Horizon PS P61 Punch Stapler Service Manual
MyBinding PS-P61 is a versatile and efficient stapler and punch unit designed to enhance your document finishing capabilities. With its ability to perform corner stapling, top stapling, and other side corner stapling on A4 sheets, and corner stapling on A3 sheets, this device offers flexible stapling options for various document sizes. Additionally, the optional punch feature allows for punching holes in A4-sized documents, making it an ideal solution for creating professional-looking reports, booklets, and presentations.
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Standard PS-P61
Punch Stapler
Service Manual
Provided By
http://www.MyBinding.com http://www.MyBindingBlog.com
SERVICE MANUAL
PS-P61 Punch Staple
510 Kuze Ooyabu-cho Minami-ku, Kyoto 601-8206, Japan
Phone:+81-75-934-6700, Fax:+81-75-934-6708, www.horizon.co.jp
Kyoto,Japan
FOREWORD
Punch Staple
Model PS-P61
This manual is designed to help you to keep the machine in a good operating condition. Read, study and keep this manual in a safe and convenient place.
Do not perform any maintenance until you read and understand the instructions in this manual.
If you have questions regarding maintenance or this publication, please contact our service division.
The machine design and specifications are subject to change without notice.
030701/PSP61/03E/DV
I
US501008-03
Safety Instruction
1. Read and understand all safety instructions with a signal WARNING, and CAUTION. If safety instructions are ignored, personal injury will result.
2. HORIZON INTERNATIONAL INC. cannot anticipate every possible situation that might involve a potential hazard. The instruction in this manual are therefore not all inclusive.
3. Be sure to unplug the power cord when replacing the parts or repairing the machine.
4. Take care with the rotating parts when the machine is operated with the covers being opened.
5. Use the original HORIZON spare parts when replacing the parts.
II
I Necessary Tool for Maintenance and Repair
Use the following tools for maintenance and repair.
1.
2.
3.
4.
5.
Screw Driver
Screw Driver
Allen Wrenches
Open-ended Wrench
Box Wrench
6.
Snap-ring Expander
No. 2
6 to 7 mm
1.5, 2, 2.5, 3, 4, 5, and 6 mm
5.5 x 7 mm 8 x 10 13 x 17
5.5 mm
II Signs and Abbreviations in This Manual
1. The following signs in this manual represent wire color.
2. The following abbreviations in this manual represent electronic and electrical parts.
Sign Color
C Brown
R Red
O Orange
Y Yellow
G Green
B Blue
V Violet
H Gray
W White
D Black
S Transparent
Abbreviation Meaning
CL
BK
SW mSW
M
LED
VR
RY
Clutch
Brake
Switch
Microswitch
Motor
Light Emitted Diode
Potentiometer
Relay
III
Contents
FOREWORD .......................................................................................................................... I
Safety Instruction ................................................................................................................... II
1. PS-P61 Specifications ...................................................................................................... 1
4. How to Remove Cover .................................................................................................... 4
5. Sensors and Electronic Parts Descriptions ................................................................... 5
6. Sensor Location and Descriptions ................................................................................. 6
7. Transport Belt Drive Descriptions ................................................................................ 7
8. Troubleshooting ............................................................................................................... 8
9. LED and ConnectorDescriptions on P.C.B. .................................................................. 11
10. Power & Signal Line Diagram ..................................................................................... 12
11. Panel Sensor Line Diagram .......................................................................................... 13
12. Staple Unit Inside Line Diagram ................................................................................. 14
13. Power Supply Line Diagram ........................................................................................ 15
14. Punch Unit and Sensor ................................................................................................. 16
15. Timing Chart 1 .............................................................................................................. 17
16. Timing Chart 2 .............................................................................................................. 18
17. Timing Chart 3 .............................................................................................................. 19
18. Check Mode ................................................................................................................... 20
IV
1. PS-P61 Specifications
Product Staple and Punch Unit for QC-P8/P10
Integrated Model QC-P8, QC-P10
Jobs A4 : Corner Staple, Top Staple, and other Side Corner Staple
A3: Corner Staple
NOTE - Only corner staple can be done with optional punch.
- Two hole punch (option) can be performed only on A4 size.
Sheet Size with Operation Panel A4 and A3
NOTE - Sheet size must be within +,-0.5 mm.
Sheet Size Width : Maximum 298 mm (11.8") Minimum : 182 mm (7.2")
Length : Maximum 432 mm (17") Minimum : 257 mm (10.2")
NOTE - Other side corner staple and top staple are limited in size.
Sheet Quality Normal Paper
Stapling and Punching Thickness 10 Sheets of 135 gsm (36# Bond)
Sheet Thickness 53 to 135 gsm (16# Bond to 36# Bond)
Optional Punch Capacity Up to 105 gsm of normal paper
Production Speed 25 Sets/min. (Corner Staple)
15 Sets/min. (Top Staple, Other Side Corner Staple and Staple with Punch)
Transport Method Connecting Section : Roller Transport
Producing Section : Belts Transport
Detector Sheet Jam, No Staple, Door, Staple Trouble, Punch Trouble, and Full Tray
(LEDs illuminate on operation panel.)
Counter
Drive
4 digits (For Maintenance)
DC Motor : 3 x 24 V DC Solenoid : 4 x 24 V/35 W
DC Motor : 1 x 24 V (with Punch)
Power 100 V 50/60 Hz, 115 V 60 Hz, 230 V 50 Hz
Power Consumption 150 W
Machine Dimensions Tray Open : 1,115 x 562 x 582 mm (43.9" x 22.2" x 22.9")
(W x D x H)
Tray Close : 775 x 562 x 580 mm (30.6" x 22.2" x 22.9")
Machine Weight 77 kg (170 lb)
1
2. Operation Overview
1. Pile sheets into bins and turn on power switch.
- Staple unit will be reset if staple unit is not at home position before power is on.
- LED conditions of operation panel
Jog Guide Illuminates at the current position. Not illuminates when irregular sheets are used.
Illuminates at the angled side staple position.
Staple Mode
Punch
Jog Time
Not illuminates.
1 time lamp illuminates.
2. Press option button on collator.
- Option LED illuminates.
- Gate in collator moves.
3. Set jog guides according to sheets.
- LED in the selected sheet size illuminates.
4. Select required mode with staple mode button.
- LED illuminates in different position as staple button is pressed.
Staple unit moves to set position a few seconds after staple mode is selected.
NOTE
- In the case of other side corner staple or top staple, staple mode cannot be selected because of limited sheet size.
- In the case of staple with punch, staple mode cannot be selected because of limited sheet size.
5. Set receiving tray and receiving tray guide according to sheet size.
6. Press check button of collator twice. As collator starts, transport unit will transport a set of sheets. The set is stapled and/or punched and delivered to receiving tray.
7. Press start button of collator. Collator starts collating and sets of sheets are produced.
When miss/double or other troubles happen on collator, collating job stops with LED illuminated.
Collator's Error : Sheet jam, misfeed, and double feed are indicated on panel of collator.
PS-P61's Error : QC-P10 : Option error message is indicated on collator.
QC-P8 : Receiving tray lamp illuminates on collator.
PS-P61 : Monitor lamp illuminates.
8. When preset counter reaches to set number, collating stops and then transport unit stops.
- In the case of the number of sets are not input in preset counter, collator stops because
sheets run out, or because receiving tray of PS-P61 is full.
2
3. Sheet Flow
Gate
Transport Unit
Transport Rollers
Sheet Feed Sensor
Jog Guide 1
Forward Roller
Delivery Roller
Staple Unit
B4 Stopper
Receiving Tray
Sheet Jog Sensor Transport Belt Jog Guide 2 Stopper Sensor Stopper
A. Corner Staple with A4 and A3 Sheet Size (8.5" x 11"/11" x 17")
1. A set of collated sheets are delivered to transport unit.
2. A set of sheets are transported by transport rollers and pass sheet feed detector.
3. Transport belt and forward roller transport a set of sheets to stopper.
4. Transport belt stops.
5. Jog solenoids is activated and jog sheets.
6. Stapler staples sheets.
7. Delivery roller lowers and transport belt delivers a set of sheets to receiving tray.
B. Top Staple with A4 Sheet Size (8.5" x 11")
Staple unit moves to top staple position and is ready to staple. The procedures 1 to 6 are the same as A.
7. Delivery roller lowers and transport belt delivers a set to the second staple position.
8. Jog solenoids is activated and jog sheets.
9. Stapler staples sheets.
10. Transport belt delivers a set of sheets to receiving tray.
C. Other Side Corner Staple with A4 Sheet Size (8.5" x 11")
Staple unit moves to the other side corner staple position and is ready to staple. The rest procedures are the same as A.
D. Punch
The procedures 1 to 6 are the same as A.
7. Punch punches sheets.
8. Delivery roller lowers and transport belt delivers a set to receiving tray.
3
4. How to Remove Cover
B4-6BC (4 pcs)
Rear Cover (L)
Front Cover (U)
B4-8Zpan (4 pcs)
4
5. Sensors and Electronic Parts Descriptions
S/N
001001 to
099001
Motor Driver
Transport Belt Motor
S/N
002901 to
008917
Brake
Clutch
Sheet Feed Sensor
Pulse Sensor
Door Open Sensor Switch
Jog Solenoid 1
Sheet Jog Sensor
Counter
Transport Unit Motor
Transport Unit Open Sensor
Power Supply Box
(Switch, Power Supply (5 V and 24 V), Breakers)
Punch Unit (Motor and Reset Sensor)
Staple Unit
(Motor, Reset Sensor and No Staple Sensor )
Stopper Sensor
Full Tray
(Receiver) P.C.B. (QPP-263A)
Full Tray (Projector)
P.C.B.(QPP-263A)
Control P.C.B. (QPW-457)
Panel P.C.B. (QPW-458)
From
S/N
100001
Jog Solenoid 2
Motor Driver
Transport Belt Motor
Stopper Solenoid
B4 Stopper Solenoid
Transport Roller Solenoid
5
6. Sensor Location and Descriptions
Jog Guide 1 Position Sensor
Staple Motor
Staple Home Position Sensor
Jog Guide 2 Position Sensor
Sketch of Staple Cabinet
6
7. Transport Belt Drive Descriptions
(1) Applied Serial Number : S/N from 002901 to 008917
Brake
Transport Belt Motor
Clutch
Timing Belt
Sheet Pulse Sensor
Transport Belt
Sketch of Inside of Staple Unit
(2) Applied Serial Number : S/N 001001 or up
Motor
Coupling
Motor Driver
7
Transport Belt
8. Troubleshooting
A. Staple position (top staple) varies by more than 10 mm.
(Cause)
Delivery roller does not lower enough and not deliver a set of sheets. Transport belt is dirty. Clearance between clutch and brake gets wider.
(Remedy 1)
Adjust delivery roller so that it lowers enough.
- Adjust solenoid so that delivery roller touches transport belt and spring is compressed about 1 mm when solenoid activates.
(Remedy 2)
Clean transport belt with alcohol soaked cloth.
(Remedy 3)
Check the clearance between clutch and brake. Standard clearance is 0.15 (+,-0.05) in both clutch and brake.
Applied Serial Number : S/N from 002901 to 008917
B. When sheet jam 1 lamp illuminates.
(Cause)
Sheets are jammed in transport unit or transport unit is open.
(Remedy)
Open transport unit and remove jammed sheets. And close transport unit firmly.
C. When sheet jam 2 lamp/ sheet jam 3 lamp illuminates.
(Cause)
Sheets are jammed in staple cabinet.
(Remedy 1)
Press eject button.
(Remedy 2)
Pull out staple cabinet and remove jammed sheets. In the case sheet jam 3 lamp illuminates, lift support guide unit and remove jammed sheets.
D. When punch trouble lamp flashes.
(Cause)
Punch unit is locked.
Attention
Punch Capability: up to 10 sheets of 105 gsm normal paper.
(Remedy)
Turn off power switch of collator, then turn on again after a few seconds. Press eject button, open staple cabinet and remove jammed sheets.
8
8. Troubleshooting
E. When no staple/staple trouble lamp illuminates.
(Cause 1)
Out of staples.
(Remedy 1)
Refill staples.
(Cause 2)
Staple unit head is not set on the proper position.
(Remedy 2)
Press eject button to reset staple unit.
F. When no staple/staple trouble lamp flashes.
(Cause)
Staple unit is locked because of staple jam.
(Remedy)
Turn off power switch of collator, then open staple cabinet and remove jammed sheets or staples. Close staple cabinet, turn on power switch of collator and press eject button. Staple unit will be reset. Check for proper stapling by collating several sets (7 to 8 sets).
G. When door lamp illuminates.
(Cause)
Staple cabinet or rear cover is open.
(Remedy)
Close staple cabinet or rear cover.
H. When receiving tray lamp illuminates.
(Cause)
Receiving tray is full, or sheets are not delivered completely.
(Remedy)
Remove sheets from receiving tray, or delivery area.
I. When sheets are delivered without stapling. (Collating Continues.)
(Cause)
Staples are not fed to stapling position in staple unit.
(Remedy 1)
Set unnecessary sheets on bin, and check for proper stapling by collating several sets (7 to 8 sets).
(Remedy 2)
Open staple unit, pull up and release staple cartridge and clean staple feed roller with alcoholic soaked cloth.
9
8. Troubleshooting
J. When sheets are delivered without stapling. (Collating stops.)
(Cause)
Collated sheets are not jogged neatly.
(Remedy 1)
Open staple cabinet and check whether jog guide is positioned to sheet size properly.
(Remedy 2)
Straighten curled sheets, and fan them well.
(Remedy 3)
Press jog switch and select 2-time jog.
K. When circuit breaker trips.
(Remedy)
Turn off power switch of collator. Check inside of collator for obvious problems such as jammed sheets. If there is a problem, remove the cause. Reset circuit breaker a few minutes after turning off power switch.
Push two left breakers to reset. Push up two right breakers to reset.
10
9. LED and Connector Descriptions on P.C.B.
CON7
L19
L18
L17
L16
L11
L10
L9
L8
L15
L14
L13
L12
CON8 CON1
L5
L6
L7
L2
L1
CON5 CON3 CON9
Control P.C.B. QPW457
LED Indication
L1 Staple Reset Position
L2 No Staple
L5 Punch Home Position
L6 No Starting PS-P61
L7 Staple/Punch
L8 Staple Home Position
L9 Not Used
L10 Transport Unit Open Sensor
L11 Not Used
L12 Sheet Feed Sensor
L13 Sheet Jog Sensor
L14 Stopper Sensor
L15 Staple Cabinet Rear Cover Open
L16 Staple Mode Button
L17 Eject Button
L18 Jog Button
L19 Punch Button
Illuminates at the reset position.
Illuminates when staples remain in cartridge.
Illuminates at the home position.
Illuminates when PS-P61 cannot start.
Illuminates when punch is selected.
Illuminates at home position.
Illuminates when transport unit is closed.
Illuminates when no sheets under sensor.
Illuminates when no sheets over sensor.
Illuminates when no sheets over stopper.
Illuminates when cover is open.
Illuminates when button is pressed.
Illuminates when button is pressed.
Illuminates when button is pressed.
Illuminates when button is pressed.
Connector
CON1 To Staple Unit
CON2 To Sheet Size Sensor and Panel P.C.B.
CON3 To Solenoids and Transport Motor
CON4 To Sensors
CON5 To Transport Roller Solenoid and B4 Stopper
CON6 To Indicate Panel P.C.B LED
CON7 To Punch Unit
CON8 To Connector which connects Collator
CON9 To Power Supply 5V 24V
CON10 To Panel P.C.B Switch
CON11 To Sensors
CON12 To Staple Motor, Clutch, Blake and Pulse Sensor
11
Staple Unit
Collator Connecting Cable
Punch unit
Staple Cabinet
Rear Cover Open Sensor
Sheet Jog Sensor
Sheet Feed Sensor
Full Tray Sensor
(Projector)
Full Tray Sensor
(Receiver)
Stopper Sensor
Staple Home Position Sensor
Transport Unit Open Sensor
Power Supply Unit
B4 Stopper Solenoid
Transport Roller
CON7 CON8 CON1 CON5
Indication P.C.B.
CON3
QPW 457
CON9
CON7 CON3 CON5 CON4 CON6 CON2 CON1
Indication P.C.B.
QPW 457
Brake
Stopper Solenoid
Sheet Jog Solenoid 1
Sheet Jog Solenoid 2
Trans. Belt Motor
Trans. Unit Motor
Counter
Clutch
Pulse Sensor (Sheet)
Pulse Sensor (Staple)
Staple Move Motor
Staple
Unit
Collator Connecting Cable
Punch Unit
Staple Cabinet
Rear Cover Open Sensor
Sheet Jog Sensor
Sheet Feed
Sensor
Stopper Sensor
Full Tray
Sensor
(projector)
Full Tray
Sensor
(Receiver)
Staple Home Position Sensor
Trans.Unit Open Sensor
Power Sopply
Unit
B4 Stopper
Solenoied
Transport Roller
CON7 CON8 CON1 CON5 CON3 CON9
Indication P.C.B. QPW457
CON7 CON3 CON5 CON4 CON6 CON2 CON1
Indication P.C.B. QPW457
Motor Driver
P.C.B.
Stopper Solenoid
Sheet Jog Solenoid 1
Sheet Jog Solenoid 2
Trans. Belt Motor
Trans. Unit Motor
Counter
Pulse Sensor (Sheet)
Pulse Sensor (Staple)
Staple Move Motor
12. Panel Sensor Line Diagram
To Control P.C.B. QPW457
A3 Longer Edge Size Sensor
B4 Longer Edge Size Sensor
A4 Longer Edge Size Sensor
B5 Longer Edge Size Sensor
CON7 CON3 CON5 CON4 CON6 CON2 CON1
Indication P.C.B. QPW458
14
13. Staple Unit Inside Line Diagram
R
Motor
W
1 2 3
7 8 9
4 5 6
10 11 12
D
H
V
O B
G
G
No
Staple
Reset Unit P.C.B.
Ground for Staple
View from Arrow Mark (Leading Cable)
Side View of Staple Unit
No Staple Sensor
Motor
Fixed Sensor
Connector QR/P1-12P-C
15
14. Transport Belt Motor Driver Wiring
Applied Serial Number : S/N 001001 or up
Transport Belt Motor
To Control P.C.B.
To Transport Belt
1 Green
2 Black
3 Blue
4 Red
5 Yellow
6 White
S/N099999 or before
To MotorTo Control P.C.B.
1 To Connector 4-10
2 To Connector 3-10
3 None
4 None
5 None
6 None
7 None
8 None
9 None
10 None
11 To Connector 3-9
12 To Connector 11-4
S/N100001 or after
None
None
To Connector 4-10
To Connector 3-10
None
None
None
None
None
None
To Connector 3-9
To Connector 11-4
The following list is shown the function select switch position in normal operation condition.
The machines having S/N 007006 or up equip with ver. 3.03 rom.
Function Select Switch
ROM Version
3.00 3.03 3.20
Normal Position Another Position Normal Position Normal Position
1.Automatic Current
Reducing Function
2.Step Select Switch
3.Input Pulse Select Switch
ON
ON 1.8゜
OFF 2 pulse
4.Power Voltage Select Switch ON 24 V
OFF
ON 1 pulse
OFF 36 V
ON
OFF
OFF
ON
ON
OFF
OFF
ON
16
15. Power Supply Line Diagram
8 1 23 4 5 6 7
D S 1A 010 F1 NR
D A 3A 010 F1 NR
NRF-110-3A
NRF110-2A
17
16. Punch Unit and Sensor
Reset Sentor
Sheet Sensor
Stopper Sensor
EE-SPY-302
Y G B
+5V
OUT
COM
6
7
4
5
8
1
2
3
SMR-08V-B
D
Motor
R
Punch Unit
SMR-03V-B
1
2
3
18
17. Timing Chart 1
19
18. Timing Chart 2
(Applied Serial Number : S/N from 002901 to 008917)
20
19. Timing Chart 2
( Applied Serial Number : S/N 001001 or up )
21
20. Timing Chart 3
(Applied Serial Number : S/N from 002901 to 008917)
In Collating
Sheet Feed Sensor
Sheet Jog Sensor
Stopper Sensor
Trans. Roller Solenoid
Stopper Solenoid
Sheet Jog Solenoid 1
Sheet Jog Solenoid 2
Transport Belt
Sheet Feed Motor
Staple
Punch
No Staple Monitor
Clutch
B4 Stopper
500mS
300mS
300mS
Sheet condition Check
About 250mS
700mS
700mS
B4 Other Side Corner Staple Correct Function
22
21. Timing Chart 3
(Applied Serial Number : S/N 001001 or up )
In Collating
Sheet Feed Sensor
Sheet Jog Sensor
Stopper Sensor
Trans. Roller Solenoid
Stopper Solenoid
Sheet Jog Solenoid 1
Sheet Jog Solenoid 2
Transport Belt
Sheet Feed Motor
Staple
Punch
No Staple Monitor
B4 Stopper
Sheet Jog Condition Check
700mS
500mS
300mS
300mS
About 250mS
700mS
B4 Other Side Corner Staple Correct Function
23
22. Check Mode
1. Staple Unit Check Mode
- Turn on power with eject button pressed.
- Every time eject button is pressed, staple works.
- Lock sensor works during check mode. If staple lock continues for more than 1 second, staple motor stops and staple trouble lamp on monitor flashes
2. Punch Unit Check Mode
- Turn on power with eject button pressed.
- Press staple mode switch to select "corner staple 0˚".
- Every time eject button is pressed, punch works.
NOTE
- Operate punch unit with 3 to 4 seconds intervals. Otherwise, motor or controller may be broken. Lock sensor works during check mode. If punch lock continues for more than 2 seconds, punch motor stops and punch trouble lamp on monitor flashes.
3. Check on Complete Functions
- Turn on power with staple mode button and eject button pressed at the same time. And complete function of PS-P61 will work successively except punch.
NOTE
- Operating PS-P61 with staple cartridge in check mode may cause staple jam. When operating in check mode, remove staple cartridge or insert sheets into staple section.
- When each of monitor lamp flashes, PS-P61 does not work. Turn off power and turn on again.
- Check mode does not reset until power is turned off. Turn on again when collating job is started.
24

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Key features
- Staple up to 10 sheets of 135 gsm paper
- Punch up to 10 sheets of 105 gsm paper
- Staple modes: corner, top, and other side corner
- Built-in counter
- Durable and reliable construction