4.0 Pinnacle 27 Operator Instructions 12 5 General Troubleshooting 5. then perform the recommended procedure in the CORRECTIVE ACTION column. 14 . WARNING! Always unplug the laminator to avoid possible electrical shock hazard before attempting to perform any repairs. When a malfunction occurs.0 Pinnacle 27 EZload/Non EZ load Troubleshooting 5. The causes of the malfunctions are isolated by the symptom of the malfunction and noting at which point in the operating cycle the malfunction occurred.6 Troubleshooting Chart Malfunction corrections are based on visual observations made by the operator. When replacing electrical components that have push on terminals. Malfunctions may be pinpointed to a defective electrical component or mechanical part by referring to the Principles of Operation. to facilitate reconnect ing them. Refer to the wiring diagrams to resolve any wiring difficulties that may occur.5. label the electrical leads that were removed. the troubleshooting guide and the wiring diagram. read down the SYMPTOM column until you find the appropriate description for your symptom. Read the corresponding PROBABLE CAUSE. The troubleshooting guide chart that follows is arranged in order of the normal operational sequence. Pinnacle27 and Pinnacle27EZ Operation Tip! FOOTAGE COUNTER/TEMPERATURE DISPLAY The Ready Light is ‘OFF’… the display shows ‘TEMPERATURE’ The Ready Light is ‘ON’…. the display shows the total feet of laminate used since the last manual reset. i. . the display shows ‘TEMPERATURE’ the display shows ‘FEET’ Please refer to the operator manual features guide for clarification if necessary. Instead. In this example simply resetting the footage counter gets rid of the ‘400’ display.e. and some of our techs. 2. This confusion may be leading to unnecessary service calls and part replacement. Summing up: The Ready Light is ‘OFF’… The Ready Light is ‘ON’…. The footage counter continues to count up until the '1. the temperature suddenly 'jumps' to a temp way over/under range. What the customer does not realize is that this is not the actual temperature any more. If the P27 is not ‘Ready’ and the ‘Ready Light’ is ‘OFF’. So ‘400’ on the display is now 400 feet of laminate used. the display shows the actual shoe temperature as it approaches the set temperature. the display shows ‘FEET’ There seems to be some confusion on the part of our customers. it is the number of feet of laminate used since the last manual reset of the footage counter (the display changes from temperature to feet when the P27 goes to ready state). The observed problem is that when the machine goes to 'ready'. changing it to ‘0’. ‘400’ or ‘105’ on the display. 3’ button is pressed and held until it resets to '0'! It does not reset to zero when the P27 is turned off or unplugged. and the green ‘Ready Light’ is ‘ON’. If the P27 is to temperature or ‘Ready’. regarding the footage/temp display on the Pinnacle27s. The giveaway here is whether or not the green ‘Ready Light’ is illuminated. Check CN1 for +5V DC on pin 4 (closest to UA5) to dc ground.5. Main board defective Test for 120VAC across EL1 on main board.0 Pinnacle 27 EZ load/Non EZ load Troubleshooting No functionality out of control panel (With main rocker switch illuminated) Interlock disengaged Check tray or upper heat shoe safety interlock Off/Standby switch defective Test and replace control panel PCB Assy If necessary Thermal fuse up /down defective (Located in heat shoe ) Test and replace If necessary (refer to wiring diagram) Circuit breaker opened Reset or replace If necessary F1 20A/125VAC fuse blown on main board Test fuse and if necessary replace main board Transformer defective Test T1 in and T1 out on main board with transformer in circuit for: (On main board) 120 VAC on T1 in and 8 VAC T 1 out 2. Check CN1 for +7V~11V DC on pin 1 (next to UA5) to dc ground. . visually inspect ntc connector termination. Reseat connector.3 on control display A. D.1 on control display CalibrationsA. Test and or replace if necessary (refer to electrical schematics). Insufficient film tension A. B. visually inspect motor connector termination. Motor jammed A. For the ez load adjust via the set screws on the ez load levers (left and right hand side). B.0 Pinnacle 27 EZ load/Non EZ load Troubleshooting Er. Left hand side cover is removed. F. A. (GW) Er. B. Replace main ntc sens or. D. . Reseat connector. Inspect encoder wheel E. visually inspect ntc connector termination. Reseat connector. visually inspect encoder connector termination. B. Encoder wheel is loose. C. . Air bubbles in film F. Replace roller ntc if 5vdc not present on control panel board. A. Install cover to resolve.2 on control display Er. Adjust film tension via the tension adjustment plate on the non-ez load. B. Main NTC sensor damaged. C.5. Roller NTC connector is loose. Resolve loading issue. Reseat connector. Encoder sensor connector is loose. Tighten equally on both sides per film roll. Excess light difussing emmiter with cover removed. B. Roller NTC Sensor damaged. Motor connection is loose . Encoder sensor is damaged E. Main NTC sensor loose. 5. 2006 .7K RA14 1 2 2 A2 3 ZC HEAT1 PWM RA16 470 RA13 470 1/2W 4 177+/-10 177+/-10 A1 G 3 BAT26-600B 2 4 HEAT UP PIN 177+/-10 1 1K QA6 2 10k 3 2SC18151 TLP3063 177+/-10 177+/-10 177+/-10 177+/-10 VPO HEAT DOWN 1 2 US Version 1 6 RA33 10K 3G ROLLER HEATER(3. November 10.96MM3PIN 3T 6 EZ 65 Main Board AC Block June 12.96MM3PIN) 1 2 3 1 2 3 QA16 2 SAnRex / T16C6 1K RA31 LINE SW PWM2 RA34 470 4 H2 HEATER SHINK for TMG16C60 Pre-Heater RA32 A2 2 CN2(NTC1) 2.5MM/2P UA4 RA30 1K 1 A1 ZC TLP3063 3 10K QA12 2 2SC18151 3 1 2 Pre-Heater Control Friday.0 Pinnacle 27 EZload/Non EZ load Troubleshooting 120 VAC TF LINEAR X'FORMER 3 LINE SW 3 2 1 EN0 1 1 2 3 4 2 1 T-OUT2 2.5MM/2P 2 1 T1-OUT1 3.96MM/2P 5 2 T1-in3. 2006 TF1 192*C UP TF2 2 7 3 6 4 5 UP TF1 TF3(Thermostat) 70*C OFF LINE RB 50OHM CN3(NTC2) 2.5MM/3P RA 50Ohm TF2 192*C UP TF2 Terminal 1(PA12)(right) 1 2 EN0 LINE SW 177+/-10 HEAT2 T250 177+/-10 2 7 3 6 VPO 1 177+/-10 177+/-10 PIN 177+/-10 RA12 UA3 5 QA10 1 H1 HEATER SHINK for BAT26-600B Terminal 2(PA12)(left) T250 6 1 RA15 4. 0 11PIN VR1 10K com G F E D C B A RDP LEDC1 LEDC2 LEDC4 LEDC3 POWER READY LO TEMP HI TEMP LEDC3 LED 7 SEG LEDC2 LED 7 SEG 8.1U/50V PROTECTION AC BUZZER NTC1 2.5MM/2P 2.1U/50V + - 3/8 10 9 1 2 4 6 7 5 8 U2C LM324 8.01U/50V 1 2 1N4148 SWC5 HI TEMP 2 DC4 1 1N4148 SWC4 LO TEMP 2 DC2 1 1N4148 SWC3 Reset 2 DC3 1 1N4148 SWC2 2 Motor Run/STOP COM5 RC22 10K 7V ~ 11V CC8 0.1U/50V 3 + 2 - 1 NTC1 U2A LM324 RC28 10K RC31 1.5MM/2P +5V 4MHZ CYC1 +5V RC6 100K CC3 CC2 30P/50V RC7 10K 0.1U/50V VSS PD1/PWM1 PD0/PWM0 17 RC26 100 13 PC1 PC4 16 RC25 14 PC2 PC3 15 CC7 0. 1N4148 2 QC5 2SA1015 1 2 PB6/AN6 1 NTC1 com G F E D C B A RDP U1 HT46R23-28 COM3 RANGE 3/8 10 9 1 2 4 6 7 5 com G F E D C B A RDP LED 11HEADER2. CN1 RC4 1K COM3 DC8 1 1 2 SW SW SLIDE 3PIN AUTO OFF PCB 1 2 RC32 100 5 + 6 - 7 U2B LM324 TO Pre-Heater NTC sensor(503GT) NTC2 RC33 10K 5.1 LED CONTROL PANEL PCB CN8 SW SLIDE 3PIN Board June 6 2006 2 RC2 1K COM1 3/8 10 9 1 2 4 6 7 5 330 330 330 330 330 330 330 330 7V ~ 11V 1 2 3 4 5 6 7 8 9 10 11 12 PROTECTION +5V PWM2 PWM Motor On/Off Motor Reverse VR-1 VR-2 SPEED EYE +5V 10 9 CC6 0.0 Pinnacle 27 EZload/Non EZ load Troubleshooting 115VAC RC8 RC9 RC10 RC11 RC12 RC13 RC14 RC15 G F E D C B A RDP COM4 2 RC3 1K COM2 LEDC1 LED 7 SEG QC4 2SA1015 RC5 1K 3 1 +5V 1 3 2 1 2 3 4 5 6 7 8 9 2 1 4 1 +5V QC3 2SA1015 3 2 1 +5V 3 RC16 10KX8 QC2 2SA1015 3 11 +5V QC1 2SA1015 3 3 +5V .0MM/2P CN2 CN2 Sleep Disable = LO 12 +5V PWM2 2 1 SLEEP DISABLE TO Main Heater NTC sensor Slide SW Function Sleep Disable SLEEP DISABLE DC5 1 test Value 1 2 PC0 RC34 10K 1N4148 SWC6 NC1(Power) 2 300*F (150C*) 250*F (120*C) 85~90*C F 12 VR-1 DC6 1 SPEED EYE CC1 30P/50V G 18 +5V 1N4148 SWC7Motor Reverse 2 RC30 1.39k CC4 0. RANGE RC29 10K Motor On/Off +5V Motor Reverse COM4 COM5 PA4/TMR 26 E PA5/INT 25 PA6/SDA 24 PA7/SCL 23 PB3/AN3 OSC2 22 PB2/AN2 OSC1 21 9 PB1/AN1 VDD 20 10 PB0/AN0 RES 19 RC24 100 D 3 PA3/AN3 C 4 PA2 B 5 PA1 A 6 PA0 COM1 7 NTC2 8 PB4/AN4 2 QC6 3 1 2SC1815 RC17 10K AC BUZZER RC18 10K AC Buzzer 3 KHz 5 NTC2 2.1U/50V RC27 100 PWM 100 + 13 - 14 U2D LM324 CC5 0.1U/50V RC23 100 11 VR 10K DC7 1 +5V PB7/AN7 PB5/AN5 BZC1 AC BUZZER VR-2 * HEATER Actual LOW TEMP: 250*F (120*C) MIRCO IC TEMP SETTING FOR ROLLER HEATER 60*C 28 COM2 RDP ICTEMP SETTING FOR MAIN * MIRCO HIGH TEMP: 300*F (150*C) 27 2 RC20 100 RC21 100 8.0MM/2P 2.39k CC9 0. 5MM/2P UA4 RA30 1K 1 A1 ZC TLP3063 3 10K QA12 2 2SC18151 3 1 2 Pre-Heater Control Friday.96MM3PIN 3T 6 EZ 65 Main Board AC Block June 12.0 Pinnacle 27 EZload/Non EZ load Troubleshooting 115VAC TF LINEAR X'FORMER 3 LINE SW 3 2 1 EN0 1 1 2 3 4 2 1 T-OUT2 2.96MM/2P 5 2 T1-in3. 2006 TF1 192*C UP TF2 2 UP TF1 7 TF3(Thermostat) 70*C OFF LINE RB 50OHM CN3(NTC2) 2. 2006 PWM2 .5.96MM3PIN) 1 2 3 1 2 3 QA16 2 SAnRex / T16C6 1K RA31 LINE SW RA34 470 4 H2 HEATER SHINK for TMG16C60 Pre-Heater RA32 A2 2 CN2(NTC1) 2.7K RA14 BAT26-600B 1 2 2 3 ZC HEAT1 PWM RA16 470 RA13 470 1/2W 4 177+/-10 177+/-10 6 QA6 2 10k 3 2SC18151 TLP3063 177+/-10 177+/-10 177+/-10 177+/-10 VPO HEAT DOWN 1 2 US Version 1 6 RA33 10K 3G ROLLER HEATER(3.5MM/2P 2 1 T1-OUT1 3. November 10.5MM/3P RA 50Ohm 3 6 4 5 TF2 192*C UP TF2 Terminal 1(PA12)(right) 1 2 EN0 LINE SW 177+/-10 HEAT2 T250 177+/-10 2 7 3 6 VPO 1 177+/-10 177+/-10 PIN 177+/-10 RA12 UA3 5 QA10 T250 A1 G 3 A2 H1 HEATER SHINK for BAT26-600B 1 Terminal 2(PA12)(left) 1 4 HEAT UP PIN 177+/-10 2 1K 1 RA15 4. 96mm 3PIN 3T 2 5 3.96mm 3PIN) 1 2 3 Terminal 1(PA12) 70*C OFF Pre-Heater 177+/-10 177+/-10 177+/-10 QA16 LINE SW 1 2 3 A2 2 LINE 1 3G TF2 192*C 2 SAnRex / T16C6 4 1K RA31 TS1(Thermostat) Heater Down 170Ohm 3 ZC TLP3063 H2 HEATER SHINK for TMG16C60 Heater Up 170OHM 1 2 T250 177+/-10 177+/-10 177+/-10 1 10 2 9 HEAT UP 8 1 PIN 177+/-10 177+/-10 4 7 5 6 PIN 1 1 2 177+/-10 177+/-10 177+/-10 HEAT DOWN 1 Terminal 2(PA12) PIN PIN 1 HEAT1 T250 1K LINE SW H1 HEATER SHINK for BAT26-600B 177+/-10 UA3 T250 QA10 1 3 VPO RA12 HEAT2 A1 G 3 2 Main-Heater 5.SW 2 S1 1 SW 3 2 1 SAFTETY SW2 15A/250VAC SW4 2 1 SAFETY SW4 15A/250VAC SW5 2 1 SAFTETY SW3 15A/250VAC 2 UP TF1 SAFTETY SW5 15A/250VAC circuit breaker 10A 250VAC EL1 JUMPER #1.5MM/2P EN0 LINEAR X'FORMER VPO TF1 192*C UP TF2 2 7 3 6 4 5 RA30 1K UP TF1 UA4 A1 1 6 UP TF2 ROLLER HEATER(3.68uf/275VAC 1M 1/2W T250 PIN PIN PIN 1 LINE SW 1 EN0 EC2 1UF/250VAC R1 V1 MOV T250 PIN CY2 103/AC400V T250 1 4 1 3 T250 PIN PIN TF3 130*C 6 T1 1 2 T1-in 3.96MM/2P T-OUT1 1 EN0 1 2 3 3 2 1 4 1 2 MAIN BOARD LINE SW 3 2.0 Pinnacle 27 Non EZ load Troubleshooting EU Version LINE 1 2 A2 6 1 BAT26-600B RA13 470 1/2W 4 2 ZC TLP3063 3 .3*22 X2PCS Power Cord L L POWER SW 16A/250V LINE T250 1 1 2 F1 10A/250VAC T250 PIN PIN T250 1 1 CY1 103/AC400V SW 1 JA1 1 EC1 2 N N T250 1 NEUTRAL T1-OUT2 0. 3*22 X2PCS Power Cord L L LINE POWER SW 16A/250V T250 1 1 2 F1 10A/250VAC T250 PIN PIN T250 1 1 LINE CY1 103/AC400V SW 1 JA1 1 EC1 2 N N T250 1 NEUTRAL T1-OUT2 0.S1 SW 2 1 SW 3 2 1 SAFTETY SW2 15A/250VAC 2 UP TF1 SAFETY SW4 15A/250VAC circuit breaker 10A 250VAC EL1 JUMPER #1.68uf/275VAC 1M 1/2W T250 PIN PIN PIN 1 LINE SW 1 EN0 EC2 1UF/250VAC R1 V1 MOV T250 PIN CY2 103/AC400V T250 1 4 1 3 T250 PIN PIN TF3 130*C 6 T1 1 2 T1-in 3.96mm 3PIN 3T 2 5 3.96MM/2P T-OUT1 3 2 1 4 1 1 2 EN0 1 2 3 MAIN BOARD LINE SW 3 2.96mm 3PIN) 1 2 3 Terminal 1(PA12) 70*C OFF Pre-Heater 177+/-10 177+/-10 177+/-10 QA16 LINE SW 1 2 3 A2 2 LINE 1 3G TF2 192*C 2 SAnRex / T16C6 4 1K RA31 TS1(Thermostat) Heater Down 170Ohm 3 ZC TLP3063 H2 HEATER SHINK for TMG16C60 Heater Up 170OHM 1 2 T250 177+/-10 177+/-10 177+/-10 1 10 2 9 HEAT UP 8 1 PIN 177+/-10 177+/-10 4 7 5 6 PIN 1 1 2 177+/-10 177+/-10 177+/-10 HEAT DOWN 1 Terminal 2(PA12) PIN PIN 1 HEAT1 T250 1K LINE SW H1 HEATER SHINK for BAT26-600B 177+/-10 UA3 T250 QA10 1 3 VPO RA12 HEAT2 A1 G 3 2 Main-Heater 5.5MM/2P LINEAR X'FORMER EN0 VPO TF1 192*C UP TF2 2 7 3 6 4 5 RA30 1K UP TF1 UA4 A1 1 6 UP TF2 ROLLER HEATER(3.0 Pinnacle 27 EZ load Troubleshooting EU Version 1 2 A2 6 1 BAT26-600B RA13 470 1/2W 4 2 ZC TLP3063 3 . 5K 4 1N4004 DB1 - RA24 90*C = Lo Ohm Value 70*C = Hi Ohm Value 1 2 QA9 2 2SC1815 1 3 RA26 10K 2 T1-OUT2 +5V PROTECTION 7V ~ 11V QA8 2SA1015 2 3 VPO + EZ 65 Main Board DC Block June 9.7K NTC1 2.0 11PIN) 7V ~ 11V 20V ~ 26V 31DQ06 DB7 + 31DQ06 + DB5 +5V PWM2 PWM Motor Reverse Motor On/Off VR1 VR-2 SPEED EYE C3 2200U/50V 2 Ib 3 Ia DA11 DA10 31DQ06 31DQ06 CA3 1000U/25V RA1 2K 1 1 CA8 0. November 10.0MM/2P H4 HEAT SHINK FOR IRF5305 RA2 4.2V 7V ~ 11V M MO1 DC24V DC FAN1 2.7k RA35 4K7 RA42 1K RA43 10K 20V ~ 26V RA39 10K RA40 10K Motor On/Off QA3 2 2SC1815 3 RA7 4K7 1 2 QA4 3 2SC1815 1 2 2 1 2 DA4 2 1N4004 13 1 2 DA5 1N4148 1 2 MOTOR CONNECTOR/3.5MM/2P RA20 22K CA10 0.1/50V L2 100UH +5V TO Fan NTC sensor CA7 0.1/50V + 1000U/25V 5V 2.5MM/3Pin 78L05/TO220 + 1N4004 DB3 2 RA28 47K 10K +5V DA6 1N4148 RA27 1.0 Pinnacle 27 EZload/Non EZ load Troubleshooting 115VAC 1 2 3 4 5 6 7 8 9 10 11 12 PROTECTION 2 RA29 1K 2 220U/16V T-OUT1 3.5MM/2P DA7 1N4004 QA5 2SC1815 1 RA10 1K Motor Reverse DA2 1N4148 UA1 RA4 2 0.5MM/2P 1N4004 7V ~ 11V DB2 UA5 CN1(2.7K FOR motor speed HI=Motor On LO=Motor Off RA8 10K 1 RA9 10K Friday.1/50V CA4 0.1/50V DA3 DA1 1N4148 3 1 2 1 2SC1815 3 QA2 - 7V ~ 11V RA18 100 2 + + 6 RA19 22K CA12 0. 2006 PCB Cool Fan 3QA15 2SD882 5. 2006 .5V ~ DC22V reverse: DC 7.011/2W( + DA9 FR104 CA16 33063AVP 8 Driver C Switch C 1 7 Isensor Switch E 2 Timing Cap 3 6 VCC 5 Comp-IN GND 4 2 28V~38V VR-1 28V ~ 38V 3 2 VR-2 2 1 680 1 10U/50V RA6 910 RA38 10K RA37 10K RA36 CA11 470P/50V RA11 10K QA13 2SA1015 1 3 QA14 2SC1815 RA5 4.96MM/2P 2 CA14 4.1U/50V SMI-SH-206D/DC6V 1 5 2 1 RA17 22K CA9 0.1U/50V DC FAN DA13 1N4004 RA22 1K 1 2 To Cool Fan RA23 1K forword: DC 8.1/50V 3 11 +5V 1 2 VOL 1 2 1 DA8 MOT QA1 L1 FR104 ZD1 20V(OPEN) IRF5305(IRF9Z34N) Choke 80~100uH 2 1 RA25 4.96MM 2PIN 2 QA7 2SD882 1 3 U2A LM358 KA1 CA6 CA5 0.7UF/25V 1 CA2 CA1 31DQ06 DB6 + 2 1N4004 + DB4 - 1 2 3 SPEED EYE 1 3 + 31DQ06 DB8 1 8 1 1000U/16V 1 2 CA15 10UF/25V CN6 2.2.1/50V FR104 RA41 0 + 2 - RA21 22K 7V ~ 11V 7 U3B LM358 CA13 0. 0 Pinnacle 27 EZload/Non EZ load Troubleshooting 5V 5V RB1 560 5V RB2 100K 5V 3 2 1 RB5 22K RB3 22K 2. November 10.0MM/3Pin 2 QB1 3 2SC1815 CN6 2.5MM/3Pin 1 1 2 3 CN4 CN4 2.5MM/3Pin 1 2 3 Low Active RB4 47K RA5 560 1 1 LED1 2 2 SPEED EYE PCB LED2 Friday.5. 2006 . 0 Pinnacle 27 EZload/Non EZ load Troubleshooting .5. 0 Pinnacle 27 EZload/Non EZ load Troubleshooting EU Version EZ Load and Non EZ Load EU Heat Shoe Wiring .5. 6 11 10 9 16 8 18 14 15 7 RH Side 12 6 13 LH Side ------------671100008800 20 670400000700 670300013000 ------------622000021200 2 19 5 4 3 911100000960 911100000970 911100000030 1 910000145300 ------------910000139480 ------------------------CONTROL PANEL ASSY 910000145240 910200036540 910200026250 660000002670 670800003400 910200037320 20 Counter PCB assy 910200026250 .