MyBinding Graphicwhizard 3000 12000 Service Manual User Graphic Whizard

User Manual: MyBinding Graphicwhizard-3000-12000-Service-Manual

Open the PDF directly: View PDF .
Page Count: 49

Provided By

http://www.MyBinding.com

http://www.MyBindingBlog.com

Graphic Whizard

3000/12000

Service Manual

21-2283 Argentia Road, Mississauga, Ontario Canada L5N 5Z2; Tel: (905) 858-7663 Fax :(905) 858-4419 Toll Free 1-8 00-265-3376

Website: www.graphicwhizard.com Email: contact@graphicwhizard

SERVICE MANUAL

VERSION 1.0

- 2 -

TABLE OF CONTENTS

Technical Highlights 3

1.0 Specifications 5

2.0 GW Junior 6

2.1 GW Junior Circuit Board Values 6

2.2 Troubleshooting 7

2.3 GW Junior Parts Diagram 7

3.0 GW 3000 Operation 8

3.1 Running a Job 8

3.2 Stopping a Job 8

3.3 Clearing a Job 9

3.4 Changing and Programming a Job 9

3.5 Error Codes 10

4.0 GW 6000 Operation 11

4.1 Running a Job 11

4.2 Stopping a Job 11

4.3 Clearing a Job 12

4.4 Changing and Programming a Job 12

4.5 Speed Control 13

4.6 GW 6000 Software Set-up and Diagnostics 13

4.7 Overview 13

4.8 Individual Items 14

4.9 GW 6000 Error Codes 17

5.0 GW 8/12000 Operation 18

5.1 Running a Job 18

5.2 Stopping a Job 20

5.3 Changing Programs 20

5.4 Programming a Job 21

5.5 The Batch Function 23

5.6 The Repeat Function 24

5.7 Motor Speed Control 24

5.8 GW 8/12000 Software Set-up and Diagnostics 25

5.9 Overview 25

5.10 Individual Items 25

5.11 GW 8/12000 Error Messages 29

6.0 Circuit Boards Layout and Diagnostics 30

6.1 GW 3/6000 Circuit 30

6.2 GW 8/12000 Circuit 31

6.3 GW 3/6/8/12000 Circuit Diagnostics 32

7.0 GW Parts List 38

8.0 Parts Diagrams 43

8.1 Feed Tray Assembly 43

8.2 Exit Tray Assembly 43

8.3 GW 3/6/8000 Operator Side 43

8.4 Electric Solenoid Drive Unit 44

8.5 Pneumatic Solenoid Drive Unit 44

8.6 Accessory Holder 45

8.7 Blade Placement on Boss Wheel 45

8.8 GW 12000 Feed Drive Components 45

8.9 GW 12000 Structural Parts Diagram 46

8.10 GW 3/6/8000 Shaft Placement 46

8.11 Conveyor Outfeed Assembly 47

- 3 -

TECHNICAL HIGHLIGHTS

Many of the benefits of our product design, construction, and materials details are not indicated in our product

literature. Obviously these details are important facts which are critical to a full understanding of our equipment

We build what we feel is the best equipment available. We take great pride and satisfaction in the knowledge that we

offer true value and performance to every customer. Our users consistently comment on the durability, ease of use

and versatility of their machines.

Their positive reactions are no accident. Listed below are the reasons.

< Feed System- we use a feed system on all our automatic machines unlike any other. The stock is fanned

forward so that the lead sheet only touches the feed tires. There is a complete lead edge retarding strip that will hold

back following sheets. We use three feed tires evenly spaced along the lead edge (the two outside tires 12" from the

edge of the stock and the third in the middle) of the page for a more consistent, straight paper feed. The pressure of

the feed tires needs only be enough that you feel a slight resistance between the stock and feed tires. This feed

system provides consistent feeding with drastically less problems of skewing, kicking, marking, scuffing and double

feeding of your stock.

< Head Driver- we are unique in the way we propel our numbering heads to the paper. We refer to it as inertia

drive. Whether using our solenoid or pneumatic drivers, there is no direct coupling of the numbering head and the

driver. The driver stroke is shorter than the head's travel to the paper. The driver has been specifically engineered to

produce rapid acceleration, impact the numbering head under inertia, and immediately release. With the inertia from

the driver, the numbering head is propelled to the paper, makes an impression on the paper and is free to return after

hitting the platen. The result is a clean and clear number. Think of it as throwing a ball against the wall and having it

bounce back rather than pushing the ball into the wall. The further benefit to this method is the reduced wear and tear

on the head frame, components, wheels etc. Resulting in longer head life.

 Electronic Impression Control- microprocessor and digital control in all our models allow us to control, with

great precision, the time for which we energize our drive. This allows us to impart more or less inertia to the head

depending on how much of the stroke we energize for, thus controlling the strength of our numbering head crash.

Simply put, the longer we accelerate for, the faster we go, the harder we hit.

 Solenoid Design- just look at one. The totally enclosed, tubular design creates the most efficient, complete

magnetic flux path providing the maximum energy output and optimum efficiency. The moving plunger is coated with

molybdenum disulphide, an anti friction coating used in jet airplane engines.

 Numbering Head- the standard numbering head offered is an all steel numbering machine manufactured by

Reiner Gmbh & Co. in Germany. It has been our head of choice since the beginnings of our machine design ten years

ago and has proved so reliable that two of our competitors subsequently chose the same supplier's numbering head

for use in their machines.

 Drive Unit Mount Assembly- thick, stiff and durable. The first of our many "never replaced due to a failure"

parts

 Shafting- all the turning shafting in our products is made from a special high tensile strength steel which offers

the strength, rigidity, resistance to deflection, and a number of other critical mechanical properties normally available

only on shafting of significantly larger diameter. The shafting is supplied "centerless ground” to exacting

specifications measured at one half of one thousandth of an inch (0.0005"). Once machined to its final dimensions.

We straighten the shafting to within one thousandth over its length to ensure consistency and accuracy in perforating

scoring or slitting operations. The shafting is also plated with a very hard skin of chromium to prevent corrosion and

marking from setscrews. This shafting has proved so durable that we have never replaced a shaft on any unit

due to wear or fatigue.

 Bushings- the shafts are supported in the machine and spin within oil impregnated bronze bushings. These

automatically release oil to the shafting as required. They are stressed in the unit at less than 30% of their rated load.

The bushings have proved so durable that we have not yet replaced one as failed in the field.

< Framework- once again we take the stand that, enough is not enough. As with the balance of the machine,

technical testing is carried out and the results used to choose materials. In this case, we use materials rated at triple

the rated requirements. We have never experienced the failure of a frame component. We tie all the parts

together with rigid cross shafts. On our two larger models, we weld the stand out of heavy section angle rather than

making it out of stamped thin steel. The result is quieter, more solid running equipment.

< Rollers- all are solid urethane. Impervious to cleaning chemistry, chemicals in the paper (such as the ones in

carbonless paper), and whatever else may contact them. They are also capable of being machined to more precise

tolerances, are more resistant to abrasion, and quite simply last longer. While we do encounter normally expected

wear on the feed tires, the main rollers are another of our "never replaced" parts.

< Electronics- so reliable we back them for five years (see our warranty for details). Enough said. If one

ever fails, the self-diagnostic features identify the problem and allow full details to the technician by phone. The

problem is immediately identified and correction can be carried out without requiring a service call. Exchanging the

circuit boards has also been made simple enough that a technician may not be required. Of course, with our network

of dealers across the country, help is never more than a phone call away.

< Drive Train- all drive components are metal. The main timing belt is steel reinforced. The motors are

brushless. All require no maintenance.

This listing could continue and provide you with every little detail we've sweated over while designing and building

your machine. We can (and will if you ask) tell you about gold plated contacts, idc type connectors, and a host of

other things. It's your right to know that you are getting your money's worth!

Our final word here is to tell you what we don't do. Quite simply, we don't add cosmetic features, which have no effect

on performance and add only to cost. We don't stand still and we continue to evolve the products based on

experience and field comments. We redesign with our existing customers in mind and make all future enhancements

retrofitable to the first machine we built. We don't run down our competitors and their products, we strive to stay a few

steps ahead of them. We know that if you really look you will recognize the value in our products.

We sincerely appreciate your interest and your time reading through this note.

Please contact your local dealer or us if you require any further details.

- 4 -

1.0 SPECIFICATIONS

GW Junior

Tabletop, footpedal operated numbering machine, standard forward head.

GW 3000

Programmable for a single hit per sheet per head, auto feed

numbering/perforating/scoring system, single speed of 3000 sheets per hour, maximum

of two numbering heads; optional conveyor outfeed and stand.

GW 6000

Programmable for up to 10 hits per sheet per head, auto feed

numbering/perforating/scoring system, three speeds of up to 6000 sheets per hour,

maximum of two numbering heads; optional conveyor outfeed and stand.

GW 8000

Programmable 100-job memory for up to 100 hits per sheet per head, auto feed

numbering/perforating/scoring system, batching capability, variable speeds of up to

8000 sheets per hour, maximum of four pneumatic numbering heads, optional conveyor

outfeed.

GW 12000

Programmable 100-job memory for up to 100 hits per sheet per head, auto feed

numbering/perforating/scoring system, batching capability, variable speeds of up to

12000 sheets per hour, maximum of four pneumatic numbering heads, conveyor

outfeed, optional air feed.

FinishMaster 100

Table top, autofeed perf/score/slit system, up to 10,000 sheets per hour, optional

conveyor outfeed and stand.

FinishMaster 150

Autofeed perf/score/slit system, up to 20,000 sheets per hour; optional air feed.

Paper weight: 12# - 12 point (45-250 gsm)

Paper formats: max. 18” x 18” (45 x 45 cm)

min. 3” x 5” (7.6 x 12.7 cm)

Electrical configuration:

Voltage: 90-135 VAC or

180-270 VAC

Frequency: 60 Hz or

50 Hz

- 5 -

Fusing: 115/250V, 3/5A

2.0 GW JUNIOR

2 Pin Impression

Control Connector

(harness: 20-015-GW)

6 Pin Connector

20-013-GW

MODULAR SWITCH

W/FUSEHOLDER

90-062-GW

SOLENOIDS

FOOTPEDAL

BLUE

BLUE

BROWN

25-012-GW

Impression Control

Potentiometer

Model J-1 Circuit Board

654

321

GREEN

BROWN

BLUE

2.1 GW Junior Circuit Board Values

On the Circuit Board (refer to diagram), there is a 6 Pin Main Connector (male). Numbering the

pins as follows, 6;5;4;3;2;1, from the wires you will have the following values:

1&6 -Power -you should then read the line voltage to the circuit (VAC).

2&3 -Footpedal -by pressing the footpedal, you will see the resistance change as

the line opens and closes.

4&5 -Solenoid -the solenoid resistance value will be approximately 40Ω (ohms).

On older machines, this value may range from 40 to 90Ω.

- 6 -

2.2 Troubleshooting

If you do not have a line voltage reading from pins 1&6, there is a break in the line and repairs are

required. First check the main fuse, then trace back the line for breaks.

If there is no resistance reading from the Solenoid, replacement is required of both the Solenoid and

Circuit Board. Once the Solenoid shorts, the Circuit Board will then have a short somewhere on the

real estate.

If there is no reading variation from the Footpedal, check the line for breaks. There may not be

correct contact at the Footpedal's contact point if there are no breaks in the line. Remove the two

side screws from the footpedal, but carefully because the top is sprung. The contact point will now

be exposed. There may be corrosion or dirt at the contact point. With very fine sandpaper, clean the

points reassemble and test. If after the above is performed and you still do not locate the problem,

the Footpedal may require replacement

In the bottom right of the Circuit Board is a 2 Pin Impression Control Connector. This connects to

the Impression Control on the Operating Panel. Make sure that the Impression Control is not

completely counter-clockwise, as this may close the circuit. As well, the Impression Control

Potentiometer on the circuit board is used to change the Impression Control range according to the

line voltage, and again it should not be fully counter-clockwise.

2.3 GW JUNIOR PARTS DIAGRAM

10-011-GW

10-054-GW

20-010-GW

10-053-GW

10-052-GW

10-043-GW

10-044-GW

25-009-GW

20-003-GW

20-002-GW

10-040-GW

10-040-GW

20-005-GW

25-004-GW

10-041-GW

10-042-GW

- 7 -

3.0 GW 3000 OPERATION

PHOTOCELL

IMPRESSION

CONTROL

SET

FWD CLR

BWD

H1

SAFETY

H2

STOP

START

The operating keyboard is comprised of various buttons and a Impression Control which

consist of one potentiometer knobs that control the crash strength of the numbering heads, and can be

adjusted to best suit the requirements of the job. For example, you may require stronger crash

numbering for carbonless sets than for single sheet bond paper. This adjustment can be done while the

machine is stopped or running.

The four buttons under the LED display will perform whatever function is shown directly on them.

SET/FWD – Is used to set up a numbering job and incrementing the motor in a forward direction.

CLR/BWD- Is used to clear programs and increment the motor backwards.

H1- Is used to control head number one which is the head closest to the operator.

H2- Is used to control head number two which is the head furthest away from the operator.

START – Is used to start the machine.

STOP- Is used to stop the machine.

Once you have plugged the machine in, turn the on/off switch to the 'on' position. The LEDs

will flicker and then stop. The GW 3000 does systematic error checks, if it detects an error the LEDs

will remain flickering, count the number of flickers and compare with the list of all possible error

codes.

3.1 Running a Job

The machine is capable of storing a 1 job 1 hit for recall and future use. Ensure that there is

paper in the feed tray first. Pressing the 'START' button will automatically begin the program that was

previously programmed in the memory.

3.2 Stopping a Job

There are two methods of stopping the machine.

1. Once the program is running, pressing the 'STOP' button will cause the machine to finish the

stock it is currently working on, move the next stock into the starting position and then stop the

motor.

2. If you want to stop the machine while stock is still left in it, simply hold on to the stock in the

feed tray. After about one second, the machine will automatically stop (since it is no longer

seeing any new sheets). This is how it also stops when all of the stock in the feed tray is gone.

3. Pressing any of the other buttons will stop the machine defaulting the machine to its idle mode.

- 8 -

3.3 Clearing A Job

To completely clear a program from the memory insert a paper in the feed tray. Press the

SET/FWD button. The paper will then feed through and stop at 75. Press the CLR/BWD button and

hold it down, next press the H2 button and this will clear the memory of the previous job.

You can now run just a perf/score/slit job by pressing START.

3.4 Changing and Programming a Job

The following describes Mode - Program Setup operation:

• Loads a new sheet of paper, regardless if paper is already in the machine or not.

• Paper is loaded into the machine at “Setup Paper Speed” and stops at “Paper Position Stop”.

• Motor advances in single steps, or continuously at Setup Paper Speed using the <FWD> and

<BWD> keys. The motor stops when the key is released.

• Motor operation will stop while holding down either of the <FWD> and <BWD> keys once

the existing programmed hit location is reached. Another key-down <FWD> or <BWD> must

be detected before moving off of the hit position.

• Heads fire according to the current program (i.e. when the sheet reaches the hit position), or

when the <H1> and/or <H2> key is pressed.

• <H2> can only be fired once <H1> is programmed at the same hit location. <H1> must be

fired first, followed by <H2>. Pressing <H2> without having first programmed <H1> does

nothing.

• If <H1> / <H2> is pressed at a current hit position, the head to fire will be toggled ON/OFF.

Pressing <H1> toggles ON/OFF SOL1, pressing <H2> toggles ON/OFF SOL2 when SOL1 is

programmed.

• If <H1> and <H2> are both programmed at the hit position and <H1> is removed, the <H2> hit

data is automatically removed from the solenoid program.

• If a solenoid head error is reported, hit data may still be programmed and saved.

• Creation of hit data can be performed at any paper position. If the solenoid is fired at a new

position, followed by pressing the <START> key, any existing old hit data will be overwritten

and the new position and hit data saved.

• When the <START> key is pressed, the changes to the program are saved to the EEPROM, the

current sheet is ejected, and the next sheet is loaded to “Paper Position Stop”.

• If the <STOP> key is pressed, any changes made during Setup are aborted and the solenoid

program will be re-loaded from EEPROM. The exception is if a EEPROM error exists, then

the solenoid program workspace in RAM will remain intact.

1. The following are the Mode - Program Setup (solenoid program) constraints:

• There is a maximum of 1 hit position in a program.

• SOL2 can only be enabled when SOL1 hit data exists, otherwise <H2> key presses will be

ignored.

• Modification of existing hit data can only occur while at the hit position.

• The user shall not be allowed to step backward past “paper stop position”

• The perf shield shall be closed before entry to Mode - Program Setup.

• An open perf shield condition with paper loaded disables the motor and solenoid operation

until the perf shield is closed.

- 9 -

3.5 Error Codes

ERROR/BLINK

NUMBER ERROR

CONDITION CONDITION

01 PAPER JAM • Paper has lodged itself above the photocell and beneath the

reflector.

 Remove paper sideways- do not pull up against the reflector.

• Dust has accumulated over the photocell.

 Blast the groove below the reflector with air.

• Photocell needs readjustment.

02 CH 1 OPEN • Head #1 is not plugged into channel #1.

03 CH 1 SHORT • The solenoid has failed and replacement is necessary.

04 CH 1 HOT • Machine has been running for a while, and the solenoids

have heated up.

 Turn the machine off to allow the head to cool down.

05 CH 2 OPEN • Head #2 is not plugged into channel #2.

• The program being ran is using two heads and there is only

one drive unit.

 Reprogram using Head #1.

06 CHANNEL 2 SHORT • The solenoid has failed and replacement is necessary.

07 CHANNEL 2 HOT • Machine has been running for a while, and the solenoids

have heated up.

 Turn the machine off to allow the head to cool down.

08 AC LINE VOLTAGE OUT OF

OPERATION RANGE

• Check line voltage.

09 MOTOR VOLTAGE OUT OF

RANGE

• Motor has been running for a while and needs cooling down.

• MSTP board needs replacing.

10 EEPROM ERROR • A component problem has occurred.

- 10 -

4.0 GW 6000 OPERATION

PHOTOCELL

SAFETY

SET

FWD CLR

BWD

H1 H2

IMPRESSION

CONTROL

START

STOP

The operating keyboard is comprised of six LED segments, various buttons and a Impression

Control which consist of one potentiometer knobs that control the crash strength of the numbering

heads, and can be adjusted to best suit the requirements of the job. For example, you may require

stronger crash numbering for carbonless sets than for single sheet bond paper. This adjustment can be

done while the machine is stopped or running.

The four buttons under the LED display will perform whatever function is shown directly on

them.

SET/FWD – Is used to set up a numbering job and incrementing the motor in a forward direction.

CLR/BWD- Is used to clear programs and increment

the motor backwards.

PHOTOCELL

SAFETY

SET

FWD CLR

BWD

H1 H2

IMPRESSION

CONTROL

START

STOP

H1- Is used to control head number one which is the

head closest to the operator.

H2- Is used to control head number two which is the

head furthest away from the operator.

START – Is used to start the machine.

STOP- Is used to stop the machine.

Once you have plugged the machine in, turn the on/off switch to the 'on' position. The LED

display will be blank for a second the two lights for the safety lid and photocell will light up. The

system will do a check on each LED line segment and then look like the above.

The Sprint 6000 does systematic error checks, if it detects an error it will display a numeric

value.

4.1 Running a Job

The machine is capable of storing a maximum of 1 job with 10 hits for recall and future use.

Ensure that there is paper in the feed tray first. Pressing the 'START' button will automatically begin

the program that was previously programmed in the memory.

4.2 Stopping a Job

There are two methods of stopping the machine.

1. Once the program is running, pressing the 'STOP' button will cause the machine to finish the

stock it is currently working on, move the next stock into the starting position and then stop the motor.

- 11 -

2. If you want to stop the machine while stock is still left in it, simply hold on to the stock in the

feed tray. After about one second, the machine will automatically stop (since it is no longer seeing

any new sheets). This is how it also stops when all of the stock in the feed tray is gone.

4.3 Clearing A Job

To completely clear a program from the memory insert a paper in the feed tray. Press the

SET/FWD button. The paper will then feed through and stop at 75. Press the CLR button and hold it

down, next press the H2 button and this will clear the memory.

4.4 Changing and Programming a Job

Whenever you wish to change or program a job,

insert a piece of paper into the feed tray and press

the SET/FWD button. The paper will go through

the machine and stop in front of the photocell.

The DIG 5 will have P indicating you are in the

program mode, DP 5 will light up indicating the

motor is on in the forward position, DIG 1-0 will

have 75 and DP 0 will light up indicating that a

hit exists in the program. To clear the memory

completely press the CLR/BWD button, while holding it down press the H2 button, you will notice DP

0 will go off, this indicates that the memory and all hits have been cancelled.

DIG 5 DIG 4 DIG 3 DIG 2 DIG 1 DIG 0

DP 5 DP 4 DP 3 DP 2 DP 1 DP 0

As a guide, refer to the orientation of the LED digit segments (DIG 5-0) and the Decimal point

functions (DP 5-0) in the picture.

DIG 5 – Displays “P” for Program Set-up.

DIG 4 – Displays “h” only if a hit has been programmed at the current position.

DIG 3 - DIG 0 – Current paper position in steps from the paper leading edge. In run mode they act as

paper count.

DP 5 – Indicates the motor direction On = Forward

DP 4 – If it is on it indicates all 10 hit positions are used.

DP 3 – No function.

DP 2 – Solenoid 1 – On indicates Head 1 will be fired at the current position.

DP 1 – Solenoid 2 – On indicates Head 2 will be fired at the current position.

DP 0 – Indicates a hit exists in the program.

Changing the position of a hit can be done by scrolling (SET/FWD or CLR/BWD) to where the

previous hit existed. Once there the head will fire and you will have an “h” displayed in DIG 4, the

numbers indicate the stepper count position. You will also have either DP 1 and/or DP 0 lit depending

on which numbering head was activated. Pressing Either H1 or H2 will toggle the lights off or on.

When DP 1 or DP 0 is off, it indicates there is no longer a hit programmed at that position. Now by

scrolling with the SET/FWD or CLR/BWD buttons you can reposition the number hit.

Once all is set, press START and “SAVE” will display in DIG 5-2 and the current sheet will

eject. The machine will go into the idle mode. This will show DIG 4-0 as 0’s. Any numbers on the

display will be a paper count; pressing the CLR/BWD button will clear this back to zero.

To run the job, insert paper into the feed tray and press start.

- 12 -

4.5 SPEED CONTROL

The GW 6000 is equipped with three speeds. Slow speed is the default when you first run the program.

While the program is running press ‘H1 and/or H2’ you will notice on the far-left side of the display

vertical lines. Three of these lines indicate high speed, two for medium and one for low speed.

4.6 GW 6000 SOFTWARE SET UP and DIAGNOSTICS

DIG 0DIG 5

DP 5 DP 4 DP 3 DP 2 DP 1

DIG 4 DIG 3 DIG 2 DIG 1

DP 0

IMPRESSION

PERF SHIELD (RED)

STOP

H2 H1 SET/FWD CLR/BWD

START

PHOTOCELL (GRN)

The GW 6000, performs a limited set of self-diagnostics on power up. A full set of diagnostic utilities is

accessed by a manufacturing test mode. The system indicates paper error conditions along with hardware

faults by displaying a message on the LED display during operation.

All settings are simple enough for the customer to be coached through via telephone. We however recommend

that they only be done on site, by the dealer.

4.7 OVERVIEW

Access to all settable parameters is available through the keyboard while in the main operating menu. This is

the menu display when the machine is first turned on. If you are not at this point, press ‘STOP’ as often as

required to return to the main operating menu.

When at this point press ‘STOP’ and while holding it down press ‘H1’ and ‘H2’ at the same time. The display

will read “tESt01”. The test program is one of 10 available items. Each of the others is accessible by scrolling

with the ‘SET/FWD’ or ‘CLR/BWD’ buttons and then ‘START’ will allow you to enter that specific item

number.

- 13 -

4.8 INDIVIDUAL ITEMS

tESt01 – TEST RUN

DIG 0DIG 5

DP 5 DP 4 DP 3 DP 2 DP 1

D G 4 DIG 3 DIG 2 DIG 1

DP 0

When selected, this program will run the default factory program. The

motor will run, stop, start and the heads will fire simulating a standard

run. This is useful after replacing a component on the machine and

testing its correct installation. We run each machine for three full days in

our plant using this program to burn in the circuits and weed out any other assembly or miscellaneous

problems. DP4 allows for a single hit program by pressing ‘SET/FWD’ it will come on or go off. This light is

usually off allowing for a ten hit program. DP0 is always on indicating hits existing in the default program.

Pressing the ‘CLR/BWD’ will clear the simulated paper count.

To exit this item press ‘STOP’.

tESt02 – DISPLAY PHOTOCELL ADC

DIG 0DIG 5

DP 5 DP 4 DP 3 DP 2 DP 1

D G 4 DIG 3 DIG 2 DIG 1

DP 0

This is a machine value for the photocell. The value should be

approximately 60. Making adjustment on the gray pot located on the

PSTEP board can change this value. This is the bigger board located on

the non-operator side of the machine. The pot is located at the top

midsection of the board beside the two, four pin connectors.

To exit this item press ‘STOP’.

tESt03 – DISPLAY VOLTAGES

DIG 0DIG 5

DP 5 DP 4 DP 3 DP 2 DP 1

D G 4 DIG 3 DIG 2 DIG 1

DP 0

This displays the motor off-line, DIG2-0 will display the line voltage (it

will be lower than the actual line voltage), DIG5-3 will read the actual

motor voltage, when off-line the voltage will read around 0. When ‘H2’

is pressed DP3 will light up indicating that the machine is now on-line at

this point the numbers to the left of the dot will be the actual motor voltage, and the number to the right is the

actual input line voltage reading. The motor voltage typically will be around 150V if the voltage is higher than

160V then there is a problem. In 220-volt systems the line voltage will be approximately half of the actual line

input voltage.

To exit this item press ‘STOP’.

tESt04

DIG 0DIG 5

DP 5 DP 4 DP 3 DP 2 DP 1

D G 4 DIG 3 DIG 2 DIG 1

DP 0

– DISPLAY SOFTWARE VERSION

This mode will indicate the software version dates of the ICPU software

and the MSTP software. Default on entry is the ICPU Software Version,

indicated by DP3. Pressing ‘H2’ will display the MSTP version in

which the DP3 will disappear and ‘H1’ will get you back to the ICPU

version.

To exit this item press ‘STOP’.

- 14 -

tESt05 – SET SOLENOID MINIMUM PULSE WIDTH

DIG 0DIG 5

DP 5 DP 4 DP 3 DP 2 DP 1

D G 4 DIG 3 DIG 2 DIG 1

DP 0

This will display and modify Channel 1 and/or Channel 2 minimum

pulse width parameters. The Minimum Pulse Width value is 10 msec

and the maximum is 20 msec. Default is set at 15 msec. It is factory set

at 13.5. DP4 is a decimal point; DP3 indicates that Channel 1 has been

selected DP1 is a decimal point, DP0 will indicate when Channel 2 has been selected. DIG5-3 are the values

for Channel 1 and DIG2-0 are for Channel 2. The ‘SET/FWD’ increments and the ‘CLR/BWD’ decrements,

these buttons will vary the value by 0.1 msec increments when pushed, holding down will fast increment the

numbers.

Pressing ‘Stop’ will abort the pulse width changes and exit to the Manufacturer Test Mode display screen.

Pressing ‘START’ will store the new pulse width changes in the EEPROM, the display will flash ‘SAVE’ and

the machine will exit to the Manufacturer Test Mode display screen.

tESt06 – TEST SOLENOIDS

DIG 0DIG 5

DP 5 DP 4 DP 3 DP 2 DP 1

D G 4 DIG 3 DIG 2 DIG 1

DP 0

This will test solenoid channel pulsing with automatic detection of head

presence on each channel. It displays the ADC reading continuously.

The Impression Pot. varies the solenoid channel pulse width. Pressing

‘CLR/BWD’ will toggle the Solenoid Test On-Line this is indicated by

DP4 being lit. Pressing and holding ‘SET/FWD’ and either ‘H1’ or ‘H2’ the machine will start continuously

simulating pulsing.

To exit this item press ‘STOP’.

tESt07 – TEST STEPPER

DIG 0DIG 5

DP 5 DP 4 DP 3 DP 2 DP 1

D G 4 DIG 3 DIG 2 DIG 1

DP 0

This will test the stepper motor; motor direction, motor on-line/off-line,

motor current limit, and running the motor either continuously or

cycling the motor on for 10 seconds and off for 1 second. DP5 indicates

the direction of the motor, when lit it is in the forward direction,

pressing ‘CLR/BWD’ will turn it off indicating the motor direction will rotate backward. The button

‘SET/FWD’ will put the light back on in the forward direction. Pressing either ‘SET/FWD’ or ‘CLR/BWD’

will run the motor in that direction for one step, continuously holding it will run the motor continuously at

setup speed. DP4 indicates whether the motor is on/off-line, pressing ‘H1’ will toggle this light on or off. DP3

indicates whether the motor is running in high/low current, when the light is on it is in high current. To toggle

from high to low press ‘H2’. To run the motor must be online, pressing ‘START’ will let you run the motor

continuously. If you press and hold down the ‘H1’ button then press ‘H2’ the motor will run for 10 seconds

then turn off for one second and repeat the whole cycle again.

If the motor is running ‘STOP’ will stop it.

To exit this item press ‘STOP’.

tESt08 – TEST LEDS

DIG 0DIG 5

DP 5 DP 4 DP 3 DP 2 DP 1

D G 4 DIG 3 DIG 2 DIG 1

DP 0

This function will test all the following indicators; individual digit

segments, entire digits, decimal points, photocell/perf shield LEDs.

Pressing ‘SET/FWD’ will cycle all the segments in DP5 and DIG5.

Each press of the ‘CLR/BWD’ will cycle through DIG4-0, DP4-0 one

digit, with each digit displaying “8”. ‘H1’ triggers the photocell LED, ‘H2’ the perf shield LED.

- 15 -

To exit this item press ‘STOP’.

tESt09 – TEST POT/KEYS This program allows individual testing of all keys and impression pot.

Each key will turn on a decimal point while pressed. ‘SET/FWD’ turns

on DP5 while pressed. ‘CLR/BWD’ turns on

DIG 0DIG 5

DP 5 DP 5 DP 5 DP 5 DP 5

D G 4 DIG 3 DIG 2 DIG 1

DP 5

DIG 0DIG 5

DP 5 DP 5 DP 5 DP 5 DP 5

D G 4 DIG 3 DIG 2 DIG 1

DP 5

DP4. ‘H1’ turns on DP3. ‘H2’ turns on DP2. ‘STOP’ turns on DP1 and ‘START’ turns on DP0.

To exit out of this mode press and hold down the ‘H2’ and then the ‘STOP’.

tESt010 – TEST/FORMAT EEPROM

This tests and formats the EEPROM sections that are used by loading

the programmable parameter defaults into the EEPROM and RAM. It

will also write an empty solenoid program into the memory. Pressing

the ‘CLR/BWD’ will commence erasing the EEPROM, DP4 will turn

on while the Test/Format is in progress. Notice, once the formatting is initiated it cannot be aborted.

To exit this item press ‘STOP’.

- 16 -

4.9 GW 6000 Error Codes

Group Condition Error

Paper Handing Errors 01 PAPER JAM

05 MSTP PAPER ERROR REPORTED IS UNDEFINED

02-04, 06-09 Reserved

Solenoid Errors 10 CH1 OPEN

11 CH1 SHORT

12 CH1 HOT

13 CH2 OPEN

14 CH2 SHORT

15 CH2 HOT

16 CH1 2 HEADS

17 CH2 2 HEADS

18 NO SOLENOID BOARD ATTACHED

19 LOW VOLTAGE SOLENOID BOARD ATTACHED

20 SOLENOID TIMEOUT

21 SOLENOID BOARD TYPE INCONSISTENT (BETWEEN MSTP AND ICPU)

22 SOLENOID ADC LIMITS ARE INCONSISTENT (BETWEEN MSTP AND ICPU)

23-28 Reserved

29 MSTP REPORTED UNKNOWN SOLENOID ERROR

Motor Errors 30 MOTOR RUN TIMEOUT

31 MOTOR TURN ON/OFF TIMEOUT

32-39 Reserved

EEPROM Errors 40 UNABLE TO READ FROM EEPROM

41 UNABLE TO WRITE TO EEPROM

42 CRC INVALID FOR EEPROM PROGRAMMABLE PARAMETERS

43 CHECKSUM INVALID FOR EEPROM SOLENOID PROGRAM

44 TESTING FAILED DURING TEST/RE-FORMAT EEPROM

45 EEPROM VERSION FORMAT ID# DOES NOT MATCH SOFTWARE

44-49 Reserved

Memory Errors 50 RAM SELF-TEST READ/WRITE FAILURE

51 CHECKSUM INVALID FOR RAM SOLENOID PROGRAM

52 CRC INVALID FOR RAM PROGRAMMABLE PARAMETERS

53 SETUP MODE SOLENOID PROGRAM HIT INDEX OUT OF RANGE

54 SOLENOID PROGRAM NUMBER IS CORRUPT

55-59 Reserved

Hardware Errors 60 AC LINE VOLTAGE OUT OF OPERATION RANGE

61 MOTOR VOLTAGE OUT OF OPERATION RANGE

62-69 Reserved

SCI Errors 70 ICPU SCI RECEIVE TIMEOUT ERROR

71 ICPU SCI RECEIVE OVERFLOW ERROR

72 ICPU SCI TRANSMIT TIMEOUT ERROR

73 ICPU SCI INVALID ACK RECEIVED

74 ICPU SCI CORRUPTED MESSAGE RECEIVED

75 ICPU SCI TRANSMIT ABORTED

76 ICPU SCI WATING PERIOD FOR MSTP MESSAGE EXPIRED

77 ICPU SCI INVALID MESSAGE TYPE RECEIVED

80 MSTP SCI RECEIVE TIMEOUT ERROR

81 MSTP SCI RECEIVE OVERFLOW ERROR

82 MSTP SCI TRANSMIT TIMEOUT ERROR

83 MSTP SCI INVALID ACK RECEIVED

84 MSTP SCI INVALID COMMAND RECEIVED

85 MSTP RECEIVE OVERRUN ERROR

86 MSTP RECEIVE FRAMING ERROR

77-79, 87-88 Reserved

89 MSTP SCI ERROR REPORTED IS UNDEFINED

Miscellaneous 90 MSTP ERROR REPORTED IS UNDEFINED

- 17 -

5.0 GW 8/12000 OPERATION

G R A P H I C W H

C A N A D A

I Z A R D

F1

>>>

F2

<<<

STOP

START

REP

BAT

ACC

ESC 0

97 8

64

2 31

5

SETUP

SETUP

IMPRESSION 2

IMPRESSION 1

FLASHES IF RAM ERROR FLASHES IF LCD ERROR

PERF SHIELD (RED) PHOTOCELL (GRN)

N

O FUNCTION

The operating keyboard is comprised of a two line LCD display, various buttons and two Impression

Controls which consist of two potentiometer knobs that control the crash strength of the numbering head, and

can be adjusted to best suit the requirements of the job. For example, you may require stronger crash

numbering for carbonless sets than for single sheet bond paper. This adjustment can be done while the

machine is stopped or running.

The four buttons under the LCD display will perform whatever function is shown directly above them

on the bottom line of the LCD display. They may not always be active (this is the case for the other buttons as

well). Three specific function buttons (SET UP, BAT, REP) are situated beside the display. A numeric

keypad, an ‘ESC’ (escape), ‘ACC’ (accept), ‘START’ and ‘STOP’ button rounds out the rest of the

keyboard. The 'ESC' button can be used at almost any time (except during actual running) in order to return

to the previously viewed menu. The functions of the rest of the buttons will be discussed later in this section.

Once you have plugged the machine in, turn the on/off switch to the 'on' position. The microprocessor

does an internal system check and the above will flash on the screen.

5.1 Running a Job

The Idle Mode is displayed below. From this menu, you can change the motor speed, modify your

paper count and select your program.

In this menu you can also enter the Batch size.

s s s s s s P G M

↓

↑

x x x c c

c c

a

c

a

c

a 1-

F1

>>>

F2

<<<

STOP

START

REP

BAT

ACC

ESC 0

97 8

64

2 31

5

SETUP

SETUP

IMPRESSION 1

IMPRESSION 2

ON = PERF SHIELD OPEN ON = NO PAPER

PERF SHIELD (RED) PHOTOCELL (GRN)

- 18 -

DISPLAY FUNCTIONS:

DISPLAY

ssssss = motor speed bar graph

PGMxxx = solenoid program in RAM

cccccc = paper count

↓ = decrement motor speed

↑ = increment motor speed

-1 = decrement paper count

aaa = CLR -> clear paper count normally; aaa = BAT -> Enter Mode - Set Batch Size when batch mode is enabled

The <<</>>> will adjust the motor speed, F1 will decrement the paper count, F2 will clear the paper count but

if it is already at 0 it will send you to the Batch mode. SETUP will select a program and START will begin

the job. You will now be in the Run Mode.

When the machine is first turned on, it defaults to Program 01 (PGM001), which is shown on the

menu. Pressing the 'START' button will automatically begin Program 01. The main operating menu will

change as the machine is running.

The Run Mode menu looks like this:

s s s s s s P G M

↓

↑

x x x c c

c c

a

c

a

c

a TLAH

F1

>>>

F2

<<<

STOP

START

REP

BAT

ACC

ESC 0

97 8

64

2 31

5

SETUP

SETUP

SOL CH2 ADJUST

PULSE WIDTH

IMPRESSION 2

SOL CH1 ADJUST

PULSE WIDTH

IMPRESSION 1

ON = PERF SHIELD OPEN

(

WILL EXIT TO Mode - Idle

)

ON = NO PAPER

PERF SHIELD (RED) PHOTOCELL (GRN)

DISPLAY FUNCTIONS:

DISPLAY

ssssss = motor speed bar graph

PGMxxx = solenoid program in RAM

cccccc = paper count

↓ = decrement motor speed

↑ = increment motor speed

HALT = motor emergency stop, exit to Mode - Idle

aaa = CLR -> clear paper count normally; aaa = BAT -> Display current batch size when batch mode is enabled

KEYPAD FUNCTIONS:

<<< >>> F1 F2 STOP START

DECREMENT MOTOR SPEED INCREMENT MOTOR SPEED MOTOR EMERGENCY

STOP

Exit to Mode - Idle

IF BATCH SIZE IS ZERO

CLEAR PAPER COUNT

ELSE:

DISPLAY BATCH SIZE

Complete numbering

Eject current sheet

Stop motor

Exit to Mode - Idle

ACC ESC SETUP BAT REP

MOTOR EMERGENCY STOP MOTOR EMERGENCY STOP MOTOR EMERGENCY IF BATCH SIZE IS ZERO MOTOR EMERGENCY

- 19 -

Exit to Mode - Idle Exit to Mode - Idle STOP

Exit to Mode - Idle MOTOR EMERGENCY STOP

Exit to Mode - Idle

ELSE:

DISPLAY BATCH SIZE

STOP

Exit to Mode - Idle

DIG 0-9

MOTOR EMERGENCY STOP

Exit to Mode - Idle

5.2 Stopping a Job

Here are methods of stopping the machine.

1. Once the program is running, there are several built in safety emergency stops. Pressing the STOP

button, any of the digits 0-9, F1, STOP, ACC, ESC, REP, and if the Batch size is 0, BAT will cause the

machine to finish the stock it is currently working on, move the next stock into the starting position and then

stop the motor. This automatically sends you into Idle Mode.

2. If you want to stop the machine while stock is still left in it, simply hold on to the stock in the feed

tray. After about one second, the machine will automatically stop (since it is no longer seeing any new

sheets). This is how it also stops when all of the stock in the feed tray is gone.

5.3 Changing Programs

The GW 8/12000 allows you several choices in programming:

PROGRAM 00 = Perf/score, automatically turns the numbering heads off.

PROGRAM 01 – 99 = Allows for a maximum of 10 hits per head.

PROGRAM 100 = Allows for a maximum of 100 hits per head.

Whenever you wish to change programs, the LCD display must be in Idle Mode press the 'SET UP'

button. The following screen will appear:

DISPLAY:

S E L E C T P R O G R A M

E

x x

D

T

x

I NUR

F1

>>>

F2

<<<

STOP

START

REP

BAT

ACC

ESC 0

97 8

64

2 31

5

SETUP

SETUP

N

O FUNCTION

IMPRESSION 2

N

O FUNCTION

IMPRESSION 1

ON = PERF SHIELD OPEN ON = NO PAPER

PERF SHIELD (RED) PHOTOCELL (GRN)

- 20 -

Once you select the program number desired, you may either 'RUN' the existing program or 'EDIT' it

by pressing the corresponding function key (F1 to RUN & F2 to EDIT).

If RUN is selected, the machine will exit to Idle Mode where you press START. The ESC key will

also return to Idle Mode in case you wish to change the counter before beginning a job.

5.4 Programming a Job

If you wish to program a job, EDIT an existing program, press F2. After selecting EDIT, if the

program already exists, the machine will ask whether you would like to erase it, start new ('NEW') or modify

it ('MOD').

P R O G R A M : X X

M O D N E

X E X I S

B

S

A

T

K

C TIXE W

F1

>>>

F2

<<<

REP

BAT

ACC

ESC 0

97 8

64

2 31

5

SETUP

SETUP

N

O FUNCTION

IMPRESSION 2

IMPRESSION 1

ON = PERF SHIELD OPEN ON = NO PAPER

PERF SHIELD (RED) PHOTOCELL (GRN)

STOP

START

This selection is done with the corresponding function key (<<< and >>> respectively).

When modifying a program, previously programmed hits can be removed from the program while

additional hits may be added.

Once you make your selection, the machine will instruct you to 'INSERT PAPER/ PRESS START'.

The LCD display will then show the following:

+

P G M : x x x P O S : c c c

c

C

c

4

2 31C >> > < < <

F1

>>>

F2

<<<

STOP

START

REP

BAT

ACC

ESC 0

97 8

64

2 31

5

SETUP

SETUP

N

O FUNCTION

IMPRESSION 2

N

O FUNCTION

IMPRESSION 1

ON = PERF SHIELD OPEN ON = NO PAPER

PERF SHIELD (RED) PHOTOCELL (GRN)

DISPLAY FUNCTIONS:

DISPLAY

xxx = solenoid program number

ccccc = current paper position in motor steps from paper lead edge

<<< = motor moves in forward direction

- 21 -

22

>>> = motor moves in backward direction

= full block character displayed when hit programmed

C1 = solenoid channel 1 head 1

3 = solenoid channel 1 head 2 = SOL3

C2 = solenoid channel 2 head 1

4 = solenoid channel 2 head 2 = SOL4

The sheet you inserted is automatically moved to position '75'. Position '0' is the lead edge of the

sheet passing the photocell. Position '75' is the first location that an entire number will print on the paper.

(Note: Each step represents approximately 1/50th of an inch).

The first two function keys step the paper either forward or backward (Note: you cannot back the sheet

back further than position '75'). The other two function keys fire either head #1 or head #2. Once a head fire

button has been pressed, the numbering head will fire and the LCD display will light up with one solid bar

around the corresponding head fired (eg.C1).

In a four head system, heads 1&3 work together and heads 2&4 respectively. To activate heads 1&3 at

any position press “F1” head 1 will fire and C1 will appear on the display press “3” on the keypad and head

3 will fire and C13 will appear. To activate head 2&4 you must press the number “2 and 4” on the keypad

and C24 will appear on your display.

Configured, we can have in any one program, with a four head machine, a combination of, at any one

time; heads 1&2&3&4, 1&3, 2&4, 1, 2. Heads 3&4 cannot activate on their own.

If the number is not in the position desired, simply press the function button again to toggle off the hit,

otherwise continue moving up or down the sheet (the hit is automatically saved). This procedure can be

repeated until the number is in the correct location. The page can be stopped a maximum of 15 times where

you may program head #1 or head #2 or both heads to fire.

Once all numbers desired have been programmed, simply press the 'ACC' button and the sheet will be

discharged from the machine. The next sheet will be forwarded to step '75' (if there is another sheet already in

the feed tray) or you will be instructed to 'INSERT PAPER/PRESS START'. The LCD display will return

to Idle Mode and you are set to run the job. Simply press the 'START' button to begin.

23

5.5 The Batch Function

Pressing the 'BAT' key before running a program will enter the batch menu.

FUNCTION:

1. Allows user to set or clear the batch size, max. batch size = 999999

2. Sets a new batch size by pressing <ACC>. The paper count and batch quantity are reset to 0.

DISPLAY:

B A T C H S I Z E x

x x

C

x

R

x

L TES

F1

>>>

F2

<<<

STOP

START

REP

BAT

ACC

ESC 0

97 8

64

2 31

5

SETUP

SETUP

N

O FUNCTION

IMPRESSION 2

N

O FUNCTION

IMPRESSION 1

ON = PERF SHIELD OPEN ON = NO PAPER

PERF SHIELD (RED) PHOTOCELL (GRN)

DISPLAY FUNCTIONS:

DISPLAY

xxxxx = batch size

SET = sets the batch size

CLR = sets the batch size to zero

At this point you may select the size of the batch desired by entering the desired batch size through the

keypad. Press the 'ACC' key when the quantity desired has been chosen. Press the 'F2' key (CLR) if you wish

to clear a quantity entered to disengage the batch function. Once again, the 'ESC' key will return you back to

the main operating menu without activating the batch function. Pressing “F1” will reset the paper count and

batch quantity.

24

When running a job with the batch function, the machine will stop after the last sheet has been

processed, leaving the sheet partially in the exit rollers, allowing you to insert a slipsheet. The LCD display

will then show the number of batches completed.

FUNCTION:

1. Displays the number of batches that have been completed of Batch Size

DISPLAY:

B A T C H Q T Y : x

x x

C

x

R

x

L TIXE

F1

>>>

F2

<<<

STOP

START

REP

BAT

ACC

ESC 0

97 8

64

2 31

5

SETUP

SETUP

N

O FUNCTION

IMPRESSION 2

IMPRESSION 1

ON = PERF SHIELD OPEN ON = NO PAPER

PERF SHIELD (RED) PHOTOCELL (GRN)

DISPLAY FUNCTIONS:

DISPLAY

xxxxx = batch quantity

EXIT = exit to Mode - Idle

CLR = clear batch quantity

This screen will show you how many batches you have completed. Multiply the 'BATCH QTY' by the

'BATCH SIZE', and you have the total quantity of your run. When the machine stops after each batch has

been completed, you may insert a slip sheet in the exit tray and simply press the 'START' button to continue

with the next set.

5.6 The Repeat Function

The repeat function key (REP) is a future feature for the GW 8/12000. Currently the repeat selector

on the numbering head is used to obtain a repeat ability.

5.7 Motor Speed Control

The motor speed can be changed while the machine is running or idle. This function is performed by

using the first two function keys under the LCD display screen (marked << and >>) when you are in the main

operating menu.

The bottom line of the LCD display shows a down arrow to slow down the motor and an up arrow to

speed it up. Maximum throughput speed is 8 000 (GW 8000) and 12 000 (GW 12 000) sheets per hour (11 x

82" or A4), with one number per page.

25

5.8 GW 8/12000 SOFTWARE SET-UP & DIAGNOSTICS

2

01 TEST IDLE

H1

<< >>

<<< >>>

H2 SAFETY

4 5

F2F1

REP

ESC 0

7

BAT

8

PHOTOCELL

1

SET

UP

6

ACC

STOP

9

START

3

On both models, the software offers a number of technician settable features and diagnostics. Using these, the

equipment can be customised to the customer's requirements and/or tuned to local electrical conditions.

The most critical of these is the minimum solenoid pulse width. Each customer location will offer a

different incoming voltage. This voltage variation can result in an incorrect range of impression control being

available to the user. While most other values will remain at factory defaults, this value must be changed for

each new machine location.

All settings are simple enough for the customer to be coached through via telephone. Upon installation or in

the event of a circuit exchange, the Set-Up routine must be followed to ensure proper set-up.

5.9 OVERVIEW

Access to all settable parameters is available through the keyboard while in the main operating menu. This is

the menu displayed when the machine is first turned on. If you are not at this point, press "ESC" as often as

required to return to the main operating menu.

When at this point to get into the Manufacturer Test Menu, press "1,2,9'". The display will read "01 TEST

IDLE". The test program is one of the 10 available options. Each of the others is accessible by pressing the

appropriate number at any time or pressing the "<<" or ">>“ keys to scroll forward or backward through the

options and then "ACC" to enter that option. Leave any item by pressing "ESC or STOP".

5.10 INDIVIDUAL ITEMS

Each of the available options provides a different function and will either assist in machine set up or in

diagnosing a malfunction. Each is detailed and explained below.

01. TEST IDLE

When selected, "1 TEST IDLE" will run the current machine program over and over without the need to load

paper. The motor will run, stop, start and the heads will fire simulating a standard run. This is useful after

replacing a component on the machine and testing its correct installation. We run each machine for a

minimum 48 hours in our plant using this program to burn in the circuits and to weed out any other assembly

or miscellaneous problems.

02. DISPLAY PCELL ADC

26

PHOTOCELL ADC: 030

<< F2>> F1

EXIT

The photocells in the GW 8000 & 12000 are of a reflective type. The actual

emitter/collector are in one stock electronic component. It is mounted on the

leading edge of the main platen operator side underneath a grooved cutout.

Above the photocell is a shiny reflector that is in a fixed position. Adjustment

on the photocell is now done directly on the main PSTEP board. The value

should be between 55-65.

03. DISPLAY VOLTAGES

This mode will display the line voltage and the actual motor voltage. When

the motor is not in operation the voltage will read approximately 0, this is

represented by the OFF beside the number. Pressing ‘F2’ will bring the motor

online (ONL). While online the typical voltage will be about 150. If the

reading is above 160 there is a problem.

MOTOR VOLTAGE : 003OFF

LINE VOLTAGE: 109

<< F2>> F1

04. DISPLAY SW DATES

ICPU : REV V990511

PSTP : REV V990528

<< F2>> F1

The software versions on the ICPU and MSTP Board are displayed.

05. SET LANGUAGE

There is a choice of five languages to choose from; ENGLISH, SPANISH,

GERMAN, PORTUGESE and FRENCH. Use the ‘<< or >>’ buttons to scroll

through the different languages, when you select the one press ‘F2 or ACC’.

<<

ENGLISH

F2

EXIT SET

>> F1

06. TEST SOLENOIDS

In this mode you can test or set the minimum solenoid pulse width. The test

mode allows you to check the functionality of the low voltage solenoid board.

Once ‘>>’ is pressed you are in the test mode.

TEST SOLENOID : LOW

TEST EXIT SET

<< F2>> F1

PW1 stands for Pulse Width for Head 1 and PW2 for H2. The values beside

them are the Pule Widths in nano seconds. They vary when the Impression

Control Dials are turned. With the dials completely counter cockwise it will

display the minimum solenoid pulse width. With the heads plugged in ‘F1’

will fire H1 each time it is pressed. ‘F2’ will fire H2 also each time it is

pressed. To obtain a continuous pulse press the ‘<<’ key. To set the

PW1 : 15000

<< >>

PW2 : 15000

F2F1

minimum solenoid pulse widths press ‘STOP’ and then ‘F2’.

mPW1 : 15.0

<< >>

mPW2 : 15.0

F2F1

The block beside the number indicates which head is currently being fired

by selecting ‘F1 or F2’. The keys ‘<< and >>’ increase or decrease the pulse

width. With the air pressure through the regulator set between 40-50 psi

adjust the pulse width value up or down to provide a well inked number

which does not emboss a light paper weight (20#/75 gsm bond). The next

head can be adjusted in this same manner. Default setting for this is 15.0 on

the pneumatic units. The factory setting is set at 12.5. When finished press

‘ACC’ to save the value to the EEPROM and you will go back to the Manufacturer Test Menu. If you do not

want to save the changes press ‘ESC’ and you will go to MFR Test Menu, or ‘Stop’ will put you in the

‘Test/Set Menu.

7. TEST STEPPER This Mode allows the user to run a Stepper Motor Test and to set the

Maximum Motor Speed. The Maximum Motor Speed is factory set and

should not be changed. To TEST the Motor press the ‘>>’ key. The factory

setting for the GW 8000 is 79 and the GW 12000 at 90.

TEST STEPPER MAIN

TEST EXIT SET

<< >> F2F1

The number beside the PER is the Motor Period in microseconds by turning

the Impression Control Dial for H2 the number will either increase or

decrease, the higher the number the slower the motor will go. Beside the MOT

V is the actual motor voltage, when OFF the voltage will be around 0.

PER : 00444 MOT V : 003

FWD BWD OFF LO

W

<< >> F2F1

To run the motor it must be Online as indicated when ‘F1’ is the toggle and

ONL appears, the machines voltage will now read around 150 V. ‘F2’ will

toggle the motor HIGH or Low Current Limit. Each pressing of the ‘<< or>>’ will move the motor one step,

continuously holding it down will run the motor only at SET-UP SPEED. If ‘START’ is pressed the machine

will run continuously only in the FORWARD direction and the Motor Period will change with the H2

Impression Dial. If the ‘SETUP’ button is pressed the motor will cycle on and off every 10 seconds.

PT1 : aaa XXXXXXXXXX

PT2 : bbb XXXXXXXXXXX

>>

<< F1 F2

8. TEST POT AND KEYS

This test program will allow you to check the functionality of all the keys on

the display and also the Impression Control Dials.The display will show two

lines. PT1 represents the ADC value of Head #1, and when the Impression

Control Dial for the head is turned the values beside PT1 will accordingly

increase or decrease. The same is done for the Impression Control Dial for

Head #2. The X’s to the left will disappear any time a key on the display pad

is pressed.

LOAD DEFAULTS

PARM PGMS EXIT

<< >> F1 F2

9. LOAD DEFAULTS

This function allows the loading of the entire factory set programs and

parameters into the EEPROM. All the existing EEPROM data will then be

overwritten. PGMS will clear all this existing solenoid programs from the

memory and load the factory set solenoid programs from 01-100. When

PARM or PGMS is pressed a secondary confirmation screen will be

displayed.

27

28

CONFIRM LOAD DEFAULT

aaaa YES BACK

<< >> F1 F2

Once PARM or PGMS is selected the confirmation screen will display which

was selected on the bottom left and then accordingly press F1 for Yes or F2 to

go back.

IIIIIIIIIIIIIIIIII FORMAT EEPROM

EXIT CLR

<< >> F1 F2

10. TEST/FORMAT EEPROM

This function will erase all programs and set the factory defaults. It will

totally erase the EEPROM and reprogram all the programmable parameter

defaults along with the solenoid program defaults. CLR will load an empty

program into all the program locations of the EEPROM it will then display a

secondary “CONFIRM FORMAT” screen before erasing the existing data,

when formatting an update completion bar will indicate the progress. Once

format is complete, the screen will display “FORMAT COMPLETE”. Note, that once formatting has

commenced, the user cannot abort formatting operation.

5.11 GW 8/12000 ERROR MESSAGES

Group Error Message Description

Paper Handing Errors PAPER JAM A PAPER JAM CONDITION EXISTS

INSERT PAPER A PAPER OUT CONDITION EXISTS

PAPER TOO LONG A PAPER LONG CONDITINO EXISTS

PAPER TOO SHORT A PAPER SHORT CONDITION EXISTS

Solenoid Errors SOL ERROR 10 SOLENOID CHANNEL 1 OPEN

SOL ERROR 11 SOLENOID CHANNEL 1 SHORT

SOL ERROR 12 SOLENOID CHANNEL 1 HOT

SOL ERROR 13 SOLENOID CHANNEL 2 OPEN

SOL ERROR 14 SOLENOID CHANNEL 2 SHORT

SOL ERROR 15 SOLENOID CHANNEL 2 HOT

SOL ERROR 16 RESERVED

SOL ERROR 17 RESERVED

SOL ERROR 18 NO SOLENOID BOARD ATTACHED

SOL ERROR 19 RESERVED

SOL ERROR 20 MSTP DID NOT REPORT SOLENOID(S) FIRED

SOL ERROR 21 ICPU AND MSTP SOLENOID BOARD TYPE DO NOT MATCH

SOL ERROR 22 ICPU AND MSTP SOLENOID ADC LIMITS DO NOT MATCH

SOL ERROR 23 SOLENOID CHANNEL 1 REPORTED ONLY 1 HEAD INSTEAD OF 2

SOL ERROR 24 SOLENOID CHANNEL 2 REPORTED ONLY 1 HEAD INSTEAD OF 2

Motor Errors MOT ERROR 30 MOTOR RUN TIMEOUT

MOT ERROR 31 MOTOR TURN ON/OFF TIMEOUT

EEPROM Errors EEP ERROR 40 UNABLE TO READ FROM EEPROM

EEP ERROR 41 UNABLE TO WRITE TO EEPROM

EEP ERROR 42 CRC INVALID FOR EEPROM PROGRAMMABLE PARAMETERS

EEP ERROR 43 CHECKSUM INVALID FOR EEPROM SOLENOID PROGRAM

EEP ERROR 44 TESTING FAILED DURING TEST/RE-FORMAT EEPROM

EEP ERROR 45 EEPROM VERSION FORMAT ID# DOES NOT MATCH SOFTWARE

Memory Errors RAM ERROR 50 RAM SELF-TEST READ/WRITE FAILURE

RAM ERROR 51 CHECKSUM INVALID FOR RAM SOLENOID PROGRAM

RAM ERROR 52 CRC INVALID FOR RAM PROGRAMMABLE PARAMETERS

RAM ERROR 53 SETUP MODE SOLENOID PROGRAM HIT INDEX OUT OF RANGE

RAM ERROR 54 SOLENOID PROGRAM NUMBER CORRUPTED

Hardware Errors LINE VOLTAGE ERROR AC LINE VOLTAGE OUT OF OPERATION RANGE

MOTOR VOLTAGE ERROR MOTOR VOLTAGE OUT OF OPERATION RANGE

SCI Errors SCI ERROR 70 ICPU SCI RECEIVE TIMEOUT ERROR

SCI ERROR 71 ICPU SCI RECEIVE OVERFLOW ERROR

SCI ERROR 72 ICPU SCI TRANSMIT TIMEOUT ERROR

SCI ERROR 73 ICPU SCI INVALID ACK RECEIVED

SCI ERROR 74 ICPU SCI CORRUPTED MESSAGE RECEIVED

SCI ERROR 75 ICPU SCI TRANSMIT ABORTED

SCI ERROR 76 ICPU SCI WAITING PERIOD FOR MSTP MESSAGE EXPIRED

SCI ERROR 77 ICPU SCI INVALID MESSAGE TYPE RECEIVED

SCI ERROR 80 MSTP SCI RECEIVE TIMEOUT ERROR

SCI ERROR 81 MSTP SCI RECEIVE OVERFLOW ERROR

SCI ERROR 82 MSTP SCI TRANSMIT TIMEOUT ERROR

SCI ERROR 83 MSTP SCI INVALID ACK RECEIVED

SCI ERROR 84 MSTP SCI INVALID COMMAND RECEIVED

SCI ERROR 85 MSTP RECEIVE OVERRUN ERROR

SCI ERROR 86 MSTP RECEIVE FRAMING ERROR

Miscellaneous UNKOWN ERROR MSTP ERROR REPORTED IS UNDEFINED

29

6.0 CIRCUIT BOARDS LAYOUT AND DIAGNOSTICS

6.1 GW 3/6000 CIRCUIT

12 V COOLING

FAN

90-032-GW

6K LED/ICPU DISPLAY BOARD

BACK

92-029-GW-X

3 K

90-029-GW

6K LED/ICPU DISPLAY BOARD

FRONT

92-029-GW-X

3 K

90-029-GW

FILTER TO MSTP BOARD CABLE

90-064-GW

HV SOLENOID TO MSTP

BOARD POWER CABLE

90-068-GW

BLACK

RED

RED

BLACK

S/N: 035

SOLENOID CONNECTION

BOARD TO FEMALE TERMINAL

90-069-GW

BLUE

YELLOW

YELLOW

BLUE

BLACK

120 V

MSTP BOARD

CONNECTOR

90-060-GW

B01

PURPLE

220 V

MSTP BOARD

CONNECTOR

90-061-GW

LD1

LD2

LD3

HIGH VOLTAGE SOLENOID BOARD

90-028-GW

90-028-GW-X

LINE FILTER

90-063-GW

BROWN

BLUE

BROWN

BROWN

GREEN

BLUE

BLUE

MODULAR SWITCH

W/FUSEHOLDER

90-062-GW

BLUE

6K MSTP EPROM

92-026-GW

3K MSTP EPROM

90-026-GW

3K MSTP BOARD

90-025-GW-X

6K MSTP BOARD

92-025-GW-X

ORANGE

RED

BLACK

VOLET

STEPPER MOTOR

W/HARNESS

90-005-GW

LD4

LD7

7

S/N: 069

LD7

LD7

PSTPSW

V990415

@1999

GRAPHIC

WHZARD

A03

LD8

LD10

LD9

LD11

PHOTOCELL

ASSEMBLY

90-067-GW

GREEN

SAFETY SWITCH

W/HARNESS

90-016-GW

BLACK

RED

RED

BLACK

BLACK

RED

PHOTOCELL VOLTAGE

POTENTIOMETER

WHITE

6K ICPU EPROM

92-027-GW

S/N: 048

GRAPIC W IZARD CANA

S6KSW

V 99031

@199

A00

TELEPHONE CABLE

90-030-GW

040

REV: A

S/N:

A00

30

6.2 GW 8/12000 CIRCUIT

12 V COOLING

FAN

90-032-GW

LD3

LED/ICPU DISPLAY BOARD

FRONT

94-029-GW

94-029-GW-X

LED/ICPU DISPLAY BOARD

BACK

94-029-GW

94-029-GW-X

LD2

LOW VOLTAGE SOLENOID BOARD

94-028-GW

94-028-GW-X

FILTER TO MSTP BOARD CABLE

90-064-GW

LOW VOLTAGE SOLENOID

CONNECTION BOARD TO

FEMALE TERMINAL

96-071-GW

LD10

220 V

MSTP BOARD

CONNECTOR

90-061-GW

PURPLE

BLACK

120 V

MSTP BOARD

CONNECTOR

90-060-GW

LD8

LD1

LINE FILTER

90-063-GW

BROWN

BLUE

HV SOLENOID TO MSTP

BOARD POWER CABLE

90-083-GW

BROWN

MODULAR SWITCH

W/FUSEHOLDER

90-062-GW

GREEN

BROWN

BLUE

BLUE

BLUE

STEPPER MOTOR

W/HARNESS

90-005-GW

MSTP BOARD

92-025-GW

92-025-GW-X

MSTP EPROM

92-026-GW

LD9

LD4

ORANGE

RED

BLACK

VOLET

LD5 LD6

S/N: 069

PSTPSW

V990415

@1999

GRAPHC

WHIZARD

A03

LD8

LD7

LD11

LD10

PHOTOCELL VOLTAGE

POTENTIOMETER

S/N: 048

PHOTOCELL

ASSEMBLY

90-067-GW

8K SAFETY SWITCH W/HARNESS

90-016-GW

12K SAFETY SWITCH W/HARNESS

96-016-GW

RED

BLACK

BLACK

RED

BLACK

RED

GREEN

WHITE

ICPU EPROM

94-027-GW

GRAPIC W IZARD CANADA

S6KSW

V 99531

@1999

TELEPHONE CABLE

90-030-GW

REV A

B00

A00

040

S/N

LD1

31

GW 3/6/8/12000 CIIRCUIT DIAGNOSTICS

Purpose:

• This document provides

• a brief overview of the functions of the LED indicators on all GW boards

• how to correct, if possible, error messages on the displays

LED Indicators:

• PSTP Board

• All LEDs have a brief (one word) indicator on the silkscreen beside the LED

• This describes the main function of the LED

• LD1: +320V Supply Indicator

• This LED indicates whether the +320V supply is alive

• If this LED is not on then the possible causes are (in order of probability):

• Machine not turned on

• Fuse Blown

• AC power connector not plugged into J2 on PSTP board or cable is broken

• Jumper not in J5 or incorrect jumper in J5 (black for 110VAC, purple for 220VAC)

• Bridge doubler not functioning – replace PSTP board

• LD2: Secondary +5V Supply Indicator

• This LED indicates whether the secondary +5V supply is alive

• If this LED is not on then the possible causes are:

• Machine not turned on

• AC power connector not plugged into J2 on PSTP board (or cable broken)

• Jumper not in J5 or incorrect jumper in J5 (black for 110VAC, purple for 220VAC)

• X2, VR2 or VR1 not functioning or short on S+5V line – replace PSTP board

• LD3: Secondary +12V Supply Indicator

• This LED indicates whether the secondary +12V supply is alive

• If this LED is not on then the possible causes are:

• Machine not turned on

• AC power connector not plugged into J2 on PSTP board (or cable broken)

• Jumper not in J5 or incorrect jumper in J5 (black for 110VAC, puple for 220VAC)

• X2, VR2 not functioning or short on S+12V line– replace PSTP board

• LD4: Motor Voltage Supply Indicator

• This LED indicates whether the motor voltage supply is alive

• This LED should only be on when the motor is brought online

• If this LED is not on then the possible causes are:

• Motor not online

• +320V supply not functioning – verify that LD1 is on

• motor switching supply not functioning – replace PSTP board

32

• LD5: Primary +12V Supply Indicator

• This LED indicates whether the primary +12V supply is alive

• If this LED is not on then the possible causes are:

• Machine not turned on

• AC power connector not plugged into J2 on PSTP board (or cable broken)

• Jumper not in J5 or incorrect jumper in J5 (black for 110VAC, purple for 220VAC)

• X1 or VR4 not functioning or short on P+12V line– replace PSTP board

• LD6: Primary +5V Supply Indicator

• This LED indicates whether the primary +5V supply is alive

• If this LED is not on then the possible causes are:

• Machine not turned on

• AC power connector not plugged into J2 on PSTP board (or cable broken)

• Jumper not in J5 or incorrect jumper in J5 (black for 110VAC, purple for 220VAC)

• X1, VR3 or VR4 not functioning or short on P+5V line– replace PSTP board

• LD7: Perf Status Indicator

• This LED indicates the status of the Perf

• If the Perf is closed, LD7 will be on

• If the Perf is open, LD7 will be off

• If this LED does not change state when opening/closing the Perf shield then the

possible causes are:

• Perf cable not plugged into J11 on PSTP board or Perf cable broken

• Perf switch broken

• Perf circuitry not functioning – replace PSTP board

• LD8: Start Photocell Status Indicator

• This LED indicates the status of the Start Photocell – paper reflects to detector

• If there is no paper under the photocell, LD8 will be off.

• If there is paper under the photocell, LD8 will be on.

• If this LED does not change state when breaking the Start Photocell then the possible

causes are:

• Start Photocell not plugged into J12 on PSTP board or Photocell cable broken

• Photocell not aligned properly or photocell broken

• Start photocell circuitry not functioning – replace PSTP board

• LD9: Paper Photocell Status Indicator

• This LED indicates the status of the Paper Photocell – paper breaks refection to

detector

• If there is no paper under the photocell, LD9 will be on

• If there is paper under the photocell, LD9 will be off

• If this LED does not change state when breaking the Paper Photocell then the

possible causes are:

• Paper Photocell not plugged into J13 on PSTP board or Photocell cable broken

• Photocell not aligned properly or photocell broken

• Paper photocell circuitry not functioning – replace PSTP board

33

• LD10: PSTP Transmit Indicator

• This LED is an indicator whenever the PSTP board communicates to the

ICPU/Display boards

• When the PSTP transmits, LD10 should flash for a short period of time

• When the PSTP is not transmitting, LD10 should be off

• If this LED does not flash ~ 4s after power up or if it is always on, then the possible

causes are:

• SCI phone cable not plugged into J15 on PSTP board and J1 on ICPU board

• SCI phone cable made incorrectly or broken

• Incorrect SW version for PSTP (3K SW not compatible with ICPU board)

• PSTP transmit circuitry not working (error message should be displayed) – replace

PSTP board

• LD11: PSTP Receive Indicator

• This LED is an indicator whenever the ICPU/Display boards communicate to the

PSTP board

• When the ICPU transmits, LD10 should flash for a short period of time

• When the ICPU is not transmitting, LD10 should be off

• If this LED does not flash ~ 4s after power up or if it is always on, then the possible

causes are:

• SCI phone cable not plugged into J15 on PSTP board and J1 on ICPU board

• SCI phone cable made incorrectly or broken

• Incorrect SW version for PSTP (3K SW not compatible with ICPU board)

• PSTP receive circuitry not working (error message should be displayed) – replace

PSTP board

• NOTE: for the 3K machine LD10 should always be on and LD11 should flash dimly when

keys are pressed on the KPAD

• High Voltage Solenoid Board

• The probable causes for HVS faults assume that there are no problems with the PSTP

board

• All of the problems listed above for the PSTP board are not present

• LD1: Primary +12V Supply Indicator

• This LED indicates whether the primary +12V logic supply on the HVS board is alive

• If this LED is not on then the possible causes are:

• Short on the P+12V line or R48 opened – replace HVS board

• Low Voltage Solenoid Board

• The probable causes for LVS faults assume that there are no problems with the PSTP

board

• All of the problems listed above for the PSTP board are not present

• LD8: Primary +12V Supply Indicator

34

• This LED indicates whether the primary +12V logic supply on the LVS board is alive

• If this LED is not on then the possible causes are:

• Short on the P+12V line – replace LVS board

• LD10: Secondary +12V Supply Indicator

• This LED indicates whether the Secondary +12V logic supply on the LVS board is

alive

• If this LED is not on then the possible causes are:

• LVS cable not plugged into J15 on LVS board and J8 on PSTP board

• LVS cable broken or not made correctly

• Short on the S+12V line – replace LVS board

• ICPU/Display Boards

• The probable causes for ICPU faults assume that there are no problems with the PSTP

board

• All of the problems listed above for the PSTP board are not present

• LD1: Secondary +5V Supply Indicator

• This LED indicates whether the secondary +5V supply on the ICPU is alive

• If this LED is not on then the possible causes are:

• SCI phone cable not plugged into J15 on PSTP board and J1 on ICPU board

• SCI phone cable made incorrectly or broken

• VR1 not functioning or short on S+5V line – replace ICPU board

• 3K Keypad

• The probable causes for LVS faults assume that there are no problems with the PSTP

board

• All of the problems listed above for the PSTP board are not present

• If Perf and Photocell LEDs do not change state when open/close perf and break Pcell

then the possible causes are:

• SCI phone cable not plugged into J15 on PSTP board and J1 on KPAD board

• SCI phone cable made incorrectly or broken

• KPAD board not functioning – replace KPAD board

Error Messages:

• Errors At Power up

• Solenoid Errors

• If this error occurs the machine should be powered down and then power back up again to verify

that the error occurs at least two consecutive times.

• If a solenoid error occurs at power up then the most likely cause is:

• Incorrect solenoid board attached to PSTP board

• Incorrect ICPU/Display SW

35

• This error cannot be cleared by a keypress – the fault must be fixed in order to clear the error

• EEPROM Errors

• If an EEP error occurs at power up then the most likely cause is:

• Switching PSTP boards without reformatting the ICPU EEPROM

• Faulty EEPROM on ICPU

• If encounter EEP errors at power up:

• Press STOP or ESC until all EEP errors are cleared

• Format EEP

• Power the machine down

• Power up the machine again

• If still encounter EEP errors replace ICPU board

• SCI Errors

• If SCI errors occur at power up they cannot be cleared by a keypress - the fault must be fixed

in order to clear the error

• To clear fault/isolate the problem refer to section above for PSTP transmit and receive LEDs

• Error could also be caused by SW mismatches – verify that PSTP SW is compatible with

ICPU SW

• RAM Errors (6K, 8K and 12K only)

• If this error occurs at power up, this error is display by flashing the Photocell LED on the display

boards

• If RAM errors occur at power up they cannot be cleared by a keypress - the fault must be fixed

in order to clear the error

• The probable cause of the problem is a faulty RAM chip – replace ICPU board

• Errors Encountered when Running Programs

• Paper Errors

• Generally paper errors can be cleared by hitting STOP or ESC

• The error message displayed should be looked up in error messages table to identify the cause

of the problem in order to fix it

• Solenoid Errors

• Generally solenoid errors can be cleared by hitting STOP or ESC

• The error message displayed should be looked up in error messages table to identify the cause

of the problem in order to fix it

• SCI Errors

• Generally SCI errors can be cleared by hitting STOP or ESC

36

• If the error message keeps recurring then there is probably a fault with either the hardware or

software

• Power down the machine and then power up again

• If get SCI errors then to clear fault/isolate the problem refer to section above for PSTP

transmit and receive LEDs

• Motor Errors

• Generally motor errors can be cleared by hitting STOP or ESC

• If the error message keeps recurring then there is probably a fault with the hardware – replace

PSTP board

3K Error Messages:

• Error messages for the 3K are displayed on the perf and photocell LEDs

• Observe when the Perf LED (red) flashes

• Count how many times the Photocell LED (green) flashes until the Perf LED flashes again

• The number of times the Photocell LED flashes corresponds to the error (see error message

table for 3K)

• Errors At Power up

• EEPROM Errors

• If an EEP error occurs at power up then the most likely cause is:

• Not formatting PSTP EEPROM

• Faulty EEPROM on PSTP

• If encounter EEP errors at power up:

• Press STOP – PSTP should automatically reformat EEPROM

• Power the machine down

• Power up the machine again

• If still encounter EEP errors replace PSTP board

• Errors During Program Running

• Paper Errors

• Generally paper errors can be cleared by hitting STOP

• The error message displayed should be looked up in error messages table to identify the cause

of the problem in order to fix it

• Solenoid Errors

• Generally solenoid errors can be cleared by hitting STOP

• The error message displayed should be looked up in error messages table to identify the cause

of the problem in order to fix it

37

7.0 GW PARTS LIST

38

PART NO. JR

. 3K 6K 8K 12K FM

100 FM

150 DESCRIPTION

10-001-GW X X X X X Red, Preinked Pad w/holder

10-002-GW X X X X X Black, Preinked Pad w/holder

10-003-GW X X X X X Uninked pad w/holder

10-004-GW X X X X X Felt Insert

10-005-GW X X X X X Red Ink, 4 oz. bottle

10-006-GW X X X X X Black Ink, 4 oz. bottle

10-007-GW X X X X X Changestick

10-008-GW X X X X X X 3/32" Hexdriver

10-009-GW X X X X X X X 5/32" Hexdriver

10-010-GW X X X X X X Ring Pliers

10-011-GW X X X X X X X ¾" Snap Ring

10-012-GW X X X X X Reverse Numbering Head (6 digits, 2 drop)

10-013-GW X X X X X Forward Numbering Head (6 digits, 5 drop)

10-014-GW X X X X X Condensed Reverse Numbering Head (8 digits, 4 drop)

10-015-GW X X X X X Date Stamp Head (month/day/year)

10-016-GW X X X X X 5/8" Wave Washer

10-017-GW X X X X X X Feed Tray

10-018-GW X X X X X X Feed Tray Side Guides

10-019-GW X X X X X X Feed Tray Slot Cover

10-020-GW X X X X X X Locking Wingnuts

10-021-GW X X X X X X Feed Platen Retarding Strip

10-022-GW X X X X X X Feed Shaft Adjust Screw

10-023-GW X X X X X X Locking Thumbnut

10-024-GW X X X X X X Roller Tire (feed/main/exit)

10-025-GW X X X X X X Roller Hub

10-026-GW X X X X X X Roller Shaft

10-027-GW X X X X X X 3/8 " Set Screw Collar

10-028-GW X X X X X X Shaft Bushing

10-029-GW X X X X X X Feed Shaft Bushing w/Spring

10-030-GW X X X X X X Shaft Bushing w/Spring

10-031-GW X X X X Solid Bottom Roller

10-032-GW X X X X Main Platen Crash Pad

10-033-GW X X X X Main Platen

10-034-GW X X X X Main Platen Grommets

10-035-GW X X X X Main Platen Mount Brackets

10-040-GW X X X X X Hand Knob

10-041-GW X X X X X 5/16" Disc Spring

10-042-GW X X X X X 5/16" Flat Washer

10-043-GW X X X Solenoid w/plunger

10-044-GW X X X Solenoid plunger

10-045-GW X X Pneumatic Cylinder

10-046-GW X X Pneumatic Valve Controller

10-047-GW X X Regulator, Manifold, Gauge Assembly w/hose

10-048-GW X X 3/8 ” Hose (4’ length)

10-049-GW X X 3/8 “ Hose Quick Connect

10-050-GW X X ¼ ” Hose (4 ½ ‘ length)

10-051-GW X X ¼ “ Hose Quick Connect

10-053-GW X X X X X Drive Unit Cover

PART NO. JR

. 3K 6K 8K 12K FM

100 FM

150 DESCRIPTION

10-054-GW X X X X X Print Head Mount

10-055-GW X X X X Exit Tray

10-056-GW X X X X Magnetic Tray Side Guides

10-057-GW X X X X X Magnets

10-058-GW X X X X X X Handwheel

10-059-GW X X X X X X X 120V Modular Line Cord

10-065A-GW X 3A,250V Fast Blow Fuse

10-065-GW X X 3A,250V Slow Blow Fuse

10-066-GW X X X X 5A, 250V Slow Blow Fuse

10-068-GW X X X X X Impression Control Dial Knob

10-071-GW X X X X X ½ “ Cord Strain Relief

10-084-GW X X X X X X Accessory Holder w/12 TPI perf blade

10-085-GW X X X X X X Accessory Holder Adjust Screw

10-086-GW X X X X X X Blade Mount Hub w/bearing

10-088-GW X X X X X X Accessory Holder w/idler wheel

10-089-GW X X X X X X Idler Wheel Tire

10-090-GW X X X X X X Boss Wheel

10-091-GW X X X X X X 2 TPI Perf. Blade

10-092-GW X X X X X X 4 TPI Perf. Blade

10-093-GW X X X X X X 6 TPI Perf. Blade

10-094-GW X X X X X X 8 TPI Perf. Blade

10-095-GW X X X X X X 12 TPI Perf. Blade

10-096-GW X X X X X X Microperf (42 TPI) Blade

10-097-GW X X X X X X Microperf (72 TPI) Blade

10-098-GW X X X X X X Slit Blade

10-099-GW X X X X X X Score Blade

10-100-GW X X X X X X Narrow Score Blade

10-101-GW X X X X X X Double Score (1/4 " separation) w/Holder & Boss

15-005-GW X X X X X Red Quick Drying Ink, 2 oz. Bottle

15-006-GW X X X X X Black Quick Drying Ink, 2 oz. Bottle

15-036-GW X X X X ¾ “ Keyed Drive Unit Mount Shaft

15-037-GW X X X X Anti-Pitch Block

15-038-GW X X X X X X 5/16” Dogged Set Screws

15-039-GW X X X X Drive Unit Mount Block (left/right pitch control)

15-052-GW X X X X Solenoid Mount Angle w/tube (left/right pitch)

15-072-GW X X Complete Drive Unit

15-073-GW X X Complete Drive Unit w/Reverse #ing Head

20-001-GW X Base Plate w/Channel

20-002-GW X Register Lay Sheet

20-003-GW X Crash Pad

20-005-GW X Slot Plate w/Arm

20-006-GW X Disk Spring #8

20-007-GW X Forward/Back Adjustment Screw

20-008-GW X Head Height Adjustment Screw

20-010-GW X Footpedal w/Cord

20-011-GW X Solenoid Cable

20-013-GW X 6 Pin Board Connector

20-014-GW X Main Label

39

PART NO. JR

. 3K 6K 8K 12K FM

100 FM

150 DESCRIPTION

20-015-GW X Impression Control Harness

25-004-GW X Circuit Enclosure

25-009-GW X Switch Plate/Circuit Mount

25-012-GW X Circuit Board- external impression control

30-025-GW X X X X Large Clutch Feed Pulley /12k

30-027-GW X X O Ring Drive Belt

30-037-GW X X X Rubber Foot

40-003-GW X X X X X X Timing Pulley- 18XL037X3/8

40-103-GW X X X X X X Timing Pulley- 18XL037X1/2

50-007-GW X X X X X X Main Structure Shaft

50-008-GW X X X X Feed Platen/8000

50-009-GW X X X X X X Shaft Adjust Blocks

50-011-GW X X X X Drive Unit Mount Shaft Bracket

50-014-GW X X X X X X Boss Wheel Shaft

50-016-GW X X X Safety Switch/12k

50-018-GW X X Exit Stripper

50-019-GW X X X X X X Cross Shaft

50-020-GW X X X X Exit Rollers Safety Shield

50-021-GW X X X X Timing Belt- 220XL037

50-022-GW X X X X Belt Tensioner

50-023-GW X X X 1 ¾ “ Feed Pulley

50-033-GW X X X X Fan Guard

50-035-GW OP OP X OP Stand/8000

50-037-GW OP OP X OP X Regular Caster Wheel

50-038-GW OP OP X OP X Locking Caster Wheel

50-040-GW X Solenoid Ferrite Bead

60-001-GW X X Conveyor Outfeed Plate

60-002-GW X X Shaft Mount Block- operator’s side

60-003-GW X X Shaft Mount Block- non-operator’s side

60-004-GW X X Shaft & Pile Tray Mount Block- op. side

60-005-GW X X Shaft & Pile Tray Mount Block- non-op.side

60-006-GW X X Pile Tray

60-007-GW X X Conveyor/Actuator Shaft

60-008-GW X X Conveyor Actuator Frame

60-009-GW X X Conveyor Actuator Arm

60-011-GW X X Conveyor Spur Gear

60-012-GW X X Conveyor Top Roller Support Arm

60-013-GW X X Conveyor Top Roller Shaft

60-014-GW X X Conveyor Top Roller

60-015-GW X X Conveyor Actuator Cam

60-016-GW X X Conveyor Belt

60-017-GW X X Conveyor Belt Spool

70-003-GW X X Feeder Side Plate

70-004-GW X X Non-Operator Small Cover

70-005-GW X X Operator Side Small Cover

70-006-GW X X Feed Platen/12000

70-007-GW X X Feed Pulley w/spur gear

70-008-GW X X 1 ½” Feed Pulley

70-014-GW X X Steel Ball Bearing

40

PART NO. JR

. 3K 6K 8K 12K FM

100 FM

150 DESCRIPTION

70-015-GW X X Nylon Ball Bearing

70-019-GW X X O-Ring Drive Belt /12k

80-006-GW X X Timing Belt 140XL037

80-007-GW X X Controller (115 VAC)

80-007-GW-X X X Controller (115 VAC) Exchange

80-008-GW X X Motor (115 VAC)

85-007-GW X X Controller (230 VAC)

85-007-GW X X Controller (230 VAC) Exchange

85-008-GW X X Motor (230 VAC)

85-010-GW X X Speed Control Potentiometer

90-001-GW X X X X Non-Operator Side Plate

90-002-GW X X X X Operator Side Plate

90-003-GW X X X X Non-Operator Side Cover w/guard

90-004-GW X X X X X X Operator Side Cover

90-005-GW X X X X Stepper Motor

90-006-GW X X X Motor Ferrite Bead

90-007-GW X X X X Motor Guard

90-009-GW X X X X Metal Display Panel

90-010-GW X X X X X X Main Bottom Roller

90-011-GW X X X X Photocell Reflector

90-012-GW X X X X X X Accessory Holder Mount Shaft

90-013-GW X X X X X X Stripper Assembly

90-014-GW X X Conveyor Actuator Spring

90-015-GW X X X Safety Shield w/hinge & actuator /3/6/8k

90-016-GW X X X Safety Switch w/harness /3/6/8k

90-024-GW X X X O-Ring Feed Drive Belt/3/6/8k

90-025-GW X MSTP Board/3k

90-025-GW-X X MSTP Board: Exchange/3k

90-026-GW X MSTP Chip

90-028-GW X X HV Voltage Solenoid Board 3/6k

90-028-GW-X X X HV Voltage Solenoid Board 3/6k: Exchange

90-029-GW X ICPU Display Board

90-029-GW-X X ICPU Display Board: Exchange

90-030-GW X X X X Telephone Cable

90-031-GW X X X X X X Low Profile Tie Mounts

90-032-GW X X X X 12V Cooling Fan

90-034-GW X Display Board Label

90-054-GW X X X X Print Head Mount Screws

90-055-GW X X X X Print Head Rotation Screw

90-059-GW X X X X X X 220V Line Cord

90-060-GW X X X X MSTP Board 120V Connector

90-061-GW X X X X MSTP Board 220V Connector

90-062-GW X X X X X X X Modular Switch w/fuseholder

90-063-GW X X X X Line Filter

90-064-GW X X X X Filter to MSTP Board Cable

90-065-GW X X X X Board Mount Stand-Off

90-067-GW X X X X Photocell Assembly

90-068-GW X X HV Sol-MSTP power Cable

90-069-GW X X Solenoid Connection: Board to Female Terminal

41

PART NO. JR

. 3K 6K 8K 12K FM

100 FM

150 DESCRIPTION

90-082-GW X X X X Wire Transfer Tube

90-085-GW X X X X Plastic Electrical Guard

92-025-GW X X X MSTP Board

92-025-GW-X X X X MSTP Board: Exchange

92-026-GW X X X MSTP Chip

92-027-GW X ICPU EPROM

92-028-GW X X HV Voltage Solenoid Board

92-028-GW-X X X HV Voltage Solenoid Board: Exchange

92-029-GW X ICPU Display Board

92-029-GW-X X ICPU Display Board: Exchange

92-030-GW X Red Screen Cover

92-034-GW X Display Board Label/6k

94-003-GW X X X X Non-Operator Side Cover w/guard

94-013-GW X X X X Boss Support Shaft

94-014-GW X X X X Boss Bearing Support Assembly

94-027-GW X X ICPU EPROM

94-028-GW X X LV Voltage Solenoid Board

94-028-GW-X X X LV Voltage Solenoid Board: Exchange

94-029-GW X X ICPU Display Board

94-029-GW-X X X ICPU Display Board: Exchange

94-034-GW X X Display Board Label

94-035-GW X X Clear Plastic Screen Cover

94-072-GW X X Complete Pneumatic Drive Unit

94-073-GW X X Complete Pneumatic Drive Unit w/Reverse #ring Head

94-082-GW X X Drive Unit Connection Label

94-083-GW X X LV Solenoid to MSTP Board Power Cable

94-084-GW X X Drive Unit Connection Mount Plate

96-009-GW X X Register Board

96-012-GW X X Register Guide

96-013-GW X X Register Board Ball Holder

96-015-GW X X Safety Shield w/Shaft

96-016-GW X X Safety Switch Harness/12k

96-017-GW X X Register Board Cross Shaft Supports

96-018-GW X X Register Board Bearing Blocks

96-023-GW X X Register Board Conveyor Spool

96-024-GW X X Non-Operator Side Stock Guide

96-026-GW X X Register Board Belt

96-035-GW X X Stand/12000

96-070-GW X X LV Solenoid Connection: Phone Jack to Solenoid

96-071-GW X X LV Solenoid Connection: Board to Phone Jack Connector

98-001-GW X X FM Non-Operator Side Plate

98-002-GW X X FM Operator Side Plate

98-003-GW X X Non-Operator Side Cover

98-004-GW OP X Counter Photo-Cell

98-005-GW OP X Counter

98-006-GW X X Display Label

98-007-GW X X Red - Alternate Push Button Switch

98-008-GW X X Green - Alternate Push Button Switch

98-009-GW X X Metal Display Panel

42

8.0 PARTS DIAGRAMS

90-015-GW

10-055-GW

10-056-GW

40-003-GW

90-024-GW

8.3 GW 3/6/8000 OPERATOR SIDE

40-103-GW

50-021-GW

90-005-GW

10-030-GW

10-031-GW

40-003-GW

50-009-GW

50-023-GW

90-010-GW

10-026-GW

50-022-GW

8.2 EXIT TRAY ASSEMBLY

10-057-GW

50-014-GW

90-063-GW

90-082-GW

90-031-GW

40-003-GW

90-062-GW

30-025-GW

10-022-GW

10-023-GW

10 026-GW

90-002-GW

8.1 FEED TRAY ASSEMBLY

10-018-GW

10-020-GW

10-019-GW

10-018-GW

10-017-GW

43

90-054-GW

10-043-GW

10-044-GW

15-052-GW

8.4 ELECTRIC SOLENOID DRIVE UNIT (15-072-GW)

10-011-GW

10-054-GW

10-053-GW

50-040-GW

15-039-GW

10-040-GW

10-042-GW

10-041-GW

January 1997

90-054-GW

10-071-GW

15-052-GW

8.5 PNEUMATIC SOLENOID DRIVE UNIT (94-072-GW)

10-045-GW

BLACK

RED

10-011-GW

10-054-GW

90-055-GW

10-046-GW

GREE

YELLW

10-053-GW

15-039-GW

96-070-GW

10-050-GW

10-040-GW

10-042-GW

10-041-GW

44

Pressure Adjustment Screw

(10-085-GW)

Locking Thumbnut

(10-023-GW)

8.6 ACCESSORY HOLDER

Blade Hub

Perf/Slit/Score Blade

(10-095-GW)

3/4 '' Snap Ring

(10-011-GW)

Position Locking

Set Screw

(

15-038-G

W

Perf & Slit Blades Ride On The

Flat Surface Of The Boss Wheel

8.7 Blade Placement on the Boss Wheel

Regular Score Blade Rides

In This Groove

Boss Wheel

(10-090-GW)

Boss Wheel Shaft

(50-014-GW)

Narrow Score Blade Rides

In This Groove

96-019-GW

70-008-GW

70-008-GW

60 011-GW

30-027-GW

70-008-GW

70-007-GW

8.8 GW 12000 FEED DRIVE COMPONENTS

45

10-030-GW

10-027-GW

10-029-GW

10-090-GW

10-030-GW

50-020-GW

10-029-GW

10-029-GW

8.10 GW 3/6/8000 Shaft Placement

10-026-GW

10-027-GW

10-029-GW

50-014-GW

10-026-GW

10-030-GW

90-015-GW

10-024-GW & 10-025-GW

10-025-GW

10-031-GW

10-026-GW

15-036-GW

10-029-GW

50-011-GW

10-058-GW

10-024-GW & 10-025-GW

10-024-GW & 10-025-GW

10-029-GW

50-010-GW

10-030-GW

10-030-GW

70-003-GW 96-017-GW 10-027-GW

96-023-GW

10-027-GW

8.9 GW 12000 Structural Parts Diagram

60-007-GW

96-018-GW

50-017-GW 70-006-GW

50-019-GW

96-024-GW

10-021-GW

50-019-GW

50-009-GW

10-032-GW

10-035-GW

90-001-GW

10-034-GW

90-082-GW

90-012-GW

50-019-GW

90-007-GW

50-019-GW

10-033-GW

90-002-GW

70-015-GW

96-012-GW

96-025-GW

70-014-GW

96-013-GW

96-009-GW

70-003-GW

94-013-GW

94-014-GW

46

60-004-GW

60-014-GW

8.11 Conveyor Outfeed Assembly

60-007-GW

60-001-GW

60-003-GW

60-008-GW

10-026-GW

60-017-GW

60-017-GW

60-017-GW

60-005-GW

10-027-GW

60-016-GW

60-002-GW

60-016-GW

60-012-GW

60-009-GW

10-027-GW

90-014-GW

60-015-GW

60-011-GW

10-027-GW

50-018-GW

60-013-GW

10-026-GW

60-017-GW

60-017-GW

60-006-GW

47

48