? 

Y N 

Replace PCB5 





Procedure 



Y N 



Y N 



Y N 

Replace PCB1 



Replace Motor M7



STR 029 Magnet1 Open Circuit 


62 

Contents 

Procedure 

Disconnect the Magnet1. Enter service mode and activate the Magnet. Measure between the Orange and Violet wire. The voltage is 


Y N 

Disconnect connector J3 and activate Magnet1. Measure between the Orange and Violet wire. (Orange2&Violet4). The 


Y N 

Replace Magnet1 

Disconnect plug J1 and activate Magnet1. Measure between the orange and the violet wire (Orange6 & Violet12) 


Y N 

Disconnect connector 3p4 and 1p2, activate Magnet1. Measure between point 2 on 3p4 and point 12 on 

1p2. The voltage is approximately 24VDC? 

Y N 

Replace PCB1, reconnect all wires. 

Run the diagnostics. Fault code STR 029 (Open Circuit) is displayed? 

Y N 

No action 

Replace PCB3 



Replace wire harness



STR 030 Magnet1 Short Circuit 

Procedure 

Disconnect the Magnet plug J3. Run the diagnostics. Fault code STR 029(Open Circuit) is displayed? 

Y N 

Disconnect connector J1. Check wires for Short Circuit across leads. (Orange6 & Violet 12) 


Y N 

Disconnect plug 1P2 from PCB1 Check wire for Short Circuit across leads. (Violet12) 


Y N 


63 

Contents 

Disconnect connector 3P11 from PCB3. Check wire for Short Circuit across leads. (Orange1) Is there a 

short Circuit? 

Y N 

Replace PCB1 

Run the diagnostics again. Fault code STR 029(Open Circuit) is displayed? 

Y N 

Replace PCB3 

Reconnect all wires. 





STR 032 Stacker Motor1 Open Circuit 

Procedure 

Check if the Belt stacker is connected Belt stacker is connected? 

Y N 

Connect Belt Stacker. 

Disconnect Belt Stacker connector J12 and activate Belt Stacker Motor1. Measure between points 3 and 4. 


Y N 

Disconnect connector J1. Measure between points 5 and 11. The voltage is approximately 22VDC? 

Y N 

Disconnect plug 1P2 from PCB1 Measure between point 3 and 10. The voltage is approximately 22VDC? 

Y N 

Replace PCB1 



Belt Stacker Motor1



STR 033 Stacker Motor1 Short Circuit 

Procedure 

Disconnect the Stacker Motor connector J12. Run the diagnostics. Fault code STR 032(Open Circuit) is displayed? 

Y N 

Disconnect connector J1. Check wires for Short Circuit across leads. (Orange5 & Violet 11) 


Y N 

Disconnect plug 1P2 from PCB1 Check wires for Short Circuit across leads. 

(Orange3 & Violet10) Is there a Short Circuit? 

Y N 

Replace PCB1 



Replace Stacker Motor 

STR 041 Jogger1 Not Home 

Procedure 

Check Jogger1 switch (S11). Is the switch activated? 

Y N 

Check if Side Jogger isn’t damaged or loosened. Side Jogger is ok? 

Y N 

Replace Side Jogger 

Correct NVM values of Side Jogger 

Check if S11 is activated using the service menu. S11 is activated? 

Y N 

Retest procedure 



64 

Contents



STR 042 Jogger2 Not Home 

Procedure 

Check Jogger2 switch (S13). Is the switch activated? 

Y N 

Check if Side Jogger isn’t damaged or loosened. Side Jogger is ok? 

Y N 

Replace Side Jogger 

Correct NVM values of Side Jogger 


Y N 



STR 043 Motor6 home to high 

Procedure 

Check Switch (S1). Is the switch activated? 

Y N 

Check if S1 isn’t damaged or loosened. Switch is ok? 

Y N 

Replace or adjust Switch S1 (See Chap. 6.3.4.) 

Correct NVM values of S1 lower than 2000? 

Y N 

Adjust S1 and calibrate (See Chap. 6.3.4.) 

Check for obstructions and retest procedure. 


Y N 




65 

Contents



STR 045 No response from MD6DC PCB1 

Procedure 

Check if the Yellow LED on PCB1 Blinks. Does the Yellow LED blink? 

Y N 

Attempt software download on PCB1. Software download succeeds? 

Y N 

Replace PCB1 

Check dipswitches on PCB1. Dipswitches are set to “0000”? 

Y N 

Set dipswitches to “0000” and restart procedure. 


Y N 


Check endresistors on PCB1 (1P4) and PCB6 (6P3). The endresistors appear to be undamaged? 

Y N 

Replace damaged endresistors. 

Check wiring between PCB1 and PCB5. Are there any loose or broken wires? 

Y N 


Y N 

Replace PCB1 

Replace wiring harness 



66 

Contents



STR 046 No response from MD6DC PCB5 

Procedure 

Check if the Yellow LED on PCB5 Blinks. Does the Yellow LED blink? 

Y N 

Attempt software download on PCB5. Software download succeeds? 

Y N 

Replace PCB5 


Y N 



Y N 


Check endresistors on PCB1 (1P4) and PCB6 (6P3). The endresistors appear to be undamaged? 

Y N 

Replace damaged endresistors. 


Y N 


Y N 

Replace PCB5 




67 

Contents



STR 051 FC1 Faulty 

Fault code STR 051 indicates that Sensor FC1 (STR-FC1) is faulty. 

Procedure 

Enter service mode and select FC1 (STR-FC1) in sensors. 

Value toggles between “0” and “1” when activated/deactivated? 

Y N 


68 

Contents 

Disconnect the connector to sensor FC1. Measure between the wires to sensor FC1 (24V and Ground) The voltage is 


Y N 

Disconnect connector J4. Measure between the wires in Plug P4 (1 & 4) The voltage is approximately 24VDC? 

Y N 


Disconnect the connector 1P13. Measure between points 8 and 9. 


Y N 

Replace PCB1 

1. Replace wire harness 

2. Replace PCB2 

Adjust or replace sensor FC1 (STR-FC1) 

Check for obstructions and retest procedure. 



Procedure 



Y N 



Y N 

Disconnect connector J4. Measure between the wires in Plug P4 (3 & 6) The voltage is approximately 24VDC? 

Y N 




Y N 

Replace PCB1 




Check for obstructions and retest procedure.





Procedure 



Y N 


69 

Contents 



Y N 



Y N 

Replace PCB1 




Check for obstructions and retest procedure 

STR 054 FC4 or FC7 Faulty 

Fault code STR 054 indicates that Sensor FC4 or FC7 (STR-FC4 or FC7) is faulty. 

Procedure 

Enter service mode and select FC4 or FC7 (STR-FC4 or FC7) in sensors. 


Y N 

Disconnect the connector to sensor FC4 or FC7. Measure between the wires to sensor FC4 or FC7 (24V and Ground) The 


Y N 



Y N 

Replace PCB1 



Adjust or replace sensor FC4 or FC7 (STR-FC4 or FC7) 

Check for obstructions and retest procedure



STR 055 ENC5 Faulty 

• Go to STR 013 – Motor5 Pulse Timeout 









Procedure 



Y N 


70 

Contents 



Y N 


Y N 

Replace PCB6 



Check for obstructions, check adjustment FC6 and retest procedure.



STR 061 S1 Faulty 

Procedure 

Enter Service mode and select S1 in switches. 

Value toggles between “0” and “1” when switch S1 is activated/deactivated? 

Y N 


Procedure 

STR 063 Interlock Circuit Faulty 

Procedure 

Check K2 for damage. There is damage to K2? 

Y N 

Replace K2 

1. Replace S1 

2. Disconnect the plugs from switch STR-S1. Check wires for Continuity/Short circuit across leads. 

Is there a short circuit/no continuity? 

Y N 

Replace PCB5 

Check mechanics 

Check if K2 isn’t loose. K2 is loose? 

Y N 

Tighten K2 




Y N 

1. Replace S2 



Y N 

Replace PCB5 

Check Mechanics 


Check the wiring for K2. Connectors 3P12 and 3P14 are plugged in? 

Y N 

Connect 3P12 and 3P14 



71 

Contents



STR 064 S3 S4 S7 S8 Faulty 

Procedure 

Check S3/S4/S7/S8 for damage. There is damage to S3/S4/S7/S8? 

Y N 

Check if S3/S4/S7/S8 isn’t loose. S3/S4/S7/S8 is loose? 

Y N 

Check is S3/S4/S7/S8 isn’t obstructed. S3/S4/S7/S8 is obstructed? 

Y N 

Check wiring for S3/S4/S7/S8. Is there damage on the wiring or a short circuit? 

Y N 

Check K2. Is K2 damaged? 

Y N 

Replace K2 


Remove obstruction 

Tighten S3/S4/S7/S8 

Replace S3/S4/S7/S8 


Replace S3/S4/S7/S8. 

Procedure 



Y N 

1. Replace S9 



Y N 

Replace PCB6 




72 

Contents




Procedure 



Y N 


Procedure 


Procedure 

1. Replace S10 



Y N 

Replace PCB1 





Y N 




Y N 

Replace PCB1 





Y N 




Y N 

Replace PCB5 




73 

Contents




Procedure 



Y N 


Procedure 




Y N 

Replace PCB5 





Y N 




Y N 

Replace PCB1 




Not available. 


74 

Contents



STR 080 36V input Low 

Procedure 

Power on machine. Measure incoming voltage on Rectifier (Black and Black). 

The voltage is approximately 26V? 

Y N 

Check if Fuse F15 is blown. Fuse F15 is blown? 

Y N 

Replace transformer 

Replace Fuse F15 

Measure outgoing voltage on rectifier (Red and Black). The voltage is approximately 26V? 

Y N 

Replace rectifier 

Measure outgoing voltage on the Transformer between the Orange and Violet wire. The voltage is approximately 10V? 

Y N 

Check if Fuse F14 is blown. Fuse F14 is blown? 

Y N 


Replace Fuse F14 

Power off the machine. Measure the Orange wire. Is there continuity? 

Y N 


Measure the Violet wire. Is there continuity? 

Y N 


Measure the Black wire. Is there continuity? 

Y N 


Measure the Red wire. Is there continuity? 

Y N 

Replace PCB3 



75 

Contents



STR 081 36V input High 

• Go to STR 080 – 36V input Low 

STR 082 36V output Low 


STR 083 36V output High 


STR 084 24V Low 

Disconnect connector 3P6. Measure between the wires (Red1 & Black3) The voltage is approximately 24V? 

Y N 

Replace PCB3 

Check the wires for damage or short circuit across leads. Is there damage or a short circuit? 

Y N 



STR 085 24V High 

• Go to STR 088 – 24V Low 

STR 086 36V M6DC PCB1 Low 

Disconnect connector 1P11. Measure between the wires (Red1&Black2) The voltage is approximately 36VDC? 

Y N 

Replace PCB1 

Check 1P11 wire for damage or Short Circuit across leads. (Red1&Black2) Is there damage or a short Circuit? 

Y N 

Disconnect connector 3P5. Measure between pin 1 and pin2. The voltage is approximately 36VDC? 

Y N 

Replace PCB3 


2. Replace K1 



76 

Contents



STR 087 36V M6DC PCB1 High 

• Go to STR 086 – 36V M6DC PCB1 Low 

STR 088 36V M6DC PCB5 Low 

Disconnect connector 5P11. Measure between the wires (Red1&Black2) The voltage is approximately 36VDC? 

Y N 

Replace PCB5 

Check 5P11 wire for damage or Short Circuit across leads. (Red1&Black2) Is there damage or a short Circuit? 

Y N 


77 

Contents 

Disconnect plug J1. Measure between the wires (Red1&Black7) The voltage is approximately 36VDC? 

Y N 

Check J11 wire for damage or Short Circuit across leads. (Red1&Black7) Is there damage or a short 

Circuit? 

Y N 

Disconnect connector 3P1. Measure between pin 1 and pin2. The voltage is approximately 

36VDC? 

Y N 

Replace PCB3 


2. Replace K1 




STR 089 36V M6DC PCB5 High 

• Go to STR 088 – 36V M6DC PCB5 Low



STR 101 JAM FC3 NOT COVERED 


78 

Contents 

Fault code STR 101, indicates that during a run, the Infeed paper path sensor (FC3), was not covered within timeout after the sheet exit 

signal from the previous finisher was detected. 

Procedure 

Clear paper area, by opening the cover and remove the booklet. Block and unblock Infeed paper path sensor (FC3) with a sheet of 

paper. The Infeed paper path sensor lights up when the sensor is blocked and doesn’t light up when the sensor is not 

blocked? 

Y N 

Go to STR 053 FC3 Faulty. 

Make sure that nothing interferes with the paper path and close cover. 

STR 102 JAM FC3 NOT UNCOVERED 

Fault code STR 102, indicates that during a run, the Infeed paper path sensor (FC3), was covered exceeding timeout. 

Procedure 

Clear paper area, by opening the cover and remove the booklet. The Infeed paper path sensor (FC3) is deactivated? 

Y N 




Fault code STR 103, indicates that during a run, the Paper path sensor (FC2), was not covered within timeout. 

Procedure 

Clear paper area, by opening the cover and remove the booklet. Block and unblock Paper path sensor (FC2) with a sheet of paper. 

The Paper path sensor lights up when the sensor is blocked and doesn’t light up when the sensor is not blocked? 

Y N 




Fault code STR 104, indicates that during a run, Paper path sensor (FC2), was covered exceeding timeout. 

Procedure 

Clear paper area, by opening the cover and remove the booklet. The Paper path sensor (FC2) is deactivated? 

Y N 


Make sure that nothing interferes with the paper path and close cover.




Fault code STR 105, indicates that during a run, the Outfeed paper path sensor (FC1), was not covered within timeout. 


79 

Contents 

Procedure 

Clear paper area, by opening the cover and remove the booklet. Block and unblock Outfeed paper path sensor (FC1) with a sheet of 

paper. The Outfeed paper path sensor lights up when the sensor is blocked and doesn’t light up when the sensor is not 

blocked? 

Y N 




Fault code STR 106, indicates that during a run, the Outfeed paper path sensor (FC1), was covered exceeding timeout. 

Procedure 

Clear paper area, by opening the cover and remove the booklet. The Outfeed paper path sensor (FC1) is deactivated? 

Y N 

Go STR 051 FC1 Faulty. 


STR 107 JAM FC4 or FC7 WASTE BIN FULL 

Fault code STR 107, indicates that during a run, the Waste bin sensor (FC4 or FC7), was covered for 5 sec and 10 booklets. 

Procedure 

Clear paper area, by opening the waste bin and remove the strips. Block and unblock Waste bin sensor (FC4 or FC7) with a sheet of 

paper. The Waste bin sensor lights up when the sensor is blocked and doesn’t light up when the sensor is not blocked? 

Y N 

Go to STR 054 FC4 or FC7 Faulty. 

1. Make sure that nothing interferes with the waste bin and close the waste bin.

6. Default / basic adjustments 

ATTENTION 

In cases there was use of Loctite by some parts this is indicated 

with a black dot near that place [Fig. 6.1a]. 

Make sure that adjusted or replaced parts are also provided 

with Loctite. 

6.1 Replacing Knives 

WARNING!!! 

Always stay clear from upper knife. The knife edge may cause serious 

injuries. Place the safety block [Fig. 6.1b] between lower knife and 

upper knife beam. 

Keep the safety block in that position as much time as possible 

throughout this procedure. 

6.1.1 Preparation 


80 

Contents 

Fig. 6.1a 

Fig. 6.1b 


1 Set the STR to A5 paper size using the User Interface (display) 

2 Turn OFF Side Trim in the UI. 

3 Turn OFF the power switch and disconnect the power to the STR. 

4 Undock the STR from other machines. 

5 Remove the Front or Rear* Cover. *Depending on knife. 

6 Open the Top Cover.

6. Default / basic adjustments (continued) 

6.1 Replacing Knives (continued) 

6.1.2 Removal Upper Knife 

Fig. 6.2 

E 

Fig. 6.5 

A 

Upper knife 

B 

Lower knife 

Trim Waste Fan 

Removal 


1 Remove Allen screws [A] and washers at both sides of the Knife 

Protection Plate. 

(See Fig. 6.2) 

2 Remove Knife Safety Plate [B] or Trim Waste Fan. (See Fig. 6.2) 

3 Place the Knife Protection Plate [C] or [D]* using 2 screws M6x10. *Depending on knife. 

(See Fig. 6.3 & 6.4) 

4 Remove Screws [E] (6X) with cup spring washers. (See Fig. 6.5) 

5 Remove Upper Knife. (See Fig. 6.5) 

Placement 


1 !!! For placement follow the Placement instructions Upper Knife. (See Chap. 6.1.5) 


81 

C 

D 

Contents 

Fig. 6.3 

Fig. 6.4



6.1.3 Removal Lower Knife 

Fig. 6.6 

Removal 


1 Remove Screws [F] with normal Washers (6x) (See Fig. 6.6) 

2 Remove Lower Knife. (See Fig. 6.5) 

3 Loosen Nuts [L] (3x) (See Fig. 6.5) 

4 Turn Screws [M] (3x) Counter Clockwise (CCW) until they passes 

edge [N] 


F 

5 1 3 4 2 6 

L 

M 

CCW CCW CCW 

Placement 


1 !!! For placement follow the Placement Lower Knife Instructions. (See Chap. 6.1.4) 


82 

N 

Contents



6.1.4 Placement Lower Knife 

1 

F 

M 

Placement 


1 

Grease the bottom side surface of the Lower Knife [1] (not the 

paper side!) a little bit and the Knife position on the Beam [2]. 

(See 1 & 2) 

2 Place the Lower Knife on the Beam against the Screws [M] (3x) (See Fig. 6.10) 

3 Place the Screws [F] with normal Washers (6x) back. 

4 Place a Safety Block between the Lower Knife and Upper Beam (See 3) 

5 

Turn the Screws [F] a little bit in the Lower Knife so the top of the 

screws do not stick out and the Lower Knife is hard to move. 

6 Remove the Safety Block 

7 Continue Adjustment Lower Knife. (See Chap. 6.1.7) 


83 

3 

2 

Contents



6.1.5 Placement Upper Knife 

Fig. 6.7 

E 

J 

H 

K 


84 

Upper knife 

Lower knife 

Contents 

Placement 


1 

Place the Knife Protection Plate [C] or [D]* using 2 screws M6x10 

on the new Knife. 

*Depending on knife 

(See Fig. 6.3 & 6.4) 

2 Fit the Upper Knife on the guide bar [H]. (See Fig. 6.7) 

3 

Place, (don’t tighten) Screws [E] (6X) with Washers and 6 Cup 

Spring Washers in the Upper Knife / block 

Turn Screws [E] so there is no tension and no play between the 

Make sure each screw has 7 

Cup Spring Washers placed 

according to Fig. 6.7 

4 Cup Spring Washers. (The Washers can still be turned by the 

fingers) 


5 Turn Screws [E] one revolution (360º) clockwise each. (See Fig. 6.7) 

6 Continue Adjustment Upper Knife. (See Chap. 6.1.6)



6.1.6 Adjustment Upper Knife 

Fig. 6.8 

Fig. 6.9 

O 

R 


85 

Contents 

Adjusting 


1 

Check if the space [J] between the Upper Knife and the Marked 

Screws [R] is 0.50mm 

Use a feeler gauge 0.50mm. 


2 Adjust the space if necessary with Screws [O] 

Never adjust Screws [R] (See 

Fig. 6.8) 

3 Turn Screws [E] two times (90º) clockwise each. (See Fig. 6.7) 

4 

Place the Knife Safety Plate [B] or Trim Waste Fan back by using 

Allen Screws [A] with washers. 


5 

Turn the Upper Knife down in the lowest position using by turning 

Crank [P] with a 13mm Wrench. 


P



6.1.7 Adjustment Lower Knife 

5 1 3 4 2 6 

L 

M 

CCW CCW CCW 

F 


86 

Contents 

Fig. 6.10 

Adjusting 


1 Gently push the Lower Knife against the Upper Knife [ 1 ]. 

Feel that the Knives touch on 

both sides (See 1) 

2 

Gently raise the Upper Knife to top position using by turning 

Crank [P] with a 13mm Wrench. 


3 Tighten Screws [G] 1-2 (See Fig. 6.10) 

4 

Turn Screws [M] (3x) until they touch the Lower Knife. 

!!! Do not force the Screws, they only need to touch the Knife 

(See Fig. 6.10) 

5 

Trim a booklet 4 sheets. 

Very slowly lower the Upper Knife by turning Crank [P]. 

!!! Check that the Upper Knife does not touch the top of the 

Lower Knife. 

When it does hits the top of the 

Lower Knife, pull back the 

Lower Knife and repeat 

procedure “Adjustment Upper 

Knife” No. 1. 

G 

N 

1



6.1.7 Adjustment Lower Knife (continued) 

Left 

M 


87 

Middle 

Contents 

Adjusting 


17 

Check the booklet 4 sheets trim quality. 

!!! Make sure there is no tearing, folding or sticking. 

Loosen Screws [G] (See Fig. 6.10). 

Determine witch Screws [M] needs to be adjusted (to adjust the 

For adjusting trim quality 

continue next step. 

18 Lower Knife) 

Adjust Screws [M] by turning them only (10º) each time. 

After that, tighten Screws [G] again and trim a booklet 4 sheets. 

It becomes very precisely!!! 

19 



If necessary repeat previous 

step. 

20 Tighten Screws [F] 3-6. 

Trim a booklet of 25 sheets. 

Tighten according to Sequence 

1-6 (See Fig. 6.10) 

21 Use the Service Mode (See Chap. 5.1.3) to cycle Motor2 or 

Motor4. 

22 



23 Tighten Screws [M] (3x) by fasten Nuts [L] (3x). (See Fig. 6.10) 

M 

Right 

M



6.1.8 Spine Support Knives 

For replacing the Spine Support Knives see Installation Manual SSK-kit (DBCI-0512-0042-0000). 


88 

Contents



6.1.9 Testing / Finishing Adjustments 


89 

Contents 

Testing 


1 

Make 4 different booklets required for the adjustment. The booklets 

should have 2, 15, 20 & 25 sheets A3 (11”x17”) 80gsm (20# bond) 

Check if the lowest sheet of 

2 Cut the 2 sheet booklet by turning Crank [P]. (See Fig. 6.9) 

the booklet is cut clean 

throughout the length. 


3 Cut the 15 sheet booklet (See Fig. 6.9) 











If the set is not correctly cut on one of the ends, loosen the five (See Fig. 6.6) 

Screws (F) & (G). (NOTE! Keep tightened the screw on the 

6 good end and loosen the one on the bad end) 

Turn Screw (M) on the bad end 1/36 revolution or 10° 

clockwise. 


7 Tighten Screws [F] 3-6 and Screws [G] 1-2. 

Tighten according to 

Sequence 1-6 (See Fig. 6.6) 

8 Tighten the Nuts [L] (3X) without turning the Screws [M] (3X) (See Fig. 6.8) 

9 Reverse “Preparation” See Chapter 6.1.1 

When the knives become dull it is possible to resharpen them. The upper knife can be resharpened 

until it is 70 mm (2”3/4) wide at the shorter end. Resharpen at a 25° angle (See Fig. 6.11). 

The lower knife can be resharpened until it is 38 mm (1”½) wide. Resharpen at a 1° angle (See Fig. 

6.11). 

Fig. 6.11


6.2 Adjusting booklet quality 


90 

Contents 

Before making adjustments to the STR, make sure that the fault/error is not present in previous 

machines. Use their Service Manual to perform a Paper Size Check. 

Make a booklet with Side Trim and check if the booklet is not Trapezium / Diamond shaped (Chapter 6.2.1 Trapezium / Diamond Shape 

Fig. 6.12). Are the front [A] and back [B] of the booklet the same size and is the booklet not Diamond shaped (Fig. 6.12)? 

Y N 

Adjust the booklet according to Chapter 6.2.1 Trapezium / diamond Shape. 

Make sure the Finished Size is conform the UI display (Chapter 6.2.2 Side Trim (Finished Size) Fig. 6.19). The Finished Size of the 

booklet is the same as indicated on the UI display ( [A] = [B] = UI ) (Fig. 6.19)? 

Y N 

Adjust the booklet according to Chapter 6.2.2 Side Trim (Finished Size). 

(Adjust the NVM value Motor6 Home Position Booklet width correction according to chapter 8.2.1 (TAG 1 & 2) or 8.3.1 (TAG 6 

and up) 

Make sure the Side Joggers are set at a correct distance. Are the Side Joggers not deforming the booklet? 

-The Side Joggers should not compress the booklet to hard or to less. 

-There should be no more than 0,5mm space between the booklet and the Side Joggers. 

Y N 

Adjust the NVM values No. 3 Motor7 and No. 5 Motor 8 Compress Correction according to Chapter 8.2.2 (TAG 1&2) or 8.3.2 

(TAG 6 and up) 

Make sure the booklet is not skewed. All corners are 90degrees? 

Y N 

Adjust the Side Joggers SQUARED against the Lower Knife according to Chapter 6.4 Replacing Side Joggers 

Is the booklet trim waste equal when the offset is set to 0mm? 

Y N 

Adjust the NVM value Motor7 and Motor8 Centering Correction according to Chapter 8.2.3 (TAG 1&2) or 8.3.3 (TAG 6 and up) 

The booklet quality is correct.


6.2 Adjusting booklet quality (continued) 

6.2.1 Trapezium / Diamond Shape 


91 

Contents 

Make a booklet with Side Trim and check if the booklet is not Trapezium / Diamond shaped (Fig. 6.12). 

Is the Booklet size [ A = B ] (Fig. 6.12) the same as the Finished Size indicated on the display and is 

the Booklet not Diamond shaped (See corners C) ? 

Y N 

Proceed adjusting Trapezium / Diamond Shape on this and following pages. 

Continue adjusting Side Trim (Finished Size) (See Chapter 6.2.2 Side Trim (Finished Size) ) 

A B A 

B 

C 

C 

Fig. 6.12



6.2.1 Trapezium / diamond Shape (continued) 

C 

A 

Adjusting 


1 Check that the Paper stop is right angled with the Lower Knives: 

Place a square (>35cm) over the Lower knives and the Transport belts 

with one side against the Lower knife. 

See A. 

ATTENTION!!! Be very careful with hands near the Lower knives! 

And pay attention not to damage the Lower knives 

with the square!!! 

See B. 

2 Move the square along the Lower knife against the Paper stop. See C. 

3 Check if there is space between the square and the Paper stop. 

Is there is space, adjust the screws [D]. 

Check is the Paper Stop does not touch the sides of the brackets 

when the Paper Stop is pushed downwards!!! 

See D. 

4 Continue adjusting Chapter 6.2.1 Trapezium / diamond Shape 

(continued). 

See next page 


92 

B 

D 

Contents





93 

Contents 

Make a booklet with Side Trim and check if the booklet is not Trapezium / diamond shaped (Fig. 6.13) 

Is the Booklet size [ A = B ] (Fig. 6.13) the same as the Finished Size indicated on the display? 

Y N 

Proceed adjusting Trapezium / diamond Shape on this and following pages. 

Continue adjusting the booklet quality by changing the NVM values (See Chapter Adjusting NVM Values 

8.2.1 (TAG1 & 2) or 8.3.1 (TAG6 and up). 

Y 

Smaller Front size Bigger Front size 

A B A 

B 

Y 

X 

Fig. 6.13 

X 

Adjusting 


1 For adjusting the Trapezium / diamond Shape the ‘F (factor)’ should be 

determined by filling in the formula: 

Subtract booklet front size (A) from booklet back size (B) and ( B – A ) / 2 = Y 

divide the number by 2 to get value Y. 

2 Divide value (Y) by booklet length (X) Y / X = F (factor) 

3 Move wheel 1 ‘C’ number of teeth = F x 640mm / 0,25mm* Use (C) in adjustment No. 

1, 2 & 3 next page. 

4 Move wheel 2 ‘D’ number of teeth = F x 216mm / 0,25mm* Use (D) in adjustment No. 

4, 5 & 6 next page. 

NOTE: A negative number of teeth (C) or (D) means decrease A (CCW). 

Only move a full teeth = 0,25mm. If (C) or (D) < 0,5 tooth round down to 0 teeth, 

If (C) or (D) > 0,5 tooth round up to 1 tooth !!! 

Y




CCW CW Wheel 1 

Wheel 2 CCW CW 

A B A B 

Fig. 6.15 Fig. 6.16 

Adjusting 


1 Mark a tooth of wheel 1 on the tooth belt, and remove the tooth belt off 

the wheel before moving wheel 1. 

(See Fig. 6.15) 

2 Move wheel 1 ‘C’ number of teeth with respect to the marked tooth belt. (See Fig. 6.14) 

3 Place the tooth belt back on wheel 1. 

4 Mark a tooth of wheel 2 on the tooth belt, and remove the tooth belt off 

the wheel before moving wheel 2. 

(See Fig. 6.16) 

5 Move wheel 2 ‘D’ number of teeth with respect to the marked tooth belt. (See Fig. 6.14) 

6 Place the tooth belt back on wheel 2. 


94 

Contents 

When A needs to be decreased, turn CCW and the Knife blocks will move towards each other. 

When A needs to be increased, turn CW and the Knife blocks will move out of each other. 

CCW CW 

CCW 

CW 

Wheel 1 

Fig. 6.14 

1 Tooth 

CCW (Counter Clockwise) = decrease A 

CW (Clockwise) = increase A 

Wheel 2



6.2.2 Side Trim (Finished Size) 


95 

Contents 

Before making adjustments to the STR, make sure that the fault/error is not present in previous 

machines. Use their Service Manual to perform a Paper Size Check. 

Fig. 6.17 Fig. 6.18 

Fig. 6.19 Fig. 6.20 

Adjusting 


1 Make a booklet without Side Trim. 

2 Measure if the size of the booklet is conform the Size displayed 

on the UI. 

(See Fig. 6.17 & 6.18) 

If not, adjust the BM. 

3 Use the ‘▲ / ▼ ’ and the ‘+ / -‘ buttons to select and adjust the 

Side Trim / ‘Finished Size’ (e.g. 287.0mm) and press the ‘Enter’ 

button. 

4 Make a booklet with Side Trim. 

5 Measure if the Finished Size of the booklet after trimming is 

conform the Size displayed on the UI. 

6 If the measured Finished Size is the same as UI-Finished Size the 

adjustment is complete. 

If not, adjusting the NVM Values by continue chapter: 

8.2 Adjusting NVM Values 

(See Fig. 6.19 & 6.20) 

(See Fig. 6.20)


6.3 Sensors and Switches 

6.3.1 Replace Photo Sensors 


96 

Contents 

There are two different kind of Photo sensors in the STR (pay attention to the yellow squares): 

� HK12PB8 [Photo Sensor Reflex 18x120mm PB (Adj.)] (OSOR-0000-0001-0000) 

� LK89PD8 [Photo Sensor Retro-Reflex 18x120mm PD8] (OSOR-0000-0004-0000) 

During operating the STR it could happen that a paper jam appears and the STR signals an error code. 

These are easy to solve by carry out the instructions displayed on the UI and/or using the Fault Code 

Descriptions (See Chap. 5.2). 

FC1 

FC2 

FC3 

FC4 

Always open the Top Cover of the STR before clearing the paper jam. 

Outfeed 

Paper-stop sensor 

Infeed sensor 

Trim wast bin 

FC7 Trim wast bin


6.3 Sensors and Switches (continued) 

6.3.1 Replace Photo Sensors (continued) 

FC3 

FC2 

Fig. 6.21 Fig. 6.22 

FC2 

Fig. 6.23 Fig. 6.24 

Removal 


1 Open the Top Cover or Remove the Base plate Cover (See Chap. 4.7) 

2 Disconnect the orange Photo sensor cable. 

3 Remove the Photo sensor [HK12PB8] inside the STR. (See Fig. 6.21 – 6.24) 

Installation 



FC1 


97 

FC3 

FC1 

Contents



6.3.1 Replace Photo Sensors (continued) 

Fig. 6.25 Fig. 6.26 


98 

FC7 

Removal 


1 Open the Top Cover or Remove the Base plate Cover (See Chap. 4.7) 

2 Disconnect the orange Photo sensor cable. 

3 Remove the Photo sensor FC4 or FC7 [LK89PD8] inside the Base. (See Fig. 6.25 & 6.26) 

Installation 



FC4 

Contents



6.3.2 Adjusting Photo Sensors 

The Photo sensors that are used in de STR have a small 

yellow adjustment screw on the back. With the aid of a very 

small screwdriver it is possible to adjust the photo sensors. 

(Fig. 6.27) 

All photo sensors should be mounted looking straight down 

on the paper path (90º on the transport belts), HK12PB8 for 

[FC1], [FC2] and [FC3]. Or straight against the Reflection 

sticker, LK89PD8 for [FC4] and [FC7]. 

Use an unprinted paper (sheet) to adjust the Photo sensors. 

After that adjust the Photo sensor one stripe further than it 

was adjusted. Other paper colors can absorb the light which 

the Photo sensor can not see. 

Photo sensors should only see the booklet between the transport 

belts or the paper trim waste between the Reflection sticker and 

the sensor. 

A photo sensor that is set too sensitive may see something 

that is not really there. If a photo sensor is not sensitive enough 

it might not see the booklet. 

When the photo sensor light is on, there is something seen 

in his range. When the photo sensor light is off, the range is clear. 

more sensitive 

less sensitive 

Fig. 6.27 


99 

Contents



6.3.2 Adjusting Photo Sensors (continued) 

Fig. 6.28 Fig. 6.29 

Fig. 6.30 

Adjusting FC1, FC2 and FC3 


1 Open the Top Cover. 

2 

3 

4 

Place an unprinted paper (sheet) in front of Infeed and turn the 

belts to insert the paper into the STR until it lies under one of the 

Photo sensor (FC1or FC2 or FC3). 

Use a small screw driver to adjust the sensitivity of the Photo 

sensor until the light on top lights up. 

When the Photo sensor lights up, the paper is in his range. 

After that adjust the Photo sensor one stripe further than it was 

adjusted in step No. 3. 

It turns off when the paper is removed. 


100 

Contents 

(See Fig. 6.28 & 6.29) 

(See Fig. 6.30)



6.3.2 Adjusting Photo Sensors (continued) 

Fig. 6.31 Fig. 6.32 

In some STR types there can be placed 2 Photo Sensors in the Base. 

In that case there are also 2 Reflection stickers. 

Adjusting FC4 and FC7 


1 

Use a small screw driver to adjust the sensitivity of the Photo 

sensor to the maximum. 

(See Fig. 6.31) 

2 

When the Photo sensor lights beam is visible on the Reflection 

sticker, it will be reflected to the Photo sensor. 

(See Fig. 6.32) 


101 

Contents



6.3.3 Replace Switches 


102 

Contents 

Removal 


1 Remove the Front or Rear Cover or Open Top Cover. (See Chap. 4.1 or 4.2) 


3 Locate the replacable Switch by using Chap. 2.2.2 

4 Loosen the Bolts and replace the Switch. 

Installation 


1 For installation follow the Removal procedure in reversed order.



6.3.4 Adjusting Switches 

A 


103 

Contents 

Adjusting S1 


Make sure or adjust that the Paperstop Unit [A] is exactly in the !!! The distances between 

1 middle of the Kniveblock guidance [B] on both sides. 

the paper stop and plates 

(Is necessary, remove covers. See Chap. 4). 

must match exactly! 

Move the Kniveblocks inwards to the Paperstop Unit by turning the (See Chap. 2.2.5) 

2 

Tooth belt 1 on the Control Board (Clockwise = CW) until the 

distance between the LowerKnives on both side is between 198mm 

and 199mm. 

B 

A 

x 

= 

198mm ≤ x ≥ 199mm 

BOTH SIDES!



6.3.4 Adjusting Switches (continued) 

S1 

Adjusting S1 

No. Action 

Turn the Upper Knives in the position that the Cams are as close as 

Remarks 

3 possible to each other. There should be a space of 1mm between 

the Cams. 

Adjust the Switch (S1) from the Paperstop (Knife blocks Width inner 

limit switch) in the middle against the Knife block. 

(See S1) 

4 

!!! The Switch has two positions of switching (move in and move 

out). When the Switch is moving out the distance between the 

LowerKnives on both side must be between 198mm and 

199mm. 

5 Move the Kniveblocks 5mm outwards (Counter Clock wise =CCW). 

Then move the Kniveblocks inwards (CW) until the Switch is 

6 moving in. Move the Kniveblocks outwards until the switch is 

moving out and stop moving the blocks. 

Check if the distance between the LowerKnives on both side is (See no. 2) 

7 between 198mm and 199mm. Otherwise adjust Switch 1 again until 

it switched between 198mm and 199mm. 

8 Check Side Trim (Finished Size) by continuing Chap. 6.22. 


104 

1mm 

Move in / move out 

Contents




A 

C 

Click!! 

B 

D 

Adjusting S2 


1 

Adjust the distance between the roll-guide [A] and the black block 

[B] of the Linear Guide to 5mm by turning the wheel. 

(See A & B) 

Adjust the Roller of the lever Microswitch [C] against the side that (See C & D) 

2 

activated the Microswitch [Click!] and then tighten the screws [D]. 

!!! Make sure that the side of the Microswitch (with roller lever) 

does not stick out the black block (except the roller lever)! 


105 

5mm 

Contents




Click!! 

2mm C 

Adjusting S11 & S13 


Adjust the Microswitch (that when the jogger plate is retracted) the (See C) 

1 

roller lever is hit and switched. 

!!! The red ridge [C]of the Microswitch is activated [Click!] and 

approximately ± 2mm pressed! 


106 

Contents




Click!! 

Adjusting S10 & S12 


Turn the Upper Knife in the highest position. 

(See A) 

1 !!! The highest position is indicated by the black stripe on the 

Cam and Bolt [A] that should be in line. 

2 

Adjust the Actuator Plate [B] so that the Microswitch just switched 

(Click)! 

Make sure the Actuator Plate and Switch are properly adjusted by 

(See B 

3 

turning the Upper knife down and back upwards. 

!!! The Actuator Plate should switch the Microswitch when the 

Upper Knife is in the highest position (black stripe is in line). 

B 


107 

A 

Contents


6.4 Replacing / Preparing Side Joggers 

D 

Fig. 6.33 Fig. 6.34 

Fig. 6.35 Fig. 6.36 

A 

Removal/Replacing 


1 

Remove the Front or Rear Cover (depending on Replacing Side 

Jogger). 

(See Chap. 4.1 or 4.2) 

2 

Loosen nuts [A] and adjust the Guiding [B] & [C] on both sides of 

the Side Jogger bracket on equal height. 

(See Fig. 6.33 & 6.34) 

3 Tighten nuts [A] 

4 

Grease the Guiding blocks of the Side Jogger Plate on the Upper, 

Side and Lower side. 

(See Fig. 6.35) 

5 Place the Side Jogger Plate in the Side Jogger bracket (See Fig. 6.36) 

Adjust the Side Jogger Plate in the Side Jogger bracket with no (See Fig. 6.36 & 6.33) 

6 

tolerance by adjusting the bolts [D]!!! 

(DO NOT adjust the Side Jogger bracket to tight because the Side 

Jogger Plate should move in and out easily) 


108 

D 

B 

C 

Contents


6.4 Replacing / Preparing Side Joggers (continued) 

Fig. 6.37 

S11 / S13 

2mm 

D 

A 

Klik!!! 

Fig. 6.38 Fig. 6.39 

B 


109 

Contents 



Adjust the Switch S11 or S13 inside the Side Jogger bracket. When the lever is coupled 

7 

(The Switch should couple when the tooth of the Side Jogger Plate 

hits the lever of the switch.) 

[Klik!!!] the red ridge of the 

Switch is pressed for about 

2mm. (See Fig. 6.37) 

8 Disconnect Connector J7/P7 or J6/P6 [A] (See Fig. 6.38) 

9 

Disconnect Side Jogger wires P-sensor8 + P-motor8 or P-sensor7 

+ P-motor7 [B] 

(See Fig. 6.38) 

10 Loosen bolts M6 (2X) [C] (See Fig. 6.39) 

Disconnect the Side Jogger switch wires 

(See Fig. 6.38) 

11 (inside the Side Jogger bracket [D] ) : white S11-3 / S13-2 

black S11-1 / S13-1. 

12 

Remove the ‘old’ Side Jogger and continue Adjusting Side Joggers 

on the next page. 

C


6.5 Adjusting Side Joggers 

D 

Fig. 6.40 Fig. 6.41 

Fig. 6.42 Fig. 6.43 



1 Place (new) Side Jogger and DO NOT tighten the bolts M6 [C] yet. (See Fig. 6.41) 

2 Connect Connector J7/P7 or J6/P6 [A] (See Fig. 6.40) 

3 

Connect Side Jogger wires P-sensor8 + P-motor8 or P-sensor7 + (See Fig. 6.40) 

P-motor7 [B] 

A 

B 

Connect the Side Jogger switch wires 

(See Fig. 6.40) 

4 (inside the Side Jogger bracket [D] ) : white S11-3 / S13-2 

black S11-1 / S13-1. 

5 

After replacing, the Side Joggers need to be align squared 

against the Lower Knifes, therefore continue No. 6. 

6 Enter the Service Program mode (See Chapter 5.1) 

7 Use the ‘▲ / ▼’ buttons to select ‘Motors’ and press ‘Enter’. (See Fig. 6.42) 

Use the ‘▲ / ▼’ buttons to select the Motor (M7 or M8) that needs (See Fig. 6.43) 

8 to be squared against the Lower Knife, press ‘Enter’ and continue 

next page. 


110 

C 

Contents


6.5 Adjusting Side Joggers (continued) 

Fig. 6.44 

2 times 

1 time 

Fig. 6.45 Fig. 6.46 


111 

Contents 



(See Fig. 6.45) 

9 

After selecting a Motor, press the ‘In’ button 2 TIMES to move the 

selected Side Jogger forward against the Lower Knife. 

!!!DO NOT PRESS THE ‘IN’ BUTTON MORE THAN 2 TIMES!!! 

The Side Jogger move toward 

the Lower Knife and after 2 

times the Side Jogger will 

squared itself against the 

Lower Knife. 

10 Tighten the bolts M6 (2X) [C] (See Fig. 6.46) 

11 After checking press the ‘OFF’ buttons to change the Status of the 

Motor back in the ‘normal’ situation. 

12 Press 3 times the ‘ ’ button and ‘Exit’ to exit the Service 

13 

Program mode and enter the Operator mode. 

Place Front or Rear Cover. (See Chap. 4.1 or 4.2) 

14 

After adjusting the Side Joggers continue chapter ‘ 8 NVM Values’ 

to calibrate the Side Jogger correction NVM values. 

8.2.2 NVM Side Jogger 

correction 

C


6.6 Adjusting Chains and Sprockets 

Fig. 6.47 Fig. 6.48 

Fig. 6.49 Fig. 6.50 

Adjusting 


1 Remover the Motorbracket on the motor axle. 

1 

After removing the Chains place a ruler against the biggest 

Sprocket. 

(See Fig. 6.47 & 6.78) 

2 

Loosen the Adjustment screw in the smaller Sprocket and slide this 

over the axle until the Sprocket lies against the ruler. 

(See Fig. 6.49) 

3 

Fasten the smaller Sprocket by tighten the Adjustment screw with a (See Fig. 6.50) 

little bit Loctite 243. 

4 Check again if the Sprocket are in line with each other. (See Fig. 6.47) 

5 Repeat this step for the other side of the Knife Block. 


112 

Contents


6.6 Adjusting Chains and Sprockets (continued) 

Chain 04B1 74links (OMKI-0000-0007-0000) Chain 04B1 82links (OMKI-0000-0001-0000) 

SHORT LONG 

Fig. 6.51 Fig. 6.52 

SHORT 

Fig. 6.53 Fig. 6.54 

Fig. 6.55 Fig. 6.56 


113 

LONG 

Contents 

Adjusting 

No. Action 

Place the right chain on the sprockets 

Remarks 

1 

The ‘long’ chain should be placed at the side where the distance (See Fig. 6.51, 6.52, 6.53 & 

between axes of the sprockets is the biggest. 

6.54) 

The ‘short’ chain at the smallest distance. 

2 Hook the links of the chains together with a separate link. (See Fig. 6.55 & 6.56)


6.6 Adjusting Chains and Sprockets (continued) 

Fig. 6.57 Fig. 6.58 

Fig. 6.59 

Adjusting 

No. Action 

Secure the link with the Chain closure using a flat screwdriver. 

Remarks 

1 Pay attention that the Chain closure is mounted along the 

rotation direction (the ‘open-side’ should be rear-facing). 

(See Fig. 6.57 & 6.58) 

2 Make sure that the Chains are in/between the Chain tensioners. (See Fig. 6.59) 


114 

Contents


6.7 Motor and Encoder positions 

Fig. 6.59 Fig. 6.60 

Motor Encoders 

No. ENC Description Remarks 

A n/a Motor 3, Knife (See Fig. 6.59) 

B n/a Motor 4, Knife (See Fig. 6.59) 

F 8 Motor 8, Side Jogger (See Fig. 6.59) 

G 5 Motor 6, Knife width adjust (See Fig. 6.59) 

C n/a Motor 1, Knife (See Fig. 6.60) 

D n/a Motor 2, Knife (See Fig. 6.60) 

E 7 Motor 7, Side Jogger (See Fig. 6.60) 

H 6 Motor 5, Belt Propulsion (See Fig. 6.60) 


115 

Contents 

A B C D 

G 

F 

E 

H


6.8 Tapping Transformer and blown fuse conditions 

Fig. 6.61 Fig. 6.62 

Fig. 6.63 Fig. 6.64 

Purpose of tapping Transformer 

To be able to change the Transformer setting, depending on different voltages. 

Removal/Adjusting 


1 Remove Rear Cover See Chap. 4.2 

2 NOTE!: Make sure the power cord of the STR is disconnected 

from the wall outlet 

3 Measure the wall outlet voltage (120V or 230V) 

4 Check to which terminal the power cable is connected. 

See A 

(The picture shows a transformer tapped for 230V) 

5 Tap the Transformer to 120V or 230V settings according to the 

label on the Transformer by moving cable [A]. 

NOTE!: Do not move cable [B]. 


116 

Contents 

(See Fig. 6.61 & 6.62) 

6 Remove the current label ‘Disconnects only…’ (See Fig. 6.63) 

7 Paste the correct label ‘Disconnects only BLTXX02 230VAC 

50Hz’ or ‘Disconnects only BLTXX02 120VAC 60Hz’ depending 

on the wall outlet voltage. 

Included in Box with 

accessories 

(See Fig. 6.64) 

Installation 


1 

For placing back Rear Cover follow the Rear Cover procedure in 

reversed order. 

See Chap. 4.2 

B 

A


6.8 Tapping Transformer and blown fuse conditions (continued) 

F12 

Fuse Rate Symptom at power on 

F12 4AT STR no com (no response) 

F14 2AT STR no com (no response) 

F15 16AT Cover open indication 

Removal 


1 Remove Cover Left / Right See Chap. 4.2 

2 Check which symptom the machine shows 

3 Remove the blown out Fuse (Transformer [F14/ F15] or Fuse 

holder [F12]). 

Installation 




117 

F15 

F14 

Contents


6.9 Adjusting Thickness detection 

Fig. 6.65 Fig. 6.66 Fig. 6.67 

CCW = 

Trim 

thinner 

booklets 

Fig. 6.68 

Fig. 6.69 Fig. 6.70 


118 

Contents 

Adjusting 


1 Make a booklet 25 sheets 80gms and a booklet 27 sheets 80gms. 

2 

Enter the Service Program mode, select Sensors and press 2 

times Next and select Sensor ‘FC6 Thickness’ and press ‘Enter’. 

(See Chap. 5.15 & Fig. 6.69) 

3 Place the booklet 25 sheets halfway the Infeed of the STR. (See Fig. 6.65 & 6.66) 

4 

Adjust screw ‘A’ of the Thickness detection from inside the STR: 

By booklet 25 sheets 80gms the Value should be Low . 

NOTE!: Do not press to hard by adjusting screw A otherwise 

the Thickness detection is pressed backwards! 

(See Fig. 6.70) 

(See Fig. 6.67 & 6.68) 

5 Place the booklet 27 sheets halfway the Infeed of the STR. (See Fig. 6.65 & 6.66) 

6 

A 

CW = 

Trim 

thicker 

booklets 

Adjust screw ‘A’ of the Thickness detection from inside the STR: 

By booklet 27 sheets 80gms the Value should be High. 

NOTE!: Do not press to hard by adjusting screw A otherwise 

the Thickness detection is pressed backwards! 

(See Fig. 6.70) 

(See Fig. 6.67 & 6.68)

7. PCB’S 

7.1 Software download 

7.1.1 PCB1 MD6DC 


119 

Contents 

INFORMATION This procedure may delete all Job settings. Make a note of all the settings to make 

sure they can be restored after downloading. 

WARNING!!! Turn off the main power switch and unplug the machine before attempting any of the 

procedures in this section. 

CAUTION!!! Electrostatic Discharge can cause software crashes, 

data and/or communications problems or damage to 

electronic components (e.g. : PCBs). 

ESD problems can be minimized by maintaining the 

machine with ground connections, and proper handling 

of circuit boards and sensors. Use ESD Ground Strap for 

protection when working with PCBs. 

Fig. 7.1 Fig. 7.2 

PAY ATTENTION!!! The right software application can be found in by the list of Factory Settings 2- 

Side Trimmer that is present inside the Back Cover. 

Downloading 


1 

Before downloading software application make sure the list of 

Factory Settings 2-Side Trimmer is present inside the Back Cover. 

See Chap. 8.1 

2 Remove Rear Cover See Chap. 4.2 

3 Check if the dipswitches are in the right position. See Fig. 7.2 

4 

Run the right software application for the type of machine and 

follow the instructions in the program. 

5 

After downloading perform a NVM reset and insert the correct NVM 

values according to the List in the Back Cover. 

See Chap. 8.1 

7 PCB’S (continued) 

1 2 3 4 

Contents

7.1 Software Download (continued) 

7.1.2 PCB5 MD6DC 












Fig. 7.3 Fig. 7.4 

PAY ATTENTION!!! Choose the right software application by the TAG of the machine. 

Please contact Service department for more information about the software. 

Downloading 


1 



See Chap. 8.1 

2 Remove Front Cover See Chap. 4.1 

3 Check if the dipswitches are in the right position. See Fig. 7.4 

4 



5 

After downloading perform an NVM reset and insert the correct 

NVM values according to the List in the Back Cover. 

See Chap. 8.1 


120 

1 2 3 4

7. PCB’S (continued) 


7.1.3 PCB6 CPU 


121 

Contents 












Fig. 7.5 Fig. 7.6 



Downloading 


1 



See Chap. 8.1 

2 Remove Front Cover See Chap. 4.1 

3 Find out the type of Tag of the machine See Chap. 2.1.1 

4 



5 



See Chap. 8.1



7.1.4 PCB8 


122 

Contents 












Fig. 7.5 Fig. 7.6 



Downloading 


1 



See Chap. 8.1 

2 Remove UI Cover See Chap. 4.8 

3 Find out the type of Tag of the machine See Chap. 2.1.1 

4 



5 

After downloading new software it is necessary to adjust the 

Contrast setting (R41) of the LCD. 

See Chap. 7.2.2 

6 



See Chap. 8.1


7.2 LED’S & TEST POINTS 

7.2.1 Motor Drive (MD6DC) PCB1 & PCB5 

+UNREG 

D15 

D1 


123 

Contents 

This board controls the motors, encoders, 

switches and sensors connected to this 

board. 

Motor control is on a low level; e.g. servo 

and/or speed control 

D1: Yellow LED flashes when power is 

on. The flashing indicates that a 

program is present and functioning. 

Should a download fail or the 5V is 

missing, LED would be OFF. 

D2: Red LED flashes whenever 

information is sent or received on the 

Internal CAN. 

D15: Green LED permanently OFF. It has 

Fig. 7.7 no direct function in this configuration. 

VCC GND/PGND 

+UNREG: Outgoing unregulated 36V, after interlock relay. Measure between Test Point +UNREG and 

Test Point GND/PGND using a voltmeter. The voltage will be shown on the voltmeter unless: 

- Voltage is outside allowed range. Voltage will be 0V. 

- Machine is interlocked (i.e. the top cover is open). Voltage will be 0V. 

VCC: Stabilised and rectified 5V made from incoming 10V AC from transformer. 

- Measure between Test Point VCC and Test Point GND/PGND using a voltmeter. 

The voltage will be shown on the voltmeter. Range 4.9-5.1V. 

GND / PGND: Ground /Power Ground is the minus when measuring either unregulated 36V (+UNREG) or 

5V (VCC). 

D2


7.2 LED’S & TEST POINTS (continued) 

7.2.2 CPU PCB6 & PCB7 

R41 

Fig. 7.8 


124 

Contents 

Attention!!! Only for Standalone make sure the Mode Selection plug [6P13] (See Chap. 2.2.4) is 

present. Otherwise communication problems can arise. 

D5 

This board controls the machine on a higher level then the 

motor control boards. 

It also measure 36V Unreg and 24V Regulates power on the 

Interlock Board. 

D5: Yellow LED flashes when power is on. The flashing 

indicates that a program is present and functioning. 

Should a download fail or the 5V is missing, Yellow LED 

would be OFF. 

VCC: Stabilized and rectified 5V made from incoming 10V AC from transformer. 

Measure between Test Point VCC and Test Point GND/PGND using a voltmeter. The voltage will 

be shown on the voltmeter. Range 4.9-5.1V. 

GND: Ground is the minus when measuring 5V (VCC). 

R41: Trim Potentiometer for Contrast setting of the LCD. 

7.2.3 Softstart PCB4 

GND 

VCC 

This board controls the power on the machine. When the power is turned on there will 

be a very high current peak for a short while. To limit this current peak the Softstart 

PCB is used. The current peak will flow through a resistor (PTC, cold resistance 18R) 

and the start current is limited to 12,7A (230VAC/18R=12,7A). 

After about 20ms the relay will short circuit the resistor and the machine is ready to use.


7.2 LED’S & TEST POINTS (continued) 

7.2.4 Interlock PCB3 

D6 

TP1 

+UNGREG +24V 

Fig. 7.9 


125 

Contents 

This board interrupts power to the motor control boards if: 

- K2 is open because one of the Interlock switches is open 

(S3, S4, S7 or S8) 

- PCB6 has not released because: 

- 36V is outside Range 

- 24V is outside Range 

- Top Cover is open (S19 closed) 

- Trim Waste Bin is open (S9 closed) 

- K2 is not activated (contact closed) 

D6: Red LED is ON when unregulated 36V is present. If 

machine is interlocked (i.e. the Top Cover or Trim 

Waste Bin is open and 36V is cut off) or 36V is 

missing, LED is OFF. 

The unregulated 36V can be measured between 

+UNREG Test Point and PGND Test Point. 

D7: Red LED is ON when 24V is present. If machine is interlocked (i.e. the Top Cover or Trim Waste Bin is 

open) LED will still be ON. 

It will also be ON if 36V is present but not 24V. In such a case the 24V stabilizing circuit on the Interlock 

PCB would be defective. To establish that actual 24V is present, measure between +24V Test Point and 

PGND Test Point. 

D9: At power up, if all covers are closed, input power is checked to be within allowed range. If input voltage 

is too high or too low a fault is presented to the operator and machine will be inoperable. If the input 

voltage is within allowed range, and all covers are closed, the interlock relay is activated. 

When interlock relay is activated the LED D9 is ON. Relay will only close if Interlock switches are also 

closed. If an interlock relay fault is detected, that is presented to the operator and machine will be 

inoperable. 

During normal operation the LED D9 is ON when covers are closed. If a cover is open LED D9 is OFF. 

Note that the fault codes are only visible in operator mode. 

TP1: Incoming unregulated 36V, before interlock relay. Measure between Test Point TP1 and Test 

Point PGND using a voltmeter. The voltage will be shown on the voltmeter regardless of the 

voltage being outside allowed range 29-43V. 

+UNREG: Outgoing unregulated 36V, after interlock relay. Measure between Test Point +UNREG and 

Test Point PGND using a voltmeter. The voltage will be shown on the voltmeter unless: 

- Voltage is outside allowed range 23-43V. Voltage will be 0V. 

- Machine is interlocked (i.e. the top cover is open). Voltage will be 0V. 

+24V: Stabilised 24V made from incoming unregulated 36V, before interlock relay. 

Measure between Test Point +24V and Test Point PGND using a voltmeter. The voltage will 

be shown on the voltmeter. Range 23-25V. 

PGND (TP2): Power Ground is the minus when measuring either unregulated 36V (+UNREG) or 24V (+24V). 

8. NVM Values 

PGND (TP2) 

D7 

D9 

Contents

8.1 Current NVM Values 

Fig. 8.1 

Inside the Back Cover of the STR there is a sheet with the Factory Settings 2-Side Trimmer (Fig. 8.1). 

After changing any NVM Values please note the adjustments on that sheet. 

Before checking the current NVM Values make sure the SerialNr on the sheet matches the 

one on the sticker PartNr: OGMO-0000-0XXX-0000 inside the STR. 

Fig. 8.2 Fig. 8.3 


1 Enter the Service Program mode. (See Chap. 5.1) 

2 Use the ‘▲ / ▼’ buttons to select ‘NVM’ and press the ‘Enter’ button (See Fig. 8.2) 

3 Use the ‘▲ / ▼’ buttons to select the different type of ‘NVM’ Values 

and press the ‘Enter’ button 

4 Press the ‘ESC’ or ‘ ’ button to exit the Service Program mode 

and enter the Operator mode. 


126 

(See Fig. 8.3)

8. NVM Values (continued) 

8.2 Adjusting NVM Values 


127 

Contents 

The following table and figure is for support of this chapter. 

The table explains which NVM is coupled to which Motor and what the result is of higher or lower 

the NVM value of the concerning Motor. 

Use the following table and figure to get a better view by what will happen during adjusting the 

NVM values in the next chapters. 

NVM ID Motor Position 

Values 

Min. Max. Def. Use. 

0 Counter Total Counter - 0 0 0 0 

1 Motor 6 

Home Position (See Fig. 8.10) 

+ : Smaller Finished size 

- : Larger Finished Size 

Infeed Position (See Fig. 8.10) 

Lower 

Right 

1800 2050 1990 1990* 

2 Motor 7 + : More Infeed Space 

- : Less Infeed Space 

Compress Correction (See Fig. 8.10) 

Left 400 500 485 485 

3 Motor 7 + : More Compression / Less Trimming 

- : Less Compression / More Trimming 

Infeed Position (See Fig. 8.10) 

Left 900 1100 1000 1000 

4 Motor 8 + : More Infeed Space 

- : Less Infeed Space 

Compress Correction (See Fig. 8.10) 

Right 400 500 485 485 

5 Motor 8 + : More Compression / Less Trimming 

- : Less Compression / More Trimming 

Right 900 1100 1000 1000 

**Recommend to use values < 2000 

Fig. 8.9 

Fig. 8.10 

2 

3 

1 4 

5


8.2 Adjusting NVM Values (continued) 

8.2.1 NVM Booklet width correction 


128 

Contents 

When switch ON the STR the Knife Blocks will move to the centre of the machine until the mechanical limit 

switch (S1) is activated. Than the Knife Blocks will move out of each other, release the switch. At this point 

the distance between the Lower Knifes x10 should be conform the NVM No. 1 Motor 6 Home Position. After 

that the Knife Blocks will move further to the adjusted Finished Size. 

It can occur that the booklet width is not conform the Finished Size on the UI display. Therefore the Booklet 

width, also called Finished Size, needs to be changed. By adjusting the NVM No. 1 Motor 6 Home Position 

the distance between the Lower Knives can be in -or decreased. 

Before making adjustments to the STR, make sure that the fault is not within the previous machine. 

Use the Service Manual of the previous machine to perform a Paper Size Check. 

1.Make an A3 booklet with Side Trim, measure the booklet Finished Size and compare with Finished Size 

on UI-display. Is the booklet Finished Size the same Finished (Trim) Size shown on the UI display? 

Y N 

Insert the measured Finished Size in the following formula: 

“new wished NVM No. 1 Home Position” = (“current NVM No. 1 Home Position”+ 

(“current Finished Size on UI display” - “measured Finished Size”) x 10). 

When A needs to be increased, fill in the formula and higher the NVM according to the result. 

When B needs to be decreased, fill in the formula and lower the NVM according to the result. 

Change the current NVM No. 1 Motor 6 Home Position in the “new wished NVM No. 1 Motor 6 

Home Position. 

Proceed back to step 1. 

Proceed to chapter 8.3.2 

Fig. 8.11 

A B



8.2.2 NVM Side Jogger correction 

NVM Side Jogger correction is a value that influence the positioning of the booklet. 

The booklet can be Side Joggered on both sides (Motor 7 and Motor 8). For each side there 

are two NVM values that can be adjusted: Infeed Position and Compress Correction. 

NVM Infeed Position 

NVM Infeed Position (NVM No. 2 Motor 7) & (NVM No. 4 Motor 8) is the distance 

between the Side Jogger and the Lower Knife in millimeters x10. 

This ‘default’ distance (485) is determined by moving the Side Joggers back against the 

mechanical switch S11 & S13 and divided by 10 (485 :10 = 48,5mm). The results is the 

‘home’ position of the Side Jogger in respect of the Lower Knife (See Fig. 8.9 [2] & 8.10 [4]). 


129 

Contents 

Motor 7 / 8 

This NVM value is set to default and should never be adjusted as it is not 

important for the actual Finished Size. 

Motor 8 / 7 

Fig. 8.12 

NVM Compress Correction 

NVM Compress Correction (NVM No. 3 Motor 7) & (NVM No. 5 Motor 8) is an offset value to repeal 

mechanical deviations and used to align the booklet. A value of 1000 has been added to the NVM values 

because the software can not handle negative numbers. With respect to the default value there can added 

an offset of -100 to +100 and with that the NVM value can be adjusted to compress the booklet more or less. 

For example : to adjust the correct NVM Compress Correction value the distance to the Lower Knife needs to 

be known. For that, determine the Paper Size Width (297mm) - the Finished Size (267mm), divided by 2 = 

(15mm) the distance to the Lower Knife for each side and that is equal to a Side Trim of 15mm per side with 

an offset of zero (See Fig. 8.12). 

NVM Infeed Postions No. 2 & 4 are determined at 485 (48,5mm). But because of mechanical deviations 

NVM No. 3 & 5 are build in to prevent the Compress Correction. Theoretically the distance to the Lower 

Knife for the Compress Correction is 48,5mm - the Side Trim of 1 side (15mm) = 33,5mm (335). 

To determine if there is an Offset subtract ‘the value of 1000’ from the current NVM No. 3 or 5 (1020) = 1020 

- 1000 = 20. A NVM value of 1 is equals to 0,1mm, which means in this case there is an Offset of 2mm. 

If a Side Trim of 15mm or 150 NVM per side is wished, but due to mechanical deviations an Offset to correct 

is necessary. In that case there is a Trim Waste of 150 - 20 Offset = 130. Before making an adjustment the 

space between the Side Joggers and the booklet was corrected with an Offset of 20. 

Fig. 8.13 Fig. 8.14 

No. Action 


2 Use the ‘▲ / ▼ buttons’ to select ‘Calibration’ and press the ‘Enter’ button. 

3 Choose the selected ‘Motor7 Compress Correction’ and press the ‘Enter’ button.



8.2.2 NVM Side Jogger correction (continued) 

Fig. 8.15 Fig. 8.16 

No. Action 

4 Choose the selected ‘Calibration Length’ and press the ‘Enter’ button. 


130 

Contents 

5 Press ‘Start’ to start the Calibration. 

After starting the Calibration function the Side Joggers move in and out, the Knife Blocks will 

move to the right Papersize, and the Transportbelt will run. 

A 

1. Send an A4 booklet of 4 sheets A3 (by preference 80grams). 

2. Check if the Side Joggers hits the booklet. 

The Side Joggers compress the booklet correctly when Side Joggering (max. 0,5mm tolerance)? 

Y N 

Add to NVM Compress Correction No.3 of Motor 7 and No.5 of Motor 8 approximately the missing 

distance in mm of the booklet x5 to both parameters. 

For Tag 6 and up: Use the ‘+ / -‘ buttons to set a NewValue(Dec) and press the ‘Save’ button. 


The booklet is NOT pressed too hard that it is bulging during Side Joggering and moves back after it is 

released. 

Y N 

Booklet is pressed too hard, decrease NVM No. 3 Motor 7 and No. 5 Motor 8. 

(Pressing the booklet to hard is so much the worse case than pressing to less) 

For Tag 6 and up: Use the ‘+ / -‘ buttons to set a NewValue(Dec) and press the ‘Save’ button. 


Press ’Stop’ to end the Calibration mode and ‘ ’ for exit the Calibration menu. Proceed to chapter 8.3.3




131 

Contents 

8.2.3 NVM Centering correction 

NVM Centering correction is a value that influence the centering of the booklet in de machine. 

The Centering correction of booklet can be adjusted with NVM Value No. 3 & 5 Compress Correction. With 

that both sides of the booklet are Side Joggered but the NVM values of the Side Joggers (Motor 7 and Motor 

8) differs. 

Fig. 8.17 

When changing a NVM value on the Right side of the machine, change the Left side of the 

machine the exact opposite of that value. 

When changing a NVM value on the Left side of the machine, change the Right side of the 

machine the exact opposite of that value. 

1. Empty the Trim Waste Bins of the STR 

2. Send an A4 booklet of 5 sheets A3 with a Side Trim of 267,0mm and Center Offset 0,0mm 

3. Measure the Trim Waste of both Bins. Are the Trim Wastes of both Bins the same Size (width)? 

Y N 

Add 5 times the difference in mm to the Compress Correction NVM value of the side that has the 

biggest width, subtract 5 times the difference in mm from the Compress Correction NVM value of 

the side that has the smallest width. (See Chap. 8.3 Fig. 8.9) 

The STR is fully adjusted. 

More Compression means less Trimming, less Compression means more Trimming 

Write down the adjusted NVM values on the list in the Top Cover. 

- 

+ 

+ 

-




132 

Contents 

8.2.4 NVM Stop if booklet too thick 

(Available from Software version SEML-0000-XXXX-V104 and up) 

NVM ‘Stop if booklet too thick’ is a value to set a warning for the Operator when a booklet is to thick to trim. 

There are 3 different warnings adjustable, which are: 

Value 1 (STR002) Value 2 (STR003) Value 3 (STR108) 

Booklet too thick! not trimmed Booklet too thick Booklet too thick 

(WARNING NO STOP: only (SOFT STOP: booklet (HARD STOP: booklet still 

message in UI display) transported outside the machine) inside the machine) 

Fig. 8.18 Fig. 8.19 Fig. 8. 20 

Change Operator Warning 

Fig. 8.21 Fig. 8.22 

Fig. 8.23 

No. Action 


2 Use the ‘▲ / ▼’ buttons to select ‘NVM’ and press the ‘Enter’ button. 

3 Use the ‘▲ / ▼’ buttons to select NVM 6 Stop if booklet too thick and press the ‘Change’ button. 

4 Use the ‘+ / -‘ buttons to set a NewValue(Dec) 1, 2 or 3 (See options above) and press the ‘OK’ 

button. 



8.3 Reset NVM Values 


133 

Contents 

If minor logic problems arise the NVM Reset procedure can be initiated. All data in the PCB will be cleared 

except the number of the Total Counter. 

Fig. 8.24 Fig. 8.25 


1 Enter the Service Program mode. (See Chap. 5.1) 

2 Use the ‘▲ / ▼’ buttons to select ‘NVM’ and press the ‘Enter’ button (See Fig. 8.24) 

3 Press the ‘ResetAll’ button, insert the correct NVM values according 

to the list of Factory Settings 2-Side Trimmer in the Back Cover, 

and confirm with the ‘Yes’ button. 

4 Press the ‘ESC’ or ‘ ’ button to exit the Service Program mode 

and enter the Operator mode. 

(See Fig. 8.25) See Chap. 8.1

9. Maintenance 

9.1 Preventive maintenance table 

If any of the checkpoints area’s or other parts show indication of wear at any point, replace the parts. 

When parts need a new lubrication, clean the surface if necessary before applying a new lubricant. 


134 

Contents 

The STR requires a minimum of 400mm of additional floor space on the back side for installation, operation 

and maintenance. 

Run the Checkpoints STR at an interval of 250.000 sets. 

Symbol key: C = Cleaning, I = Inspect, L = Lubricate, R = Replace, W = Wipe 

Checkpoints area’s STR after 250.000 sets Checkpoints NOTE 

Paper path C Dry Cloth / Brush 

Sensors C Dry Cloth / Brush 

Transport module I Inspect 

Upper belt (1x) W Moister Cloth 

Lower belt (3x) W Moister Cloth 

Trim knives I Inspect 

Knives (L+R) I Inspect 

Knife guiding blocks L / I Grease 

Protection plate knife guidance L / I Grease 

Knife chains L Oil 

Knife sprockets L Oil 

Side Jogger guidance L Grease

9. Maintenance (continued) 

9.2 Schematics 

9.2.1 DTEO-0000-0121-0000 

9.2.2 DTEO-0000-0142-0000 

9.2.3 DTEO-0000-0143-0000 


135 

Contents

10. Technical Information 

Capabilities: 

Compatibility: Online STR: 

Capacity: Up to 25 sheets 

(80 g/m 2 , 100 pages booklet) 


136 

Electrical: 

Contents 

Power source: from Booklet Maker 

50Hz: 220/230V, 2.0A 

60Hz: 220/230V, 2.0A 

Physical: 

Operational On Pallet in box 

Height ≈855 mm 1440 mm 

Width 740 mm 760 mm 

Depth 700 mm 1410 mm 

Weight ≈215 Kg ≈257 Kg 

60Hz: 100/110/120/127V, 4.0A 

(upon request) 

The 2-Side Trimmer should only be connected 

to an approved electrical system which is rated 

at a maximum of 16A and which is protected by 

circuit breakers. 

Booklet specifications 

before trimming: bypass: trimmed: 

Minimum booklet height: 204 mm 150 mm 200 mm 

Maximum booklet height: 340 mm 320 mm 320 mm 

Maximum booklet thickness 5 mm 

Technical specifications 

Speed 1800 booklets/hour 

Trimming size (min-max) 2mm - 35mm each side 4mm - 70mm together 

Paper Weight (min-max) 60 g/m2 - 300 g/m2 Note: on booklets from about 

20 sheets or more, always use 

coversheets from 120 g/m 2 or 

higher to prevent possible 

deviations (like crinkles) on the 

booklet. 

A-symmetrical trim (min-max) ±15mm 

Input / Output sheets Booklet Width (X) from 50 mm Note: Heights between 320 

up to 245 mm 

mm and 340 mm must be 

Booklets Height (Z) 204 mm trimmed back to 320mm or 

up to 340 mm 

shorter. 

Booklet Staple Clearance from 

top/bottom (minimal) 

40mm 

Noise Level (max) 70dB

PAGE INTENTIONALLY BLANK 


137

continued - Ernst Nagel GmbH

Create successful ePaper yourself

Delete template?

Save as template?