Infinity Solutions 7K Plus Manuel utilisateur

Infinity Solutions Manufacturing

192 Gannett Drive South Portland, ME 04106

(207) 899-1714

7K Plus Service Manual

iii

Table of Contents

Table of Contents ..............................................................................................................................................iii

Service Manual Notes.........................................................................................................................................v

Tools Needed.....................................................................................................................................................................v

Parts:..................................................................................................................................................................................v

Technical Help ...................................................................................................................................................................v

Additional Notes.................................................................................................................................................................v

1. Machine Overview ..........................................................................................................................................6

1.1. Covers.........................................................................................................................................................................7

2. Drive Train.......................................................................................................................................................8

2.1. Conveyor Drive Pulley & O-Ring ................................................................................................................................8

2.2. Drive Motor: Belt, Pulleys, and Clutch........................................................................................................................9

2.3. Gears ..........................................................................................................................Error! Bookmark not defined.

2.4. Double Sided Timing Belt and Drive Pulleys............................................................................................................11

3. Feed Table.....................................................................................................................................................12

3.1. Feed Table................................................................................................................................................................12

3.2. Feed Drive Belts .......................................................................................................................................................13

4. Feed Gauge...................................................................................................................................................14

5. Nip Wheel ......................................................................................................................................................15

6. Conveyor.......................................................................................................................................................16

6.1. Extended Conveyor Belts .........................................................................................................................................16

6.2. Conveyor Belts............................................................................................................Error! Bookmark not defined.

7. Wiper..............................................................................................................................................................17

8. Rolls...............................................................................................................................................................18

9. Electrical........................................................................................................................................................20

9.1. Drive Motor ...............................................................................................................................................................20

9.2. Touch Screen............................................................................................................................................................20

9.3. PLC...........................................................................................................................................................................21

9.4. Power Supply............................................................................................................................................................21

9.5. Motor Drive ...............................................................................................................................................................21

9.6. Doubles Detection.....................................................................................................................................................22

9.6.1 Optic Cable..........................................................................................................................................................................22

9.6.2 Optic Amplifier......................................................................................................................................................................22

9.6.3 Sensor Alignment.................................................................................................................................................................23

9.6.4 “Teaching” the Optic Amplifier..............................................................................................................................................23

9.7. Feed Counter............................................................................................................................................................23

10. Troubleshooting .........................................................................................................................................24

10.1. Machine Will Not Power On....................................................................................................................................24

10.2. Machine Powers On But Will Not Run....................................................................................................................24

10.3. Machine Stops Running..........................................................................................................................................25

10.4. Paper Jams.............................................................................................................................................................25

10.5. Improper Functioning of the Machine.....................................................................................................................26

10.5.1 Misaligned Folds................................................................................................................................................................26

10.5.2 Paper Feed Problems........................................................................................................................................................26

10.5.3 Dirty forms..........................................................................................................................................................................27

10.5.4 Motor Runs only in one direction........................................................................................................................................27

10.5.5 Erratic speeds......................................................................................................................Error! Bookmark not defined.

10.5.6 Excessive Noise.................................................................................................................................................................27

10.5.7 Poor Stacking.....................................................................................................................................................................27

10.6. Sensors...................................................................................................................................................................27

10.6.1 Doubles Detection..............................................................................................................................................................27

10.6.2 Reflective Counter Sensor.................................................................................................................................................28

10.6.3 Door Switch........................................................................................................................................................................28

10.6.4 Fold Plate Switch ...............................................................................................................................................................28

10.7. Electronic Components...........................................................................................................................................30

10.7.1 Touch Screen.....................................................................................................................................................................30

10.7.2 Power Supply.....................................................................................................................................................................30

10.7.3 PLC....................................................................................................................................................................................30

10.7.4 Driver .................................................................................................................................................................................30

10.7.5 Drive Motor ........................................................................................................................................................................30

11. Appendix .....................................................................................................................................................31

12. Addendums………………………………………………………………………………………………………….31

v

Service Manual Notes

Tools Needed

• Set of standard Inch Allen Wrenches

• 7/16” Deep Socket & Driver

• 1 ¼ “ Socket

• Torque Wrench, with 12 ft*lbs capabilities

• Philips head Screw Driver

Parts:

For parts please contact Infinity Solutions Manufacturing:

Phone: (207) 899-1714

Fax: (207) 228-1890

www.infinitysolutionsmfg.com

Part numbers are included for components shown in exploded views through out the manual and in the

appendix.

Technical Help

The majority of service operations are covered in this manual. However, if you are unable to resolve a

problem please contact technical support at Infinity Solutions Manufacturing.

Phone: (207) 899-1714

Additional Notes

This manual is for use with the Infinity Solutions 7K plus.



1. Machine Overview

•Read the operators manual to become familiar with the machine operation.

Feed Gauge

Electrical Side

Cover

Control Panel

Motor Side

Cover

Conveyor Nip

Wheels

Feed Table

Extended Conveyor

Lower Fold Plate

Upper Fold Plate

Figure 1: Overview

1.1. Covers

a) Removal

1. Remove the cover screws (4x).

2. Slide the cover off the machine.

b) Installation

1. Installation is the reverse of removal.

Cover

Power Switch / Breaker

Power Cord Plug

Figure 2: Power Connection and Switch

Figure 3: Covers

Cover Screw (4x)

2. Drive Train

2.1. Conveyor Drive Pulley & O-Ring

a) Removal

•Disconnect the power cord from the machine.

1. Remove the drive train side cover.

2. Roll the o-ring off of the conveyor pulley.

3. Remove the conveyor pulley.

a)Loosen the set screw.

b)Pull the pulley off of the shaft.

b) Installation

1. Place the conveyor pulley onto the shaft with the hub on the

inside.

2. Align the O-Ring grove in the pulley with the O-Ring grove on the roll shaft.

Figure 4: Drive Train

Note: if motor belt is marked 5M450 15, then see addendum

Motor Pulley and Clutch

Feed Drive

Pulley

Motor Belt

28-0832-00

Door Switch

Double Sided Belt

Conveyor Pulley

Roll Gears

Feed Pinion

Pulley

Feed Drive

Belt

O-Ring

Figure 5: Conveyor Drive

Note: The conveyor pulley is mounted on a floating shaft and the pulley will self align itself, however is best if they

are closely aligned to begin with. Tighten the set screw

3. Roll the o-ring onto the conveyor pulley.

4. Ensure the o-ring or pulley can not contact any other drive train components.

Note: For conveyor pulley and O-ring part #’s see the Appendix. If existing pulley does not have shown hub,

then the clear o-ring must be used. Otherwise, the black one is needed.

2.2. Drive Motor: Belt, Pulleys, and Clutch

a) Removal

•Disconnect the power cord from the machine

1. Loosen all four motor screws and slide the drive motor forward to loosen the belt tension.

2. Slide motor belt off of the motor pulley.

3. Remove the motor clutch and pulley.

a)Loosen set screw.

b)Pull the motor clutch and pulley off of the motor shaft.

Note: If the motor pulley needs to be removed from the clutch,

remove the set screws, the large center nut on the clutch and

disassemble. To break the nut loose reinstall the belt, place a

socket driver on the end of the hex shaft and loosen the center

nut on the clutch. Alternately, if the clutch is already removed,

the inside can be placed in a vise and the center nut can be

loosened.

4. Remove the roll drive pulley.

a)Loosen both the set screws.

b)Slide the pulley off of the shaft.

b) Installation

1. Install the roll drive pulley onto the roll shaft with hex end. Ensure the drive key is properly placed in the

keyway. Butt the pulley up with the coinciding pulley on the shaft and tighten both set screws.

2. Install the motor clutch and pulley onto the motor shaft. Ensure the drive key is properly placed in the

keyway. Note that an undersized 3/16 key is used.

3. Slide the belt onto the pulleys. Align the motor clutch and pulley on the motor shaft so that the belt rides on

the middle of the pulley. Tighten the set screw.

4. Adjust the belt tension (See Section 2.2.c)

5. Check for clearance of the belt between nearby pulleys and ensure there will be no interference. If any

interference is found realign pulleys.

c) Adjustments

Belt Tension

1. With the motor mounting screws loose, slide the drive motor back until the belt is taut. Tighten the motor

mounting screws.

Motor Clutch Adjustment

The motor clutch must be adjusted if:

(i) Being replaced

(ii) The motor pulley has been removed from the clutch

(iii) The center nut on the clutch has been loosened or

tightened.

Figure 7: 1 and 2/3 forms

folded together

Figure 6: Drive Motor System

Note: If improperly adjusted premature component failure or poor machine performance can occur.

1. Use a torque wrench to tighten the center nut of the clutch to 12 ft/lbs.

2. With the drive train completely assembled and all protective guards in place plug in the machine and power it

on.

3. Test the adjustment by running a 1 2/3 folded form (See Figure 7) through the back of the machine while it

runs at full speed (See Figure 8 ).

a)To feed the form into the back of the machine, remove the rear fold plate. The fold plate switch will have to

be depressed to run the machine in the forward direction.

b)The form should make it through with minimal slipping of the motor. Note: by listening to the motor you

will be able to hear if it slips. If the form does not make it through the machine then the clutch is too loose:

tighten the clutch and repeat.

4. To determine if the clutch is too tight run two forms folded together through the back of the machine. The

paper should not make it through the machine, however the clutch should slip. You will be able to briefly hear

this just as the motor shuts down. If the clutch does not slip at all loosen the center nut.

5. Repeat steps 3 and 4 until both above criteria are met.

Note: If pulley material is aluminum, then see addendum

Figure 9: Motor Clutch Exploded View

Figure 8: Back of the Machine

Insert folded form Here

for clutch adjustment

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