Service Manual GERA Butterfly Extra III GF 500 Folder for HP T7100, T7200, PageWide XL

Transcription

1 Service Manual GERA Butterfly Extra III GF 500 Folder for HP T7100, T7200, PageWide XL Butterfly - Extra M950XLTX GERAFOLD 500 M500XLTX June 2018

2 Intro ABOUT THIS DOCUMENTATION... II DOCUMENTATION DESIGN AND PURPOSE... II LIMITATIONS... II SERVICE DOCUMENTATION REVISIONS... II FIELD SERVICE BULLETINS... II ORGANIZATION... II HOW TO USE THIS DOCUMENTATION... III INTRODUCTION... III SECTION 1: SERVICE CALL PROCEDURES... III SECTION 2: REPAIR ANALYSIS PROCEDURE... III SECTION 3: FOLD QUALITY... III SECTION 4: REPAIR AND ADJUSTMENT... III SECTION 5: PARTS LIST... III SECTION 6: GENERAL PROCEDURES... III SECTION 7: WIRING DATA... III OTHER INFORMATION... IV THE USE OF CAUTION, WARNING, AND NOTE STATEMENTS... IV CONVENTIONS... IV REFERENCE SYMBOLOGY...V INTRODUCTION TO REFERENCE SYMBOLOGY... V ACRONYMS... V REFERENCE SYMBOLS... V SCHEMATIC SYMBOLS... V AC AND DC VOLTAGE REFERENCES... V ABBREVIATIONS... V REFERENCE SYMBOLOGY... VI Butterfly Extra III GF500 Folder Jun 2018 Intro Service Manual I

3 ABOUT THIS DOCUMENTATION Documentation Design and Purpose This Service Documentation contains diagnostic, repair, and maintenance information, that has been designed to assist the Service Representative in the isolation and repair of faults, as well as, maintenance of the Mondial Folder. This documentation assumes that the user is familiar with the electrical and mechanical standards that are commonly used throughout the industry, as well as, certain GERA design and documentation conventions. This documentation also assumes that the user has successfully completed any required training and is familiar with the use of any special tools that are required to service this product. Limitations This service documentation does not support specific electrical, mechanical, or operational considerations of any accessory device or machine modification not authorized by GERA Company for this product. Service Documentation Revisions ORGANIZATION This documentation is divided into eight sections. In addition to the Introduction, the following sections are contained within this documentation. Section 1 - Service Call Procedures Section 2 - Repair Analysis Procedure Section 3 - Fold Quality Section 4 - Repair and Adjustment Section 5 - Parts list Section 6 - General Procedures Section 7 - Wiring Data A detailed description of the information contained within each section of the service documentation will be found in the following subsection This service documentation may be subject to periodic revision in order to reflect any changes in electrical or mechanical hardware, as well as any possible additions or corrections necessary to ensure the technical accuracy of the documentation. Field Service Bulletins Field service information specifically applicable to the machine may occasionally be issued in the form of electronic or critical bulletins. Because bulletins contain important information, they should always be retained within this service documentation for quick reference. Butterfly Extra III GF500 Folder Jun 2018 Intro Service Manual II

4 HOW TO USE THIS DOCUMENTATION Introduction This section provides the Service Representative with information pertaining to the organization and use of this service documentation, and includes the following supportive reference data: Reference Symbology Signal Nomenclature DC Voltage Range Specifications Section 1: Service Call Procedures This section is used by the Service Representative as a structured process for determining the type and sequence of actions that are performed during a service call. The Service Call Procedures section is designed to assist in the effective recognition of machine symptoms and problems, as well as, providing instructions for the maintenance and corrective actions that are required to return the machine to the full operating condition. Section 1 of this service documentation is the entry level for all service calls. The Service Representative should begin each service call with the Initial Actions/Systems Checks procedure found in Section 1. The Service Call Procedures section is composed of six Integral elements: Initial Actions/ System Checks, Call Flow, Maintenance Procedures, Call back, and Final Actions. The maintenance and diagnostic activities in this section may direct the Customer Service Engineer to perform additional service activities found elsewhere in the documentation, such as, Removal and Replacement Procedures (RAPS), and Adjustment Procedures. The Initial Actions/Systems Checks procedure identifies certain required actions that are necessary to obtain a basic appraisal of machine/system operation at the start of the service call. It is used to test, confirm and define the problem areas. This subsection is used to assist the CSE in diagnosing the not readily apparent machine problems when there are conflicting or ambiguous symptoms present. It is important that this procedure be used in order to ensure that the correct symptom is being diagnosed. The Call Flow procedure guides the CSE through the normal sequence of events in a service call. The Message Display Entry Chart subsection contains a specific procedure that must be performed on the service call regarding a message displayed on the Folder Control Panel. The Maintenance Procedures subsection contains a list of the cleaning and lubrication activities that are designed to extend and enhance the reliability and performance of the machine. The Call-back subsection lists procedures to be performed if it has been less than 3000 linear feet (900 meters) or less than seven customer working days since the last service call. Call-back is a short procedure designed to ensure that basic system operation has been maintained since the last call by performing a minimum amount of maintenance. After correcting the problem that resulted in the Call-back, go to the Final Action and perform the activities indicated. The Final Actions subsection is used to identity the actions necessary to clear the call with the Customer and to complete any administrative tasks that are associated with completing the service activity. Section 2: Repair Analysis Procedure Section 2 of this documentation contains the Repair Analysis Procedures (RAPS) necessary to repair all faults other than the folds faults. The Service Representative will be referred to this section from some other section of this documentation during the service call. When a machine defect or fault has been resolved by using a RAP, the Service Representative should immediately return to the point in the service call from which section 2 was entered. Section 3: Fold Quality This section contains the Fold Quality Repair Analysis Procedure used to diagnose fold quality defect problems within the Mondial Folder. Section 4: Repair and Adjustment This section contains all repair and adjustment procedures for the machine. Repairs (REPS) and adjustments (ADJS) are identified by the use of a standard chain prefix number. Section 5: Parts List This section contains a list of spare parts for the machine. All parts list page reference numbers begin with the letters 'PL', followed by a prefix number, a decimal point, and a sequential number used within the subsystem. Section 6: General Procedures This section contains procedures and Information of a general nature that apply to the machine. The General Procedures subsection contains frequently used procedures that relate to the diagnosis, the set-up, or the operation of the machine. It also includes specific information that is pertinent to the operation of the machine, but will not be found in any other part of the service documentation. This information may include product codes, environmental operating data, installation space requirements, paper and electrical specifications. This subsection may also contain information regarding supplemental tools and supplies, general service notes, a glossary of commonly used terms, and a Change Tag Index of authorized machine modifications and retrofits. Section 7: Wiring Data This section contains support information to assist in the electrical diagnosis of machine problems and is a central location for electrical wiring diagrams. This section is used in conjunction with other diagnostic or maintenance procedures that are contained in other sections of the service documentation. This section may contain the following: Block Schematic Diagrams (BSD s) are used as an optional aid to troubleshoot electrical problems. Butterfly Extra III GF500 Folder Jun 2018 Intro Service Manual III

5 OTHER INFORMATION The Use of Caution, Warning, and Note statements Information relative to the completion of a task in a safe or thorough manner will be supplied in the form of a Caution, a Warning, or a Note statement. These statements are found throughout the service documentation. Cautions, Warnings, and Note statements appear before the steps to which they apply. These statements should be read before continuing to the next step in a procedure. The definition of a Caution, Warning, or Note is as follows: Caution - A Caution statement indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in damage to, or destruction of, equipment. Warning - A Warning statement indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in personal injury or loss of life. Note - A Note statement indicates an operating or maintenance problem, practice, or condition that is necessary to accomplish a task efficiently. The Use of Acronyms, Abbreviation, Specific or Unique Terms, and Conventions A list of acronyms and abbreviations used in this service documentation will be found In the Reference Symbology subsection, contained elsewhere in this section. Conventions The following conventions are used in this service documentation: [n-nn] bolding Hyphenated numbers enclosed in brackets Indicate a diagnostic code to be used When used in a sentence beginning with 'Press the', any bolded numbers or words will represent an actual key-pad button on the Control panel Butterfly Extra III GF500 Folder Jun 2018 Intro Service Manual IV

6 REFERENCE SYMBOLOGY Introduction to Reference Symbology This section describes and defines the various acronyms, abbreviations, reference symbols, Signal Nomenclature, and AC and DC power specifications. The following is a description of some of the terms found in this section: Acronyms Acronyms are used throughout this service documentation to denote common terminology. Although some acronyms may be unique to this product, most acronyms used in this document are known throughout the service industry. Table 1 lists the acronyms that are found in this service documentation. Reference Symbols Reference symbols consist of various icons used in this documentation to denote supportive data that can be found in other sections of this documentation. The purpose of these symbols is to inform the Service Representative of procedures, adjustments, or other information that is important for successful diagnosis and repair. Schematic Symbols These symbols represent various electrical and mechanical components or devices that are commonly found In GERA equipment. These symbols are included as an aid to understanding the representations used in the Circuit Diagrams (CDs). AC and DC Voltage References The expected AC and DC voltage levels found in this machine are defined in this section. These specifications represent the expected range for AC (machine Input power source) and DC (machine internal power supplies) voltages that are encountered during normal operation Abbreviations Table 2 lists the electrical wire colors that are identified in this service documentation and reflects the use of standardized abbreviations. Acronym Definition AC Alternating Current ACH Alternating Current High ACN Alternating Current Neutral AMP Ampere BSD Block Schematic Diagram BTU British Thermal Unit CD Circuit Diagram FQ Folding Quality DC Direct Current ESD Electrostatic Discharge HFSI High Frequency Service Item LED Light Emitting Diode PL Parts List PWB Printed Wiring Board RAP Repair Analysis Procedure VAC Volts Alternating Current VDC Volts Direct Current ADJ Adjustment Table 1 General Acronyms Abbreviation Wire Color BLK black BLU blue BRN brown GRAY gray GRN green G/Y green / yellow ORN orange PINK pink RED red VIO violet WHT white YEL yellow Y/G yellow / green Table 1-1 Wire Color Abbreviation Butterfly Extra III GF500 Folder Jun 2018 Intro Service Manual V

7 REFERENCE SYMBOLOGY Note, adjustments, and parts list, support the checklists and the RAP information. The symbols that refer to this supportive data are shown below Note Adjustment 1 This symbol is used to refer to notes usually found on the same page. Voltage Source Status Code Flag C1.01 This symbol refers to an adjustment procedure located in Section 4 of this Service Documentation. The number adjacent to the symbol indicates the number that is assigned to that adjustment This is an indication of the source voltage that is used for operation of a component. A box in the control logic section of the circuit diagram represents the status code. 2 This symbol indicates an area of a Circuit Diagram that you should check. Component Control [0403] The code [0403] is an example of an output diagnostic test. Switches and Relay Contacts Parts List PL 1. 1 WARNING WARNING CAUTION! NOTE CAUTION ESD Reference to an Exploded Drawing - The spared component is found in the particular drawing in the Parts List. This WARNING alerts users to areas of the product where there is the possibility get an electric shock This WARNING alerts users to areas of the product where there is the possibility of personal injury This CAUTION alerts user that a wrong operation could damage the Folder This symbol alerts user to pay attention in the operation described This symbol Is used when components In the copier are susceptible to damage from electrostatic discharge. Observe ESD procedures to avoid component damage. Safety interlock switch that is open Safety interlock switch that is closed. Switch/relay contacts with momentary contacts shown normally open. Switch/relay contacts with momentary contacts shown normally closed. Connectors numbering This symbol indicates the numbering of the connector pins The Signal Flow This symbol indicates an interrupted signal in a horizontal direction. Ground This symbol indicates a machine ground. Connector Motor JXX 5 Plug I Jack Connector and pin number Motor Butterfly Extra III GF500 Folder Jun 2018 Intro Service Manual VI

8 Thermistor Driver Solenoid Thermistor Bead, used to sense temperature A Driver that is used to switch on DC components Clutch or Solenoid. Tag Information A TAG number within a circle and pointing to one or more item number, 1 shows that the part has been changed by the TAG number within the circle. A TAG number within a circle without apex shows that the entire drawing 1 has been changed by the TAG number within the circle. A TAG number within a circle having a shaded bar and pointing to one or more item number, shows that the configuration of the part shown is the 1 configuration before the part was changed by the tag number within the circle A TAG number within a circle having a shaded bar without apex shows that 1 of the entire drawing was the configuration before being changed by the tag number within the circle Display messages In this way will be indicated a code that appear on the Control Panel DOOR OPEN In this way will be indicated a message that appear on the Optional Control Panel Signal Nomenclature The signal is named to imply the condition of the machine when the signal is available. For example: Step Motor On (L) +5 Vdc 1. STEP MOTOR ON = Signal Name 2. (L) = logic State when the signal is available in it's named state. In this case, the signal is low when the Main Motor is energised VDC = Logic level when the signal is High. DC Voltage Levels DC Voltages should be measured between the test point and the machine frame, unless instructed otherwise. The table below shows the value of the voltages. Logic Voltage Levels Voltage +12 VDC +24 VDC Table 2 Specification H +2VDC L +12VDC Measurements of logic levels must be made with reference to the specified ground point, unless some other point is referenced in a diagnostic procedure. Nominal Voltage Logic State Actual Voltage Ranges +5 VDC H +4.8 VDC to +5.2 VDC Table 3 Butterfly Extra III GF500 Folder Jun 2018 Intro Service Manual VII

9 1. Service Call Procedure 1. SERVICE CALL PROCEDURE SERVICE CALL PROCEDURES INITIAL ACTION FOLDER REGISTRATION SYSTEM CHECKOUT CSE CALL ESCALATION FINAL ACTIONS Butterfly Extra III GF500 Folder Jun 2018 SERVICE CALL PROCEDURES Service Manual 1-1 SERVICE CALL PROCEDURE

10 SERVICE CALL PROCEDURES Introduction Initial Action/System Checks This diagram is designed to identity and classify the folder problem and to refer you to the appropriate Repair Analysis Procedure ( Section 2) or Fold Quality (Section 3). System check out and Final Action The open a service ticket to GERA Service Team is required to access to the GERA web site and check the folder registration in order to: Order spare Activate Warranty Contact Tech support with a Problem Report Form To open a service ticket to Gera Service Team goto web page: and fill form about folder model and region Call Flow Chart Initial Actions / System Check out Open to GST a service ticket Identity and classify the folder problem by using RAP and Fold Quality Section Perform: RAP, REP, ADJ and fill the Problem Report Form with analysis of the failure Final Actions Final Action is designed to ensure service call is ticket is correctly closed Butterfly Extra III GF500 Folder Jun 2018 SERVICE CALL PROCEDURES Service Manual 1-2 SERVICE CALL PROCEDURE

11 INITIAL ACTION ASK THE OPERATOR TO DESCRIBE THE PROBLEM ENSURE THAT THE POWER CORD IS CONNECTED AND THE GFI CABLE IS ACTIVATED. ENSURE THAT THE CUSTOMER S CIRCUIT BREAKER IS NOT TRIPPED FOLD. TEST PRINT IN ORDER TO VERIFY THE PROBLEM IF THE PROBLEM STILL EXISTS, THEN CONTINUE. IF PROBLEM DOES NOT EXIST, DO A SYSTEM CHECKOUT AND REPAIR ANY FAULTS DETECTED STATUS INDICATORS FOLD QUALITY OTHERS PROBLEMS FOLDER MESSAGES: Alarm Status describing a folder status after a POST Error Alarm describing what fold process error occurs by fold a copy FOLD QUALITY PROBLEMS: - Go Section 3, Fold Quality SELECTION / INDICATION: - Go to the Generic RAP - Go to Section 2, Contents Butterfly Extra III GF500 Folder Jun 2018 INITIAL ACTION Service Manual 1-3 SERVICE CALL PROCEDURE

12 FOLDER REGISTRATION After the folder installation procedure is performed it is mandatory to perform the final Install Check List and the submit the Folder Registration form available in the gera web site. The Installation Check List and the Folder Registration are step required to activate folder warranty and free help desk support by the GERA SERVICE TEAM. The Folder Registration Form can be completed on line at and is required to: Order Spare Activate Warranty Contact Tech support with the online Problem Report Form SYSTEM CHECKOUT Procedure Run and fold the common sizes used. Folded prints are delivered to the output tray. Refer to the Initial Action in order to classify the problem and begin your repairs. CSE CALL ESCALATION 2ND LEVEL GERA is supporting world wide as second /third level local engineer by providing by and remote assistance, by recording each call and providing history action log of the product and provide procedure and action to close the issue 1. Make sure that the Product has been registered on the GERA web site and store a copy of the form in the folder. This will enable Ordering Spares Activate Warranty Contact Tech support with a Problem Report Form 2. Get the Gera Folder serial number 3. Evaluate the problem using Section 3 Fold Quality or Section 2 RAP in the Service Manual and adjust or repair as necessary 4. Open a ticket to GERA by using the Problem Report Form on-line using this web link 5. Fill the on line PRF with the required details, make a print for your records and then submit to GERA SERVICE TEAM by pressing Submit button. FINAL ACTIONS 1. Fill in the machine service log and the service report. 2. Fold some prints and leave samples with the customer. Evaluate the print folding. The folding quality is acceptable. Go to Section 3, Fold Quality and/or proceed with the ADJ 3.1. Go to the Final Action if you re performing a service call, otherwise if you re performing step 19 of the installation procedure, proceeds with step 20. Butterfly Extra III GF500 Folder Jun 2018 FOLDER REGISTRATION - FINAL ACTIONS Service Manual 1-4 SERVICE CALL PROCEDURE

13 2. Repair Analysis Procedure 2. REPAIR ANALYSIS PROCEDURE... 2-I How to read this section Sensor default status chart STATUS MESSAGE RAPS BUTTERFLY All Led (P1, P2, P3, P4 and red Led) are OFF P1 led flashing FOLDER OFFLINE P1 LED Lit ON and red Led is On with error code P1, P2 LED Lit On steady All Led (P1, P2, P3, P4 are lit ON and red led is OFF FAN FOLDER UPPER POCKET SENSOR COVERED RAP (ALL) FAN FOLDER LOWER POCKET SENSOR COVERED RAP (ALL) CROSS FOLDER C6 POCKET SENSOR COVERED RAP (ALL) CROSS FOLDER C7 POCKET SENSOR COVERED RAP (ALL) ERROR MESSAGE RAPS BUTTERFLY FOLDER ENTRANCE ALARM RAP FAN FOLDER ALARM RAP CROSS ALARM RAP GENERIC RAPS BUTTERFLY POWER OFF RAP FOLDING PROCESS DOESN T START FOLDER TEARS THE PAPER FROM THE PLOTTER ENTRY FLAP DOES NOT RISE RAP (EXTRA) LAST FAN FOLD PANEL DAMAGED RAP STATUS MESSAGE RAPS GERAFOLD TOUCHSCREEN OFF FOLDER OFFLINE (GF500) INSERT SD CARD MESSAGE VIZIC TEXT ERROR MESSAGE RAPS GERAFOLD FOLDER ENTRY ERROR RAP FEED ERROR Butterfly Extra III GF500 Folder 2-I Service Manual Jun 2018 Repair Analysis Procedure

14 PINCH ERROR FAN FOLDER ERROR 12 RAP CROSS FOLDER ERROR RAP (GF500X) GENERIC RAPS GERAFOLD POWER OFF, EMERGENCY RAP FOLDING PROCESS DOESN T START ENTRY FLAP DOES NOT RISE RAP LAST FAN FOLD PANEL DAMAGED RAP (GF500X) GERAFOLD 500 GENERIC RAPS ERROR MESSAGES ERROR 02 : LOST COMMUNICATION ERROR 03 : WRONG FOLD PROGRAM ERROR 04 : UNKNOWN FOLD SPEED ERROR 05 : MOTOR 24Vdc POWER MISSED ERROR 06 : SIZE ERROR LENGTH ERROR 07 : SIZE ERROR WIDTH ERROR 08 : LENGTH STYLE ERROR ERROR 10 : FEED ERROR ERROR 11 : PINCH ERROR ERROR 12 : FOLDING ERROR ERROR 30--> 34 CROSS ERROR (GF500X) ERROR 40--> Butterfly Extra III GF500 Folder 2 Service Manual Jun 2018 Repair Analysis Procedure

15 HOW TO READ THIS SECTION This section provides information on how to understand the correct operation of input sensors, motors, solenoids, clutches and troubleshoot and identify folder problems. Refer to the correct Butterfly folder version : BASE, PLUS, EXTRA, SIMPLE COMPLETE and GeraFold 500 This section identifies typical folder messages. STATUS Message : each time the folder is powered up the folder logic provides a Power On Self Test (POST). This operation when completed (3 seconds) results in folder idle condition ( no error message or red LED indication or acoustic alert). The check verifies that all sensors are clear (no paper present) and all interlocks are closed and all motors are in the home position. ERROR Message during the fold process the folder logic monitors the paper path, if the copy cannot complete a defined paper path section within a specified time, the folder generates a fold error message. In this case, the CSE must evaluate and troubleshoot the reason that the copy was able to start but not complete the specific paper path section. Butterfly User interface is provided by simple folder Control Panel with some LED indicators and audible beep. GeraFold 500 User Interface is provided by a Touchscreen panel with messages The folder after power cycle POST state a STATUS MESSAGE Butterfly STATUS Message = RED LED FLASHIG & 4 beeps every 30 sec. GeraFold 500 Status Message = ERROR CODE MESSAGE from 40 to 49. The folder during the fold process may detect a paper jam, to locate it on: Butterfly : ERROR Message = RED LED FLASHIG + Beeps every 30 sec. ENTRY ALARM 1 Beep FAN ALARM 2 Beeps CROSS ALARM 3 Beeps GeraFold 500 : ERROR Message = ERROR CODE ENTRY ALARM Error code 10; 11 FAN ALARM Error code 12 CROSS ALARM Error code 30; 31; 32; 33; 34 ERROR 10 Butterfly provides CSE software named Diagnostic & Adjustment Tool used to connect the folder to a PC and provides a virtual control panel able to perform Diagnostic and NVM Adjustment selections. (Ref. Section 6) GeraFold 500 also provides CSE through Touchscreen panel the possibility to perform Diagnostic and NVM Adjustment selections. SENSOR DEFAULT STATUS CHART SENSOR DEFAULT STATUS CHART Since the folder has many sensors it s important to identify the sensor type : standard, reflection, or barrier, LED indication and default LED status when uncovered and the relative signal output voltage input to the Main Controller. Sensor type: Case LED a. Standard black red b. Reflection pwb yellow c. Barrier pwb green Sensor Identification name on BSD [C2] [C3] [C4 [C5] [CC] [C6] [C8] [CA] [CS] [CST] [C7 COMPLETE] [C7] Type c a b Pwb LED Covered or not by paper Pin 1-2 Out, -Sensor Signal voltage Diagnostic Graphic Input/Output test on uncover > 9 Vdc green off cover < 2 Vdc red off uncover < 2 Vdc green on cover > 9 Vdc red off uncover > 9 Vdc green on cover < 2 Vdc Red CP [BASE] Sensor Vertical off uncover on cover In order to determine the folder sensor fault: Remove all paper jams in the folder Switch the folder off and on. After the POST, if the folder detects one or more sensor faults, the folder will flash the Red LED on the UI (Butterfly), Error code message(gf 500) and 4 Beeps. In order to locate the folder faulty sensor on Butterfly : Open the top and rear folder cover panel and see if the corresponding LED on the sensor pwb is illuminated on ([C4], [C5], [CC], [C6], [C8], [C7], [CS], [CA], [CST].Remove the upper cover REP 1.1 or unilluminated sensors ([C2], [C3], remove rear cover REP In order to locate the folder faulty sensor on GF5000 : the error code identify which sensor is covered by paper. When the fault is identified refer to the specific RAP for corrective action. To determine if output motor on Butterfly are working : press the selection key on the folder UI and hold, this will enable all the motor rotating in order to remove eventual paper jams and enable CSE to detects if output are operating. To determine if output motor on GF500 are working select the option "clean" or perform the diagnostic procedure to enable CSE to detects if output are operating Butterfly Extra III GF500 Folder 2-3 Service Manual Jun 2018 Repair Analysis Procedure

16 STATUS MESSAGE RAPS BUTTERFLY All Led (P1, P2, P3, P4 and red Led) are OFF This RAP is used when all led on the Butterfly keyboard is off. Folder and Printer are in communication but on folder Keyboard all led are off Initial Action Ensure the folder is working correctly Procedure Check the 4 LED on folder keyboard. The folder is turned On? Turn On the folder and check the correctly working. Perform the automatic ejection. The Motor turns? Check the flat cable under the keyboard if is disconnected. Go to the Electric Diagram and troubleshoot the wiring flat cable between the drive motor J1 and the Main controller J16 P1 led flashing FOLDER OFFLINE This RAP is used when the P1 led on the Butterfly keyboard is flashing The folder can swing and be open on side to enable off line use or to replace media roll in the printer, a micro-switch located in the lower side of the folder feet can close the mechanic assembly hanging the folder to the printer Initial Action Ensure the folder is on line position close against the printer and by moving folder or printer the switch never open the circuit while printer is printing Procedure Check the P1 LED on folder keyboard. Is the P1 LED flashing on? The folder is on line position. The folder is off line mode or the Door switch 1 must be adjusted in order to avoid unexpected open circuit Go to the Electric Diagram and troubleshoot DS1 B6 Switch P1 LED Lit ON and red Led is On with error code 7 Use this RAP when the P1 LED on folder front panel is On and red Led is On with error code 7 on Printer keyboard. Procedure Check the P1 LED on folder control panel. The P1 LED is On with red Led flashing On? Restart printer and folder. Check the lateral doors under keyboard is closed correctly? Check PWB Drive Controller red leds default all off. one or more led is On? Troubleshoot the open circuit Electric Diagram and Check the wiring between the Drive Controller itself and the Stepper Motor Drive (item 5 and 6 on service manual p 5-21). If no result please open call to Gera Service Team by filling Problem Report Form available at: P1, P2 LED Lit On steady Use this RAP when the two P1, P2 LED on folder keyboard are lit On with red led off. Procedure Check the P1 & P2 LED on folder keyboard. Both LED are Steady? Restart printer and folder. The yellow led on Canbus blue box lit On? Troubleshoot the open circuit Electric Diagram and Check the wiring from J20 on Main controller to Canbus and from Canbus to J6-1. Check folder firmware is well loaded? Reload the right firmware and restart folder. If no result please open call to Gera Service Team by filling Problem Report Form available at: All Led (P1, P2, P3, P4 are lit ON and red led is OFF Use this RAP when all LED on folder keyboard are lit On with red led off Procedure Check with butterfly utility tools if all values are not lost and correctly setted as MTF documents. If no result please open call to Gera Service Team by filling Problem Report Form available at: Butterfly Extra III GF500 Folder 2-4 Service Manual Jun 2018 Repair Analysis Procedure

17 FAN FOLDER UPPER POCKET SENSOR COVERED RAP (ALL) This RAP is used when the Upper Pocket Sensor [C3] is covered by a paper jam or is inoperative. The Sensor [C3] is a barrier type, signal default level high, green Led on pwb lit on. Check : Butterfly Control Panel red Led flashing and emitting 4 beeps GeraFold 500 Touchscreen error code message 43 The default sensor Led status is light on. To locate Upper Pocket Sensor [C3] refer to Electric Diagram and PL 1.4 Procedure Open the folder rear plate REP 1.2, localize sensor C3 led, should on, if off look for paper jam. Once folder path is clear by paper, cover and uncover the sensor with paper, the sensor Led status should change. Is the sensor Led lit on and changing status? Clean the sensor C3 and check the alignment between emitter and receiver. Problem corrected, led still off? N Connect the voltage meter on sensor pwb connector (+) pin 4 and GND (-) pin 2 to check +12Vdc. Is 12 Vdc present? Go to the Electric Diagram and check the wiring for an open circuit or on Main Controller PWB if 12 Vdc is present between J6-4 and J6-1, if not replace Controller. Change sensor see PL 1.4 Check if sensor signal gets the Main Controller, sensor connector pin 2 to J6 on the Main Controller. Is sensor signal output changing status? Main Controller J6 pin 1 and 4 (high > 9Vdc )? If no before change Main Controller pwb open call to Gera Service Team by filling Problem Report Form available at FAN FOLDER LOWER POCKET SENSOR COVERED RAP (ALL) This RAP is used when the Lower Pocket Sensor [C2] is covered by a paper jam or is inoperative. The Sensor [C2] is a barrier type, signal default level high, green Led on pwb lit on. Check : Butterfly Control Panel red Led flashing and emitting 4 beeps GeraFold 500 Touchscreen error code message 42 The default sensor Led status is light on. To locate Lower Pocket Sensor [C2] refer to the Electric Diagram and PL 1.3 Procedure Open the folder rear plate REP 1.2, localize sensor C2 led, should on, if off look for paper jam. Once folder path is clear by paper, cover and uncover the sensor with paper, the sensor Led status should change. Is the sensor Led lit on and changing status? Clean the sensor C2 and check the alignment between emitter and receiver. Problem corrected, led still off? N Connect the voltage meter on sensor pwb connector (+) pin 4 and GND (-) pin 2 to check +12Vdc. Is 12 Vdc present? Go to the Electric Diagram and check the wiring for an open circuit or on Main Controller PWB if 12 Vdc is present between J2-8 and J2-3, if not replace Controller. Change sensor see PL 1.3 Check if sensor signal gets the Main Controller, sensor connector pin 3 to J2-7 on the Main Controller. Is sensor signal output changing status? Main Controller J2 pin 7 and 8? If no before change Main Controller pwb open call to Gera Service Team by filling Problem Report Form available at Butterfly Extra III GF500 Folder 2-5 Service Manual Jun 2018 Repair Analysis Procedure

18 CROSS FOLDER C6 POCKET SENSOR COVERED RAP (ALL) This RAP is used when the Cross Lower Pocket Sensor is covered by a paper or does not work. Initial actions Remove the paper jam if present; ensure that the paper path is free and that the Cross Folder doors are closed. Turn the folder off and then on, check : Butterfly Control Panel red Led flashing and emitting 4 beeps GeraFold 500 Touchscreen error code message 46 The default sensor Led status is light off. To troubleshoot Cross Pocket Sensor [C6] refer to the Electric Diagram Procedure Remove the cross folder plate REP 2.3, localize sensor C6 led, should off, if on look for paper obstruction. Once folder path is clear, cover and uncover the sensor with paper, the sensor Led status should change. Is the sensor Led changing status? Clean the sensor and the black paint area Is now sensor Led still off and not changing status? Y Connect the voltage meter on sensor pwb connector (+) pin 4 and GND (-) pin 2 to check +12Vdc. Is 12 Vdc present? Go to the Electric Diagram and check the wiring for an open circuit or on Main Controller PWB if 12 Vdc is present between J3-6 and J3-1, if not check if 12Vdc led on Main Controller is lit on. Change sensor see PL 2.1 Check if sensor signal gets the Main Controller, sensor connector (OUT) pin 1 to J3 pin 5 on the Main Controller PWB. Is sensor signal with open circuit? If no before change Main Controller pwb open call to Gera Service Team by filling Problem Report Form available at Troubleshoot the open circuit Electric Diagram. CROSS FOLDER C7 POCKET SENSOR COVERED RAP (ALL) This RAP is used when the Cross Upper Pocket Sensor is covered by a paper or does not work. Initial actions Remove the paper jam if present; ensure that the paper path is free and that the Cross Folder doors are closed. Turn the folder off and then on, check : Butterfly Control Panel message after POST red Led flashing and emitting 4 beeps GeraFold 500 Touchscreen error code message 47 The default sensor Led status is light off. To troubleshoot Cross Pocket Sensor [C7] refer to the Electric Diagram Procedure Remove the top cover REP 1.1, localize sensor C7 led, should off, if on look for paper obstruction. Once folder path is clear, cover and uncover the sensor with paper, the sensor Led status should change. Is the sensor Led changing status? Clean the sensor C7 and check reflection mirror is clean Problem corrected, sensor Led still off? N Connect the voltage meter on sensor pwb connector (+) pin 4 and GND (-) pin 2 to check +12Vdc. Is 12 Vdc present? Go to the Electric Diagram and check the wiring for an open circuit or on Main Controller PWB if 12 Vdc is present between J3-8 and J3-2, if not check if 12Vdc led on Main Controller is lit on. Change sensor see PL 2.1 Check if sensor signal gets the Main Controller, sensor connector (OUT) pin 1 to J3 pin 7 on the Main Controller PWB. Is sensor signal with open circuit? If no before change Main Controller pwb open call to Gera Service Team by filling Problem Report Form available at Troubleshoot the open circuit Electric Diagram Butterfly Extra III GF500 Folder 2-6 Service Manual Jun 2018 Repair Analysis Procedure

19 ERROR MESSAGE RAPS BUTTERFLY FOLDER ENTRANCE ALARM RAP Use this RAP when the folder stops and the red led is flashing and 1 beep. This occurs when the print jams at fan folder entry, is not detected by the entry sensor [CS] or the entry drive is missed [M2] Initial Actions Remove the jammed paper on the fan folder entry and verify all folder doors are closed. Check if folder entry sensor [CS] fan entry REP 1.1 and PL 1.1 operates correctly and copy lead edge enters without hesitation, the entry flap position may obstruct the copy entry, perform the Adj 1.4. Procedure The folder receives information the copy is printed when the sensor CS is covered with the lead edge of the paper (PLUS, COMPLETE, SIMPLE), after 3-5 seconds the folder check if the fan folder entry sensor [CS] is covered and drives the Step motor [M2]. If the check fails the folder declare the error. (BASE) When the sensor CP is covered start the motor M2, after 120 second the sensor CS should be covered. If the check fails the folder declare the error. Check if the motor [M2] runs when paper covers the entry sensor CS? Go to the Electric Diagram and check the [M2] Stepper Motor Drive HGD 04 or NDC04, belt drive. Are all connectors and D1 green Led PWB off? Stepper Motor Drive HGD/NDC 04 red led on, or motor fault before replace please open call to Gera Service Team (see below ) Check +24Vdc input AM2 connector. Are these voltages present? Check Power Supply output and open circuit till to connector AM2 on Stepper Motor drive PWB Check the [CS] sensor Electric Diagram for missed input voltage 12Vdc or sensor signal sent to main Controller PWB. Is sensor operating correctly? Replace sensors. Please check the entry flap motor operation then please open call to Gera Service Team by filling Problem Report Form available at FAN FOLDER ALARM RAP Use this RAP when the folder stops and the folder UI red led flashing and 2 beeps This occurs when the print edge is entered the fan folder unit, after the Print Guide phase the copy should enter the fan folder pocket and cover the fan folder sensor on time, if not the folder rises this alarm. Folder UI red led on and 2 beep Initial Actions Remove the jammed paper on the fan folder entry and verify all folder doors are closed. Open the fan folder plates and observe if the copy attempt to enter the fold pocket, check if copy lead edge during the print guide stops against the mobile roller and is guided correctly, refer to NVMs for settings where and how long print stops. Procedure Are the motor [M3] and Mobile Roller (C) rotating? Go to the Electric Diagram and check the NDC 06 PL 4.1 and drive belt. Is the M3 Stepper Motor Drive PWB D1LED (green) on? Does motor M3 running? (Press arrow button on UI for ejected procedure) Stepper Motor Drive NDC 06 red led on, or motor fault before replace please open call to Gera Service Team Open side folder plate and look for belt and pulley arrangement Check the Electric Diagram for open circuit on power distribution +24Vdc to Stepper motors. Are these voltages present? Check the Electric Diagram for Power Supply missed output and/or open circuit till to Stepper Motor drive PWBs and stepper motors. Check the [CC] on the Electric Diagram for missed input voltage 12Vdc or sensor signal sent to main Controller PWB. Is sensor operating correctly? Replace sensors. Please check Sensor [C2] [C3] and relative RAP if paper covers the sensor and it does not change M3 rotation, or troubleshoot paper stuck during the fold pocket entrance. Please open call to Gera Service Team by filling Problem Report Form available at Butterfly Extra III GF500 Folder 2-7 Service Manual Jun 2018 Repair Analysis Procedure

20 CROSS ALARM RAP This error message occurs if the print does not enter in the cross section or paper jams inside the cross section and do not finish the folding procedure. Use this RAP when the folder stops and the folder UI red led on and 3 beeps On printer UI Error 3 message Initial Actions Remove the jammed paper on the cross folder and verify all folder interlocks are close. Verify if paper jam is due to the paper curl output that exceed specifications; refer to the Quick Guide and see FQ2 9. FQ2 2 Procedure Does the copy complete the Cross Folder process without damage and drops on the basket correctly? Check diagnostic input test if cross folder sensors [C6] [C7] [C8] are changing status by covering them with paper, go to the Electric Diagram for troubleshoot wiring or for an open circuit problems. For reflection sensor C7 types verify stainless plate working as mirror is not dirt by dust of toner and correctly positioned Are all cross folder sensors operating correctly? Replace the damaged sensor. Check cross folder paper path in order to see if knives or plates may interfere to paper movements. Is anything impeding the paper path? Verify if direct lamp may influence the Cross folder exit sensor operation. Fix cross folder paper path by adjusting roller gap or pressure, knives stroke, plate position. Refer Adj. 2.1 Open call to Gera Service Team by filling Problem Report Form available at GENERIC RAPS BUTTERFLY POWER OFF RAP Use this RAP when the folder Control Panel LEDs does not light on, or when the UI Selection key is pressed and the Cross Folder Exit wheel are not rotating. Initial Action Close all folder door, turn the folder off and on, the folder during the POST runs some motors and light on the folder Control Panel led, Press the selection key and the Cross Folder Exit wheels should rotate, if one or more these events are performed follow the procedure. Procedure Remove the folder back panel REP check Led L1 on Power Supply PL 4.1 Is the green Led on? Check if power cable is plug into Iec connector, if main switch is on. Are the line fuses F1 and F2 operating? Replace with GERA spare Fuse 1.6A(50Hz) Is the Power Supply 24Vdc output available? If not replace Power Supply PL 4.1 Y Check Main Controller 24 Vdc Input J18 and J17 Is the 3,3Vdc LED on Main Controller Pwb light on? Check cabling from PS1 24Vdc output to J18 Main Controller If there is not an open circuit open a service call to GST Is the 24Vdc Main Controller LED lit on? Check cabling from PS1 24Vdc output to J17 Main Controller If there is not an open circuit up to J17 before change Main Controller open a service call to GST Check if Stepper Motor Controller PWB PL 4.1 item 4 Led D4 indicating 5Vdc on. Is the 5 Vdc LED on? Check Main Controller 5 Vdc LED is on? N Troubleshoot connector J16 flat cable before replace Main Controller PWB. Butterfly Extra III GF500 Folder 2-8 Service Manual Jun 2018 Repair Analysis Procedure

21 FOLDING PROCESS DOESN T START Use this RAP when the fan folder process doesn t start, the copy enters the fan folder entry covers the sensor CS enabling the roller to pinch the paper lead edge, the entry flap goes down and paper buckle increases until touches the floor. Even if the sensor CA detects paper buckle big enough should enable the start, the folder does not start fold process. Procedure Check diagnostic input test if the sensor [CA] is changing status by covering it with paper. Go to the Electric Diagram for troubleshoot wiring or for an open circuit problems. Is the [CA] sensors operating correctly? Replace the damaged sensor or restore wiring Increase the [CA] sensor sensitivity performing the ADJ 1.3 or see if the folder is beeping before the paper buckle as error, check operation of the sensor CST or if CS is released by paper after the start. If problem persist open call to Gera Service Team by filling Problem Report Form available at FOLDER TEARS THE PAPER FROM THE PLOTTER Use this RAP when the folder pulls and tears the paper output from the plotter. The paper covered the CS, the flap goes down and CST should be uncovered within 2 second and the folder is waiting the sensor CA covered. Use this RAP when the folder stops and the folder UI red led on and 2 beeps Initial Actions Verify that the operator doesn t open the plotter front door during the printing-folding process. Procedure Check diagnostic input test if the sensor [CA] is changing status by covering it with paper. Go to the Electric Diagram for troubleshoot wiring or for an open circuit problems. Is the [CA] sensors operating correctly? Replace the damaged sensor or restore wiring perform ADJ 1.3 by operating on trimmer default setup at 11 am sensibility if sensor detects paper buckle over 5mm far from the flap reduce the sensibility if when paper is lay down on flap surface and is not all the times detected increase sensor sensibility. Perform the ADJ 1.3 and check the correct adjustment of [CA] sensor Prevent and minimize environmental conditions that cause wrong [CA] sensor reading (for example lights or sunny windows); does the problem persist? Y Open call to Gera Service Team by filling Problem Report Form available at ENTRY FLAP DOES NOT RISE RAP (EXTRA) Use this RAP when the folder Entry Flap does not rise on, or when by pressing the keyboard selection key is pressed and Entry Flap does not change position Initial Action Close all folder doors, turn the folder off and on, the folder at the POST moves the Entry Flap motor UP to home position, If not press and hold the selection key the Entry Flap moves up or down, When the Entry Flap does not move, follow the procedure below: Procedure Remove the folder Fan Cover REP 1.4 Check Led status of Position Sensor PS9 labelled TOP is the Led light on? The Entry Flap is DOWN (work position) at folder power on is audible or visible the Entry Flap Motor rotating? to check motor operation, open Rear Covers REP 1.2 e locate PWB FM2 unplug orange cable labelled (M+( and (+) and join them shortly, this will provide 24vdc direct to the motor, is the motor rotating? Check PS1 24Vdc output to J17 Main Controller connector The 24dc green leds should lit on, if not, check Power Supply Count if motor turns 5 turn in 15 second? If yes then is required to change PWB FM2 If it turn less than 5 turn in 15 second, in this case is required to change also the Motor Entry Flap. Entry Flap Motor with 24vdc, internal gearbox or leverage assembly may be broken and need to be replaced The Entry Flap should UP home position ( small disk cut) It's possible to lower the Entry Flap by pressing arrow key? Check PS1 24Vdc output to J18 Main Controller 3,3dc 5 dc 12 dc green leds should lit on Is the 24Vdc Main Controller LED lit on? Check plug J17 on Main controller connector Open call to Gera Service Team by filling Problem Report Form available at before replace Main Controller PWB. Butterfly Extra III GF500 Folder 2-9 Service Manual Jun 2018 Repair Analysis Procedure

22 LAST FAN FOLD PANEL DAMAGED RAP Use this RAP when the fan folding last panel of specific length size range ( mm) +n times 420mm, exit damaged or jam before to fell in the conveyor. Initial Action Send a copy length 840mm folded 210 and check if the Finger Guide works correctly and then follow the procedure. Procedure Finger Guide Remove the folder upper cover panel REP 2.4 Check Led status of Position Sensor PS3 labelled TOP is the Led light on? The Finger Guide is DOWN (work position), at Folder power on is audible or visible the Finger Guide Motor rotating? Open Rear Covers REP 1.2 and locate PWB FM1 unplug orange cables labelled (M+) and (+) and join them shortly, this will provide 24vdc direct to the motor, is the motor rotating now? Check PS1 24Vdc output to J17 Main Controller The 24dc green leds should lit on, if not, check Power Supply Count if motor turns n turn in n seconds? If yes then is required to change PWB FM1 If the motor turns less than n turn in n seconds, in this case is required to check the mechanical lazy operation. Finger Guide Motor with 24vdc, internal gearbox or leverage assembly may be broken, so is required to replace motor. Cover the position sensor PS3 and check if Finger Guide works, if not go to step 2 Butterfly Extra III GF500 Folder 2-10 Service Manual Jun 2018 Repair Analysis Procedure

23 STATUS MESSAGE RAPS GERAFOLD500 TOUCHSCREEN OFF This RAP is used when Touchscreen on the GeraFold 500 is off. Initial Action Ensure the folder is working correctly Procedure Check if the folder is turned On? by pressing the top button Turn On the folder and check the correctly working.? Check the flat cable under the keyboard if is disconnected. Go to the Electric Diagram and troubleshoot the wiring flat cable FOLDER OFFLINE (GF500) This RAP is used when the printer UI declare that the folder is detached The folder can be open to enable off line use, a micro-switch located in the left side of the folder hook can close the mechanic assembly hanging the folder to the printer Initial Action Ensure the folder is on line position close to the printer and by moving folder the switch never open the circuit while printer is printing Procedure Check the printer UI message. the folder is detached? The folder is on line position. The folder is off line mode or the Door switch 1 must be adjusted in order to avoid unexpected open circuit Go to the Electric Diagram and troubleshoot DS1 B6 Switch INSERT SD CARD MESSAGE Use this RAP when the folder Touchscreen the message Insert SD card. Procedure Check on folder Touchscreen if the SD card is inserted correctly into the slot position? Turn off the folder and remove the SD card and insert it correctly into the slot. Check the white cable connection extension from the external slot to the internal slot of the Touchscreen PWB? Insert correctly the extension cable into the slot of the Touchscreen pwb If no result please open call to Gera Service Team by filling Problem Report Form available at: VIZIC TEXT Use this RAP when the message Vizic Technologies is shown on the folder Touchscreen. Procedure Check the message Vizic Technologies is shown on the folder Touchscreen? Restart the folder. The wiring cables are not connected to the Pwb? Troubleshoot the open circuit Electric Diagram and Check the wiring from Touchscreen Pwb to the Main controller. Check correct connection serial Tx Rx communication pin Correct cables and provide a new power cycle If no result please open call to Gera Service Team by filling Problem Report Form available at: Butterfly Extra III GF500 Folder 2-11 Service Manual Jun 2018 Repair Analysis Procedure

24 ERROR MESSAGE RAPS GERAFOLD500 FOLDER ENTRY ERROR RAP FEED ERROR 10 Use this RAP when the folder stops and the folder Touchscreen shows error code 10. This occurs when the copy jams at folder entry section and paper is detected by the Fan entry sensor [CV] but not by the sensor [CS]. Initial Actions Remove the paper jam at the entry folder. Check if folder entry sensor [CS] operates correctly and copy lead edge enters without hesitation, the entry flap position may obstruct the copy entry. Procedure Print a copy and ensure paper lead edge cover entry sensor [CV], after 3-5 seconds the folder check if the fan folder entry sensor [CS] is covered. If the check fails the folder declare the error code 10. The Paper is under the sensor CS? N Y Check the [CS] sensor Touchscreen Diagnostic test--> Input sensor for missed input voltage 12Vdc or sensor signal sent to main Controller PWB. Is sensor operating correctly? Replace sensors Check paper curl specification. The paper curl is within the specification N load paper roll with 75<gsm<90 Y.Check if the folder entry flap is not obstructing the paper lead edge. N Adjust the folder height referring to the installation instruction If no result please open call to Gera Service Team by filling Problem Report Form available at: PINCH ERROR 11 Use this RAP when the folder stops and the folder Touchscreen shows error code 11. This occurs when the copy jams at folder entry section and paper is detected by the entry sensor [CS] but not detected by the sensor [CC] or the entry drive is missed [M2] Initial Actions Remove the paper jam at the entry folder and verify all folder doors are closed. Check if folder entry sensor [CS] fan entry REP 1.1 and PL 1.1 operates correctly and copy lead edge enters without hesitation Procedure The folder receives information the copy is printed when the sensor CS is covered by the paper, after 3-5 seconds the folder check if the fan folder entry sensor [CS] is covered and drives the Step motor [M2]. If the check fails the folder declare the error. Check if the motor [M2] runs when paper covers the entry sensor CS? Go to the Electric Diagram and check the [M2] Stepper Motor Drive. Are all connectors and Led PWB off? Stepper Motor Drive red led on, or motor fault before replace please open call to Gera Service Team (see below ) Check +24Vdc input connector. Are these voltages present? Check Power Supply output and open circuit till to connector on Stepper Motor drive PWB Check the [CS] sensor Electric Diagram for missed input voltage 12Vdc or sensor signal sent to main Controller PWB. Is sensor operating correctly? Replace sensors. Please check the entry flap motor operation then please open call to Gera Service Team by filling Problem Report Form available at Butterfly Extra III GF500 Folder 2-12 Service Manual Jun 2018 Repair Analysis Procedure

25 FAN FOLDER ERROR 12 RAP Use this RAP when the folder stops and the folder UI shows an error code 12. This occurs when the copy is entered the fan folder section, after the Print Guide phase the copy should enter the fan folder pocket and cover the fan folder sensor [C2] or [C3], if not the folder goes in error and on the Touchscreen a message "error 12" is shown Initial Actions Remove the paper jam and bypass door switch. Observe if the copy attempt to enter the fold pocket, check if copy lead edge during the print guide stops against the mobile roller and is guided correctly, refer to NVMs for settings where and how long print stops. Procedure Enter in Diagnostic output test and run motor[m3] Is the motor [M3] turns? Go to the Electric Diagram and check the CSD and drive belt. Is the M3 Stepper Motor Drive PWB LED (green) on? Does motor M3 running? (Press arrow button on UI from "clean" option) Stepper Motor Drive CSD red led on, or motor fault before replace please open call to Gera Service Team Open side folder plate and look for belt and pulley arrangement Check the Electric Diagram for open circuit on power distribution +24Vdc to Stepper motors. Are these voltages present? Check the Electric Diagram for Power Supply missed output and/or open circuit till to Stepper Motor drive PWBs and stepper motors. Check the [CC] on the Electric Diagram for missed input voltage 12Vdc or sensor signal sent to main Controller PWB. Is sensor operating correctly? Replace sensors. Please check Sensor [C2] [C3] and relative RAP if paper covers the sensor and it does not change M3 rotation, or troubleshoot paper stuck during the fold pocket entrance. Please open call to Gera Service Team by filling Problem Report Form available at CROSS FOLDER ERROR RAP (GF500X) This error message occurs if the copy does not enter in the cross section or paper jams inside the cross section and do not finish the folding procedure. Use this RAP when the folder stops and the folder UI shows an Error code ( ) message Initial Actions Remove the paper jam on the cross folder and verify all folder interlocks are close. Verify if paper jam is due to the paper curl output that exceed specifications; refer to the Quick Guide and see FQ2 9. FQ2 2 Procedure Does the copy complete the Cross Folder process without damage and drops on the basket correctly? Check diagnostic input test if cross folder sensors [C6] [C7] [C8] are changing status by covering them with paper, go to the Electric Diagram for troubleshoot wiring or for an open circuit problems. For reflection sensor C7 types verify stainless plate working as mirror is not dirt by dust and correctly positioned Are all cross folder sensors operating correctly? Replace the damaged sensor. Check cross folder paper path in order to see if knives or plates may interfere to paper movements. Is anything impeding the paper path? Verify if direct lamp may influence the Cross folder exit sensor operation. Fix cross folder paper path by adjusting roller gap or pressure, knives stroke, plate position. Refer Adj. 2.1 Open call to Gera Service Team by filling Problem Report Form available at Butterfly Extra III GF500 Folder 2-13 Service Manual Jun 2018 Repair Analysis Procedure

26 GENERIC RAPS GERAFOLD500 POWER OFF, EMERGENCY RAP Use this RAP when the folder Touchscreen does not light on when the emergency key is pressed. Initial Action Close folder doors, turn the folder off and on, the folder during the POST runs some checks, the entry and exit flap should run from work to home position it not follow the procedure : Procedure Remove the folder back panel REP check Led on Power Supply SP PL 4.1 Is the green Led on? Check if power cable is plug into IEC connector, if main switch is on. Are the line fuses F1 and F2 not blowed? Replace with GERA spare Fuse 2A(50Hz) Is the Power Supply SP output available led green on? If not replace Power Supply PL 4.1 Check if on the C695456R PWB, the led green "PWIN" is on? if not check wiring J3 or replace PWB FOLDING PROCESS DOESN T START Use this RAP when the folding process doesn t start, the copy enters the fan folder entry covers the sensor CS but not enabling the roller to pinch the paper lead edge, the entry flap doesn't go down and paper buckle increases until printer declare jam. Procedure Check diagnostic input test if the sensor [CS] is changing status by covering it with paper. Go to the Electric Diagram for troubleshoot wiring or for an open circuit problems. Is the [CS] sensors operating correctly? Replace the damaged sensor or restore wiring Restart the folder and check M2 motor turns, the M2 turns? Check diagnostic output test if the feed motor is working correctly? N Remove the folder back panel REP check Led on Power Supply SP PL 4.1 Is the green Led on? Check if power cable is plug into IEC connector, if main switch is on. Are the line fuses F1 and F2 not blowed? Replace with GERA spare Fuse 2A(50Hz) Is the Power Supply SP output available led green on? If not replace Power Supply PL 4.1 Is the green led on into the driver CSD? if not check for door interlock open? Check for missing 48Vdc to the driver CSD If there isn't an open circuit before to change Main Controller C695456R open a service call to GST Y Close open door and If problem persist open call to Gera Service Team by filling Problem Report Form available at Butterfly Extra III GF500 Folder 2-14 Service Manual Jun 2018 Repair Analysis Procedure

27 ENTRY FLAP DOES NOT RISE RAP Use this RAP when the folder Entry Flap does not rise on Initial Action Close all folder doors, turn the folder off and on, the folder at the POST moves the Entry Flap motors down and up, When the Entry Flap does not move, follow the procedure below: Procedure Remove the folder Fan Cover REP 2.4 Check Led status of Position Sensor PS9 labelled TOP is the Led light on? The Entry Flap at folder power on. Is the Entry Flap Motor moving? Open Rear Covers REP 2.2, enter in Diagnostic output test and check motor movement. The 24dc green led should lit on, if not, check Power Supply Entry Flap Motor with 24vdc, internal gearbox or leverage assembly may be broken and need to be replaced The Entry Flap should UP home position ( small disk cut) It's possible to lower the Entry Flap through diagnostic output test through Touchscreen? Y Open call to Gera Service Team by filling Problem Report Form available at before replace Main Controller PWB LAST FAN FOLD PANEL DAMAGED RAP (GF500X) Use this RAP when the fan folding last panel of specific length size range ( mm) +n times 420mm, exit damaged or jam before to fell in the conveyor. Initial Action Send a copy length 840mm folded 210 and check if the Finger Guide works correctly and then follow the procedure. Procedure Remove the folder upper cover panel REP 2.4 Check Led status of Position Sensor PS3 labelled TOP is the Led light on? The Finger Guide is DOWN (work position), at Folder power on is audible or visible the Finger Guide Motor rotating? Open Rear Covers REP 2.2 and locate PWB and join them shortly, this will provide 24vdc direct to the motor, is the motor rotating now? N Check PS1 24Vdc output to the C695456R PWB The 24dc green led should lit on, if not, check Power Supply Finger Guide Finger Guide Motor with 24vdc, internal gearbox or leverage assembly may be broken, so is required to replace motor. Cover the position sensor PS3 and check if Finger Guide works, if not go to step 2 Butterfly Extra III GF500 Folder 2-15 Service Manual Jun 2018 Repair Analysis Procedure

28 GERAFOLD 500 GENERIC RAPS ERROR MESSAGES ERROR 02 : LOST COMMUNICATION The folder can lose the communication with the printer if : The cable connection between folder and printer was detached The folder was uninstalled from Printer FP ERROR 03 : WRONG FOLD PROGRAM The error 03 happen when the operator select a wrong folding program ERROR 04 : UNKNOWN FOLD SPEED The error 04 happen when the folder receive a command to fold with a speed different than the specification (2"/s, 4"/s, 6"/s) ERROR 05 : MOTOR 24Vdc POWER MISSED The motor power 24Vdc is missed, check the lateral grey cover (under the Touchscreen) is closed or the micro-switch is not working. ERROR 06 : SIZE ERROR LENGTH The error 06 happen when : Paper length information sent to the folder not correct the operator select a file to be printed and folded with length out of specifications ERROR 07 : SIZE ERROR WIDTH The error 07 happen when : the printer send a wrong paper width information to the folder the operator select a file to be printed and folded with width out of specifications ERROR 08 : LENGTH STYLE ERROR The error 08 happen when : the printer send a wrong folding style information to the folder the operator select a file to be printed and folded with folding style out of specifications ERROR 11 : PINCH ERROR The error 11 happen when : The paper reachs the entry sensor [CV] but the entry roller do not pinch paper lead edge The paper is more curled than the specification ERROR 12 : FOLDING ERROR The error 12 happen when : The paper cover all entry sensor (CS, CC) but do not reach in time the folding pocket sensor (C2, C3). The paper jam between the folding sensor (C2 or C3) ERROR 30--> 34 CROSS ERROR (GF500X) This error message occurs if : The copy does not enter in the cross section and it stops over the conveyor section paper jams inside the cross section and do not finish the folding process ERROR 40-->49 This error message occurs when one or more sensors are covered by pieces of paper or do not work correctly Error 40 = [CS] covered Error 41 = [CC] covered Error 42 = [C2] covered Error 43 = [C3] covered Error 45 = [C5] covered Error 46 = [C6] covered Error 47 = [C7] covered Error 48 = [C8] covered Error 49 = [CV] covered ERROR 10 : FEED ERROR The error 10 happen when : The height between folder entry flap and printer exit diverter is not as installation instruction The paper curl is out of specification A3 size do not reach the folder entry rolls. Paper too short Butterfly Extra III GF500 Folder 2-16 Service Manual Jun 2018 Repair Analysis Procedure

29 3. Folding Quality INITIALIZATION PROCEDURE FOLD DEFECTS FOLD QUALITY DEFINITION FOLD QUALITY RAPS FQ 1 FOLD SKEW FQ 2 FQ2 FOLD DAMAGE FQ 3 FOLD DIMENSIONS FQ 4 FOLD OUTPUT Butterfly Extra III GF500 Folder Jun 2018 INITIALIZATION PROCEDURE Service Manual 3-1 FOLDING QUALITY

30 Initialization Procedure Prior to troubleshooting fold quality defects, ensure the following parameters are correct: Check that the print exits correctly from the printer, without dog-ears, wrinkles or curl. The paper roll must be aligned to the blue printer line reference and positioned correctly. The lead edge on the paper roll must be 90 straight, otherwise on the printer press key for cut paper lead edge Do not open door or change folding style during folding process. The Folder and the printer must be correctly aligned.adj3.5 Fold defects Fold quality applies to entire print. Defects can occur anywhere on the print. These defects could be print damage or incorrect folded package dimensions. Always eliminate problems that cause media damage before attempting to fix fold quality problems. Some media damage problems can cause fold quality problems. To fix folding quality problems: 1. Compare the fold defect to the Fold Quality Definition. 2. Go to the specific folding quality RAP (Damage, Skew,etc. ) 3. Identify the defect by comparing the print appearance with the drawing shown in the Defect column. Refer to the Probable Cause column and inspect each parameter to determine which has caused the specific defect. These causes have been listed in order of most likely to have caused the illustrated defect. If a defect is classified with N.R. (Not Recognized) this means that it is not pertaining with the Butterfly Folder Model. 4. When the Probable Cause is identified, refer to the corresponding Corrective Action and perform the indicated adjustment(s) or repair procedure(s). 5. Perform the Corrective Action Fold Quality Definition The following terms are some of the most commonly used terms that describe fold quality problems. FOLD SKEW FOLD DAMAGE FOLD DIMENSIONS WRONG FOLD OUTPUT Butterfly Extra III GF500 Folder Jun 2018 INITIALIZATION PROCEDURE Service Manual 3-2 FOLDING QUALITY

31 Fold quality RAPS FQ 1 FOLD SKEW Defect Probable Cause Corrective actions Edges not parallel Fan Skewing A. Not correct alignment between Folder and Printer Skew On the right (fig.1) Skew On the left (fig.2) B. Paper comes from the printer to far right A. Not correct alignment between Folder and Printer B. Printer Cutter is not aligned A. Perform ADJ 3.5 B. Check loading paper roll A. Perform Printer- Folder Alignment Adjustment ADJ 3.5 B. Refer to HP FQ 2 FQ2 FOLD DAMAGE Defect Probable Cause Corrective actions With Fold Program : Pass Through (Butterfly) A. Not correct print guide on A. Adjust Print Guide the mobile roller position and stop time against mobile roller refer Sec.6 Butterfly Adjustment Adj35 GF500 "No fold stop distance" Adjustment No Fold rear exit (GF500) Creasing in the cross panels B. Conveyor Sensor [CC] does not work correctly A. paper curl out of specification into the cross folder path B. Conducted Feed Roller sticky B. Check the [CC] sensor through Diagnostic Input Test A. Check the core of paper roll if 2 replace it with core 3 Perform ADJ 4.2.b B. Check the Conducted entry Roller in the Cross Folder and clean the surface with alcohol Stair and/or Torsion effect A. Wrong alignment between Folder and Printer A. Perform Printer- Folder Alignment Adjustment ADJ 3.5 A. When the copies enter in the cross folder the paper is inflated with air A. Check the paper if > 90 gsm on core 2 replace it with 80 gsm on core 3 B. Perform ADJ 4.2.b Rollers marks on the cross fold panel Cross Skewing Incorrect distance between Cross Folder rolls Perform ADJ 4.2.a Wrinkles on Fan folded panels A. Check the paper output from the printer B. Incorrect Mobile Roller Pressure A. Follow printer specifications to avoid wrinkles B. Perform ADJ 3.1 and decrease the pressure Butterfly Extra III GF500 Folder Jun 2018 FOLD QUALITY RAPS Service Manual 3-3 FOLDING QUALITY

32 Fold Damage continue Defect Probable Cause Corrective actions FQ 3 FOLD DIMENSIONS Defect Probable Cause Corrective actions First panel cross folded damaged A. High Pressure Cross Fold Rollers B. Cross Conducted Feed Roller sticky/tacky Double Fold Lead Edge damaged in Cross Folder Entry with A2 and A3 Paper curl exceed curl specification Wrinkles on Unfolded copies A. When the lateral edge of the panel is damaged A. Check the printer paper output B. Incorrect Mobile Roller Pressure Last fan folding panel is damaged A. Perform ADJ 4.1 and decrease the pressure of the cross folder rollers B. Check the Conducted Feed Roller surface (item 5 PL 2.2); if sticky, clear the roller according to the Maintenance Procedure in the Sec. 6 and install TAG 10 A. Check the Printer output and the paper type B. Require to install TAG 11 A. Move the folder to (-2 mm ) ADJ 3.5 A. Follow printer specifications to avoid wrinkles B. Perform ADJ 3.1 and decrease the pressure Check Finger Guide functionality and perform RAP LAST FAN FOLD PANEL DAMAGED Unequal fan panels Uneven cross fold panels A1/D size Uneven cross folds panels A0/E size Print exits unfolded from the fan folder lower pocket Incorrect fold setup NVM Incorrect environment temperature/low roll pressure. Margin exceed ±3mm A. Incorrect NVM panel 1B 1B = 297 ±3mm B. Sensor [C6] misread C. Cross Motor Speed low A. Incorrect NVM panel 2B 2B = 297 ±3mm B. Sensor [C6] or [C7] misread C. Cross Motor Speed low A. [C3] sensor does not detect the print correctly B. selection program not correct A. Refer Sec.6 Folder Adjustment Addresses Ad23,24 B. Refer sec 4 Pressure adjustment Adj 3.1 A. Perform into the Sec. 6 Folder Adjustment Addresses Ad27 B. Sizes not standard are not applicable A. Refer to the Sec. 6 Folder Adjustment Addresses Ad28 B. Check [C6] sensor with Input Test and performing C6 RAP C. Perform ADJ 4.3 A. Refer to the Sec. 6 Folder Adjustment Addresses Ad31 B. Check [C6] and [C7] sensor with Input Test and performing C6 and C7 RAP C. Perform ADJ 4.3 A. Check [C3] sensor, see Sec.6 Diagnostic Input Test B. Check current folding program on the key board Butterfly Extra III GF500 Folder Jun 2018 FOLD QUALITY RAPS Service Manual 3-4 FOLDING QUALITY

33 Fold Dimensions continue Defect Probable Cause Corrective actions FQ 4 FOLD OUTPUT Defect Probable Cause Corrective actions Print folded with only one cross fold A. Possible Upper Cross Folder Knife Motor malfunctions. B. Sensor C5 does not work A. Check [M7] motor by Output Test and C5 sensor by Input Test through the sec.6 Diagnostic B. If not work see troubleshoot Sec.2 Title block folded inside Title block not correct position Rotate the paper and place the sheet on the short side first and with the Title block on the upper right see Operator manual page.23 Print not completely fan folded A. The print length exceeds the maximum number of fan panels 17 panels. B. Uncovered sensor CS during the passage of the paper A. Refer to the Sec. 6 Folder Adjustment Addresses Ad34 B. Check the alignment between folder and printer ADJ 3.5 A2/C size folded landscape requested portrait No Fold Rear Exit stops in Fan Folder / irregular functioning A2 paper size printed with A1 paper size Sensor CS does not work A. Not applicable B. Use roll 420 mm. Check CS sensor by through Diagnostic Input Test Only fan folder, Cross Folder is bypassed [C4] or [C5] sensors do not detect the print correctly Check [C4] and [C5] sensor with Input Test Paper folded in part Update the last Firmware Butterfly Extra III GF500 Folder Jun 2018 FOLD QUALITY RAPS Service Manual 3-5 FOLDING QUALITY

34 4. Repair and Adjustments 4. REPAIR AND ADJUSTMENTS FAN FOLDER REPS (BUTTERFLY) REP 1.1 TOP COVER REMOVAL REP 1.2 REAR COVERS REMOVAL REP 1.3 FRONT COVER REMOVAL REP 1.4 FAN COVER REMOVAL FAN FOLDER REPS (GERAFOLD 500) REP 2.1 TOP COVER REMOVAL REP 2.2 REAR COVERS REMOVAL REP 2.3 FRONT COVER REMOVAL REP 2.4 FAN COVER REMOVAL REP 2.5 C2 SENSOR REPLACEMENT (ALL) REP 2.6 C3 SENSOR REPLACEMENT (ALL) CROSS FOLDER REPS REP 3.1 CROSS FOLDER COVERS REMOVAL REP 3.2 CROSS FOLDER OPENING (BUTTERFLY) REP 3.3 LOWER CROSS FOLDER COVER REMOVAL REP 3.4 UPPER COVERS REMOVAL (Extra III version) REP 3.5 CROSS MOTOR REPLACEMENT (Extra III ) FAN FOLDER ADJUSTMENT (ALL) ADJ 3.1 MOBILE ROLLER PRESSURE ADJ 3.2 CONVEYOR ROLLERS ADJ 3.3 FRONTAL SENSOR READING ADJ 3.4 ENTRY FLAP POSITION ADJ 3.5 FOLDER AND PRINTER ALIGNMENT (EXTRA III ) ADJ 3.6 ENTRY FLAP POSITION (GF500) ADJ 3.7 FOLDER AND PRINTER ALIGNMENT (GF500) ADJ 3.8 PAPER BUCKLE ADJUSTMENT (Extra III) ADJ 3.9 FOLDER ENTRANCE ADJUSTMENT (Extra III) CROSS FOLDER ADJUSTMENTS (ALL) ADJ 4.1 CROSS FOLDER ADJUSTMENT ADJ 4.2 CROSS ADJUSTMENT (ALL) ADJ 4.3 CROSS MOTOR SPEED (Extra III) FOLD PROGRAM ADJUSTMENT (EXTRA III) ADJ 5.1 PROGRAM 190 x 297 (DIN B) ADJ 5.2 PROGRAM 210 x 297 (DIN C) ADJ 5.3 PROGRAM 210 x ADJ 5.4 PROGRAM 190 M x 297 ( DIN A ) ADJ 5.5 AFNOR FOOL PROOF TABLE ADJ ,8.5, 9 Landscape FOOL PROOF TABLE ADJ 5.7 INVERSE DIN FOOL PROOF TABLE ADJ 5.8 PJL SETTING FOR HPGL WINDOWS DRIVER FOLD PROGRAM ADJUSTMENT (GF500) DIAGNOSTIC PACKAGE (GF500) Butterfly Extra III GERAFOLD 500 Folder Jun 2017 Service Manual 4-1 REPAIR AND ADJUSTMENTS

35 1. FAN FOLDER REPS (BUTTERFLY) REP 1.2 REAR COVERS REMOVAL Removal REP 1.1 TOP COVER REMOVAL Removal 1. Switch off the Folder 1. Switch off the Folder 2 Remove the Upper Front Cover Plate through the two screws on the cover itself in order to accessthe mobile roller and the [C2] and [C3] sensors 2 Loose the two screws front side and remove the top cover by lift and pushing it gently. 3 Remove the Lower Rear Cover Plate by the two screws in order to access the electronic board cross bar. If the Upper cover item 2 is provided with FAN pay attention to the connector during the cover removal Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-2 REPAIR AND ADJUSTMENTS

36 REP 1.3 FRONT COVER REMOVAL Removal 1. Switch off the Folder 2 Remove the Front Cover Plate through the six screws on the cover itself. REP 1.4 FAN COVER REMOVAL Removal 1. Switch off the Folder 2. Remove the Top Cover REP Disconnect the JC1 connector between the four fans 4. Remove the Fan Cover through two screws Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-3 REPAIR AND ADJUSTMENTS

37 2. FAN FOLDER REPS (GERAFOLD 500) REP 2.2 REAR COVERS REMOVAL Removal REP 2.1 TOP COVER REMOVAL Removal 1. Switch off the Folder 1. Switch off the Folder 2 Remove the Upper Front Cover Plate through the two black knobs on the cover itself in order to access the mobile roller, the [C2] and [C3] sensors 2 Loose the five screws front side and remove the top cover by lift and pushing it gently. 3 Remove the Lower Rear Cover Plate by the two screws in order to access the electronic board cross bar. If the Upper cover item 2 is provided with FAN pay attention to the connector during the cover removal Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-4 REPAIR AND ADJUSTMENTS

38 REP 2.3 FRONT COVER REMOVAL REP 2.4 FAN COVER REMOVAL Removal Removal 1. Switch off the Folder 1. Switch off the Folder 2. Remove the Top Cover REP Disconnect the orange connector powering fan motors 4. Disconnect the connector of the fan sensor orange connector Fan sensor connetor 2 Remove the Front Cover Plate through the two screws on the cover itself. 5. Remove the Fan Cover through two bolts Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-5 REPAIR AND ADJUSTMENTS

39 REP 2.5 C2 SENSOR REPLACEMENT (ALL) REP 2.6 C3 SENSOR REPLACEMENT (ALL) 1 Switch off the Folder 2 Perform REP 1.2 item 2 and REP 1.3 Front and Rear Cover Removal 3 The receiver is fixed with two screws behind a Plexiglas protection; the emitter is mounted on a bracket fixed with one screw. That s advisable replace the only receiver before. 1 Switch off the Folder 2 Perform REP 1.2 item 2 and REP 1.3 Front and Rear Cover Removal 3 The receiver is fixed with two screws behind a Plexiglas protection; the emitter is mounted on a bracket fixed with one screw. That s advisable replace the only receiver before. Receiver (two screws) Receiver (two screws) Emitter (one screw on the bracket) Emitter (one screw on the bracket) Butterfly Extra III GERAFOLD 500 Folder Service Manual Jun REPAIR AND ADJUSTMENTS

40 3. CROSS FOLDER REPS As Training Support see also the video: CROSS FOLDER OPENING CROSS FOLDER COMPONENTS REP 3.1 CROSS FOLDER COVERS REMOVAL Removal 1 Switch off the folder 2 Pull and open the Cross Folder Door REP 3.2 CROSS FOLDER OPENING (BUTTERFLY) Removal In order to access the Cross Folder Knives Motor M6, M7 and position sensors for check or replacement it is possible to open the whole assembly. 1 Perform REP 2.1 to remove Cross Folder Covers 3 Open the two nuts by using a 13 mm wrench 2 Remove the lower plate locate under the cross folder basket. 3 Loose the Cover upper screw 4 Loose the Cover lower screw 4 Pull gently the Cross Folder assembly for 30 opening 5 Remove the Front or Rear Cross Cover (or both, as needed) by lift gently the plate.! CAUTION: keep the Cross Folder assembly when the nuts are loosed since it could be open because of its own weight Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-7 REPAIR AND ADJUSTMENTS

41 REP 3.3 LOWER CROSS FOLDER COVER REMOVAL Removal 1. Remove the Tray by lift it up (Butterfly Plus) REP 3.4 UPPER COVERS REMOVAL (EXTRA III VERSION) Removal 1. Remove the Upper Front Cover (three screws below) 2. Remove the lower Cross Folder Cover by loosening the two screws showed by the arrow 2. Remove the Upper Front Cover (five screws below) Remove the plate at the end of the basket (4 screws) to get the DS3 sensor Remove the plate at the cross folder exit (2 screws) to get the M8 Motor Replacing the tray mind that it is really inserted through the two slots in the Folder body otherwise the copied will not well collected. NOTE: Do not remove further covers in the upper part of the Butterfly Extra unless strictly necessary; in case contact GERA Service Team Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-8 REPAIR AND ADJUSTMENTS

42 REP 3.5 CROSS MOTOR REPLACEMENT (EXTRA III ) Cross Folder Chain Removal First Pocket Plate Removal 1. Remove the upper cover of the 1st pocket (loosen 2 screws) Remove the connector from C6 sensor Remove the chain by release the chaintensioner by pushing arrow red direction. 3. Remove the cross folder plate section (4 screws) 4. Remove cross folder lower plate (2 screws) Cross folder Motor Removal 2. Release the chain from the motor toothed pulley 1. Remove motor cover (4 screws) 3. Replace the Cross folder Motor (4bolts) 2. Disconnect the wires in order to release motor Fig B 4. Check to fix bolts with the black sheaths designed to minimize vibration Fig.B 5. Wiring the motor (Do not reverse orange/blu inlet).fig A 6. Install Chain with correct route Fig.C 7. Press Control panel Arrow key and check chain rotation (counter clockwise) Fig A 8. Check correct motor speed Fig C Butterfly Extra III GERAFOLD 500 Folder Service Manual Jun REPAIR AND ADJUSTMENTS

43 4. FAN FOLDER ADJUSTMENT (ALL) ADJ 4.1 MOBILE ROLLER PRESSURE Purpose The Mobile Roller must have even right and left pressure to drive paper straight, adjustment may be required when there are stair, torsion effect and/or wrinkles on fold package. Check 1. Switch off the folder and Remove the Front Door (REP 1.2) 2. Refer to values on the Final Test Report Form F5 ; to get similar measure a Spring Force and paper strip 210x840mm are required. Feed paper between the Mobile Roller and the Lower Folding Roller 25mm/1 then pull the paper strip and read weight required to remove paper from rollers. ADJ 4.2 CONVEYOR ROLLERS Purpose Ensure mechanical drive of aluminum rollers by the drive belt, the conveyor rollers are located over the system. Adjustment Perform REP 1.2 (item 3) and remove the Lower Rear Cover Plate. The tension of the green belt can be adjusted by the two screws and bolt on the belt pulley; keep present that the pulley assembly is hidden behind the conveyor frame, so it is necessary operate underneath the folder. Adjustment Adjust the pressure by rotating the two knobs left and right side, target of the settings is to get even pressure left and right side of the rollers by avoiding at same time poor pressure may cause poor paper traction and/or uneven folds, or high pressure ay cause wrinkles on fold package. Very sensitive adjustment is advisable to perform not more than 1/8 of turn at a time, when available refer to label indicating the factory setup pressure 0, if changed report on Final Test Report Form new value. Each sign on the yellow label correspond about to a 100 g difference. Counter Clockwise: increase the pressure Operate both sides, release the nuts and adjust the belt tension by the bolts Clockwise: decrease the pressure Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-10 REPAIR AND ADJUSTMENTS

44 ADJ 4.3 FRONTAL SENSOR READING Purpose The purpose is to adjust the sensitivity of the frontal sensor [CA]. Check The sensor operative surface has to be clean. Adjustment Operate on the sensor potentiometer with a short screwdriver: clockwise for increase the sensor sensitivity, counterclockwise for decrease. Anyway, refer always to the default position of the potentiometer from factory showed below. Potentiometer ADJ 4.4 ENTRY FLAP POSITION Purpose ONLY W/O TAG 16 up to Sn N/A from Sn The purpose is to adjust the position of the Fan Folder entry Flap Adjustment 1 Remove the Top Cover (REP 1.1) and the Fan Cover (REP 1.4) 1. Loose the Nut 2. Adjust the flap position - clockwise: Entry Flap UP - counter clockwise: Entry Flap DOWN Default position (11.00) In the correct range the sensor has to detect the paper (led on) between 3 10 mm. If the sensor is too sensitive (detects the paper distant more than 10 mm) the folder pull and tear the paper from the printer. If the sensor sensitivity is poor (doesn t detect paper nearest of 3 mm) the folder doesn t start the folding process. To get proper paper buckle setup, use the printer media advance option and simulate folder paper entry, when paper increase the paper buckle, ensure that the sensor CA setup detects paper and enable motor M2 to run when entry flap bracket touch the rubber washer. If the Entry Flap position is right, the copy printed from the plotter passes between the flap and the plastic tube before entry in the fan folder. If the Entry Flap position is too low, the copy printed from the plotter hits the plastic tube If the Entry Flap position is high, the copy printed from the plotter hits the entry flap when is conveyed in the fan folder entry. Fig. 2 Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-11 REPAIR AND ADJUSTMENTS

45 ADJ 4.5 FOLDER AND PRINTER ALIGNMENT (EXTRA III ) Purpose The purpose is to ensure a correct alignment between the Printer and the Folder Print a copy with dimension 841x1600 mm, the fan fold document will clarify the settings required. Adjustment The adjustment can be done by loosening the two bolts that fix the hinge bracket on the folder foot; The yellow label marks the reference to the factory set up with even floor a. When the Fan fold defect FQ1-1 : Move the folder in order to get +1 or +2 on the yellow label b. When the Fan fold skewing defect FQ1-2: Move the folder in order to get 1 or 2 on the yellow label According to the skew effect see fold quality section FQ1-4 the Folder has to be drawn nearer or distanced from the Printer as showed below c. When the Cross Fold damage defect (FQ2-7) and when the folder is in error and emits 1beep as an entry alarm ( FOLDER ENTRANCE ALARM RAP) A B a <2mm a >5mm HP Printer (B > A) : move X = B - A GERA BUTTERFLY (A > B) : move X = A - B Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-12 REPAIR AND ADJUSTMENTS

46 ADJ 4.6 ENTRY FLAP POSITION (GF500) Purpose The purpose is to check and adjust the correct entry flap position that should be between min 750mm and max 760mm ADJ 4.7 FOLDER AND PRINTER ALIGNMENT (GF500) Purpose The purpose is to check if printer and folder are correctly allined and levelled The height from floor to the folder hooks extremities is 674mm±2mm Adjustment For correct folder height it's necessary to : 1. Remove cross folder lower plate 2. Remove lateral cover under Touchscreen 3. By using open wrench 17mm act on the nuts Adjustment 1. Loose the Nut 3. Adjust the flap position - clockwise: Entry Flap UP - counter clockwise: Entry Flap DOWN Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-13 REPAIR AND ADJUSTMENTS

47 ADJ 4.8 PAPER BUCKLE ADJUSTMENT (Extra III) Purpose The purpose of this procedure is to correctly setup entry flap position and sensor sensibility when printing multiple copies in draft mode, second copy lead edge may overlap the first copy causing a jam. Adjustment When paper buckle is not detected properly see Fig.1 this may be due to : a. Wrong flap position : Verify distance between the entry flap and the folder in home position (Fig.2) Verify distance between the entry flap and the folder frame in work position (Fig.3). b. wrong sensor sensibility : If the copy is so buckled (Fig.1) causing a paper jam this may be due to a poor sensibility of the sensor CA who can t detect the paper correctly If the buckle is too short and the white roll bar raises covering the sensor CST causing an alarm this may be due to a high sensibility of the sensor CA who becomes so sensible and may be affected by the external factors like the sun light or read quickly the paper To adjust the sensibility of the sensor CA refer to Adj 3.3 FRONTAL SENSOR READING To have an idea of the paper buckled problem see this link ADJ 4.9 FOLDER ENTRANCE ADJUSTMENT (Extra III) Purpose The purpose of this procedure is to ensure the correct paper entry When it cover the sensor CS the motor M2 runs, the paper cover the sensor CC and the entry flap goes down. If the folder don t start the process the red led is flashing and emits 1 beep as entry alarm this may be due to wrong folder and printer alignment If tolerance is not as per specified range refer to Adj 3.4 ENTRY FLAP POSITION and operate in order to meet distance Fig. 1 Adjustment If distance a < 2mm the paper cover CS but with the movement of the printer the paper can be obstructed by the white pin and don t cover the CC sensor in this case see Adj 3.5.c Flap edge Paper edge If distance a > 5mm the paper don t cover Cs sensor and the folder don t know the existence of this paper and don t start the folding process in this case see Adj 3.5.c Fig. 2 Fig. 3 a Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-14 REPAIR AND ADJUSTMENTS

48 5. CROSS FOLDER ADJUSTMENTS (ALL) ADJ 5.1 CROSS FOLDER ADJUSTMENT Purpose To adjust the Butterfly Cross Folder Rolls pressure and distance to fix loss of copy driver, copy skew defect or wrinkles on copy. Adjustment Open the Cross Folder Cover (REP 2.1) Each roller assembly pressure and distance between can be adjusted following the procedure below. Warning this is not a easy operation since different rollers distance may generate paper skew depending the fold package thick. For creasing, wrinkles problems decrease the pressure or increase the distance, for paper convey, paper drive loss problems increase the pressure or reduce the distance. Refer to factory default values as table below. Pressure adj: turn clockwise to increase d F4 c b F3 Cross folder Right side Left Side Distance (mm) Extra III Version Pressure (Kg) a b c d F1 F2 F3 F Cross folder motor [M6] provided knife movement for A3/B as by pass, and for A2/C, A1/D size as first cross folds. Fan fold package when enters the cross folder may hit rollers or knife and skew the entry, please observe carefully the cross folder process and send a Problem Report Form PRF on line to GERA Service Team before to attempt any operation. Figure below shows mechanical enhancement TAG 4 new knife design Distance adj: turn clockwise to decrease: 1 turn = 0.6 mm ½ turn = 0.3 mm ¼ turn = 0.15 mm F2 a F1 Cross folder Right side Left Side Distance (mm) GF500 Version Pressure (Kg) a b c d F1 F2 F3 F4 0,5 1,2 1,2 1,5 0,8 0,75 0,6 1 0,5 1,2 1,2 1,5 0,8 0,75 0,6 1 Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-15 REPAIR AND ADJUSTMENTS

49 ADJ 5.2 CROSS ADJUSTMENT (ALL) Purpose a. Copy A2, A1 size with second panel 2B with red edge is not aligned to panel 1B and over tolerance 3mm (FQ1-5) b. Copy A0 size with third panel 3B with red edge is not aligned to panel 2B and over tolerance 4mm (FQ1-5) c. When the copy inflated with air enters in the cross folder rising folder damage defect (FQ2-3) Adjustment a. For the size A1 and A2 action on the gap b with a ¼ turn clockwise by operating on Distance adj. described in adj.4.1 example left side from 0.7 to 0.55mm ADJ 5.3 CROSS MOTOR SPEED (Extra III) See also the support videos: CROSS FOLDER MOTOR M5 SPEED CHECK CROSS FOLDER CHAIN TENSION Purpose Check the Cross Folder motor speed within the speed specifications. Adjustment After removed the Cross Folder Cover REP 2.1 actuate the Cross Folder by pressing the Selection Key on Control Panel and check the rotation through the Conducted Feed Roller slot b. For the size A0 action on gap c with a ¼ turn clockwise by operating on Distance adj. described in adj.4. example left side from 0.2 to 0.05mm 1. Check Motor speed is within the specifications: 60 turns in 60 ± 1seconds Values under 59 seconds increase 24 Vdc output; Values over 61 seconds decrease 24 Vdc output. Power Supply 24 Vdc Output adjustment by trimmer adjusting screw. Open the Electronic Parts Cover (REP1.2) and adjust the Power Supply Output. c. Action on pressure Adj F2 between rollers to decrease the pressure with ½ turn counterclockwise Adjusting Screw 2. Check Motor speed if different between A0 and A1 size: Print A1 size and check the values less than 60 turn/1 min Print A0 size and do same test equal to 60 turns/1 min Check if there is a mechanical impediment who prevent the roller to turn correctly. Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-16 REPAIR AND ADJUSTMENTS

50 6. FOLD PROGRAM ADJUSTMENT (EXTRA III) Use this section for check the correct folding path in Fan Folder and in Cross Folder. ADJ 6.1 PROGRAM 190 x 297 (DIN B) Step-1 Print 1 ISO A2 594x420 Panel mm Address 1A B 2A A / 41 4A / 42 2B 1B A 2A 3A 4A 2B 123 / Print 3 ISO A2 594x420 LR sizes and collect. Step-2 Print 1 ISO A1 841x594 1A 2A 3A 4A 5A 1B 2B Print 3 ISO A1 841x594 LR sizes and collect Panel mm Address 1A A A / 41 4A / 42 5A / 23 1B B 297 / ADJ 6.2 PROGRAM 210 x 297 (DIN C) Step-1 Print 1 ISO A3 420x297 length 420mm ±2mm only 2 panels 1A,2A Panel mm Address 1A A B / / Print 3 ISO A3 420x297 LR sizes and collect. Step-2 Print 1 ISO A2 594x420 1A 2A 3A 1B 2B Print 3 ISO A2 594x420 LR sizes and collect. Step-3 Print 1 ISO A1 841x594 Panel mm Address 1A A A / 41 1B B 123 / Step-3 Print 1 ISO A0 1189x841 Check dimensions and adjust. 1B Panel mm Address 1A A A / 41 2B 4A / 42 5A / / 6A / / 3B 7A / / 1B A 2A 3A 4A 5A 6A 7A 2B B / / Print 3 ISO A0 1189x841 sizes and collect Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-17 REPAIR AND ADJUSTMENTS 1A 2A 3A 4A 1B 2B Print 3 ISO A1 841x594 LR sizes and collect Panel mm Address 1A A A / 41 4A / 42 1B B 297 /

51 Step-4 Print 1 ISO A0 1189x841 Check dimensions and adjust. Step-3 Print 1 ISO A1 841x594 1A 2A 3A 4A 5A 6A 1B 2B 3B Panel mm Address 1A A A / 41 4A / 42 5A / / 6A / / 1B B B / / 1A 2A 3A 4A 1B 2B Print 3 ISO A1 841x594 LR sizes and collect Panel mm Address 1A A A / 41 4A / 42 1B B / / Print 3 ISO A0 1189x841 sizes and collect Step-4 Print 1 ISO A0 1189x841 ADJ 6.3 PROGRAM 210 x 305 Step-1 Print 1 ISO A3 420x297 length 420mm ±2mm only 2 panels 1A,2A Panel mm Address 1A A B / / 1A 2A 3A 4A 5A 6A 1B 2B 3B Panel mm Address 1A A A / 41 4A / 42 5A / / 6A / / 1B B B / / Print 3 ISO A3 420x297 LR sizes and collect. Print 3 ISO A0 1189x841 sizes and collect Step-2 Print 1 ISO A2 594x420 1A 2A 3A 1B 2B Panel mm Address 1A A A / 41 1B B / / Print 3 ISO A2 594x420 LR sizes and collect. Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-18 REPAIR AND ADJUSTMENTS

52 ADJ 6.4 PROGRAM 190 M x 297 ( DIN A ) Step-1 Print 1 ISO A2 594x420 Print 3 ISO A2 594x420 LR sizes and collect Step-2 Print 1 ISO A1 841x594 To perform the dimensions of the panels like A1,A2,B1, we need to perform Adj 5.1 To perform the margin of the A2 size 594x420 adjust through Address To perform the dimensions of the panels like A1,A2,B1, we need to perform Adj 5.1 To perform the margin of the A1 size 841x594 adjust through Address 25 1A 2A 3A 4A 5A Print 3 ISO A1 841x594 LR sizes and collect Step-3 Print 1 ISO A0 1189x841 3B 2B 1B To perform the dimensions of the panels like A1,A2,B1, we need to perform Adj5.2 or Adj5.3 To perform the margin of the A0 size 1189x841 adjust through Address 25 1A 2A 3A 4A 5A 6A 7A Print 3 ISO A0 1189x841 sizes and collect Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-19 REPAIR AND ADJUSTMENTS

53 ADJ 6.5 AFNOR FOOL PROOF TABLE ADJ 6.7 INVERSE DIN FOOL PROOF TABLE ADJ ,8.5, 9 Landscape FOOL PROOF TABLE All copies folded by Landscape folding programs, exit from the upper pocket and according to the paper size some copies are folded with two short panels in order to provide exit by the upper pocket and is not a fold mistake Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-20 REPAIR AND ADJUSTMENTS

54 ADJ 6.8 PJL SETTING FOR HPGL WINDOWS DRIVER To allow copies to be not folded and exit from the rear tray basket it's necessary to : o flag the "No fold" option on the printer UI To print and fold by other submission tools as "HP Smartstream, HP instant utility pro, Reprocontrol, Power plotter..." the folding program ID must the same as the folding program ID listed on the EWS browser o Unflag the output option on the Windows driver (highlighted in red ) By printing to file through Adobe,Autocad,Solidworks... the result is 0 see below SET MEDIADESTINATION = SET FOLDINGMETHODTYPE = SET FOLDINGMETHODENUM = 0 To allow copies to be folded to the folder default setup it s necessary to : o o flag the option From folder front panel on the printer UI Flag the output option "Folding" on the Windows driver (highlighted in red ) : By printing to file Adobe,Autocad,Solidworks...the result is 2 see below SET MEDIADESTINATION = SET FOLDINGMETHODTYPE = SET FOLDINGMETHODENUM = 2 EWS => Reprocontrol=> In case of incompatibility between Folding program ID listed on the EWS and the folding program ID listed on a third software, the folder can not recognize the job and will not accept to fold it. Below the number of the folding style sent through different submission SET FOLDINGMETHODENUM = 0 -> Copy not SET FOLDINGMETHODENUM = 1 -> Not SET FOLDINGMETHODENUM = 2 -> From folder front SET FOLDINGMETHODENUM = 3 -> 190 x SET FOLDINGMETHODENUM = 4 -> Margin x SET FOLDINGMETHODENUM = 5 -> 210 x SET FOLDINGMETHODENUM = 6 -> 210 Inverse SET FOLDINGMETHODENUM = 7 -> AFNOR SET FOLDINGMETHODENUM = 8 -> 7,5 inch x 11 SET FOLDINGMETHODENUM = 9 -> 7,5 inch + Margin x 11 SET FOLDINGMETHODENUM = 10 -> 8,5 inch x 11 SET FOLDINGMETHODENUM = 11 -> 9 inch x 12 inch Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-21 REPAIR AND ADJUSTMENTS

55 7. FOLD PROGRAM ADJUSTMENT (GF500) Use this section for check the correct folding path in Fan Folder and in Cross Folder ADJ 7.1 PROGRAM 210 x 297 (DIN C) Step-1 Print 1 841x2000 1A 2A 3A 4A 5A 6A 7A 8A 9A 10A Blue icon means fan fold panel adjustment Green icon means cross fold panel adjustment Through Touchscreen the user can access to the adjustment Step-2 Print 1 ISO A1 841x594 1B Panel Address Panel 1A 2A 3A 4A 5A 1B 2B Address 1st 2nd 3rd Even Odd 1st 2nd 3B / 1A 1st 2A 2nd 3A Pre fold up Adj 4A A1 2nd last panel 2B 5A // 1B 1A 2A 3A 4A 5A 1st 2B // Print 3 ISO A1 841x594 LR sizes and collect Grey column is only for A1 size and only CSE can access to these Addresses to change values 1B 2B 3B Step-3 Print 1 ISO A0 1189x841 Check dimensions and adjust. 1B Panel Address 1A 1st 2A 2nd 3A 3rd 2B 4A Pre fold down 5A // 6A // 3B 7A // 1B 1st 1A 2A 3A 4A 5A 6A 7A 2B 2nd 3B // Print 3 ISO A0 1189x841 sizes and collect Step-4 Print 1 ISO A2 594x420 1A 2A 3A 1B 2B Print 3 ISO A2 594x420 LR sizes and collect To perform the dimensions of the panel 1A of the A2 and A3 size it's necessary to access the reserved area and adjust the value "A2/A3 1st panel adj" Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-22 REPAIR AND ADJUSTMENTS

56 ADJ 7.2 PROGRAM 190 M x 297 (DIN A) Step-4 Print 1 ISO A2 594x420 Print 3 ISO A2 594x420 LR sizes and collect To perform the margin of the A2 size 594x420 adjust through Touchscreen : --> 8. DIAGNOSTIC PACKAGE (GF500) Purpose : Report diagnostic folder failure details to Gera Service Team or paper jam or recurring folding error. The procedure guide how to generate a diagnostic package. It's important to enable easy problem duplication. Adjustment : 1. Activate the diagnostic package before to run the fold job with problems. 2. Enter the service menu : 3174 Step-5 Print 1 ISO A1 841x594 2 To perform the margin of the A1 size 841x594 adjust through Touchscreen : 1 1A 2A 3A 4A 5A Print 3 ISO A1 841x594 LR sizes and collect Step-6 Print 1 ISO A0 1189x841 --> 3. Run the fold job. maximum 20 plots, once the folder display an error save the diagnostic package file on SD by pressing the "letter" icon 3B 2B 1B 1A 2A 3A 4A 5A 6A 7A Print 3 ISO A0 1189x841 sizes and collect To perform the margin of the A0 size 1189x841 adjust through Touchscreen : --> 4. Turn off the folder 5. Remove the SD card and copy the diagnostic package.txt file and send as attachment to GERA SERVICE TEAM Butterfly Extra III GERAFOLD 500 Folder Jun 2018 Service Manual 4-23 REPAIR AND ADJUSTMENTS

57

58 1. FAN FOLDER PL 1.1 INFEED SENSORS PL 1.2 INFEED MOTORS AND POSITION SENSORS PL 1.3 FAN FOLDER MOTORS AND SENSORS PL 1.4 FAN UPPER AND LOWER POCKET SENSOR PL 1.5 FAN TRASMISSION ITEMS PL 1.6 CONVEYOR (EXTRA - PLUS) PL 1.7 FAN MOBILE ROLLER PL 1.8 FAN FOLDING ROLLERS PL 1.9 FOLDER FAN PL 1.10 ANTISTATIC BRUSHES AND FOAM ROLLS CROSS FOLDER PL 2.1 CROSS MOTORS AND SENSORS (EXTRA - PLUS) PL 2.2 CROSS BELTS AND ROLLERS (EXTRA - PLUS) PL 2.3 CROSS MOTORS PARTS (COMPLETE) GENERAL PL 3.1 EXTERNAL PARTS AND SENSORS PL 3.2 PARTS ON THE PLOTTER (PLUS - BASE) PL 3.3 PARTS ON THE PLOTTER (EXTRA EXTRA II) PL 3.4 PARTS ON THE PLOTTER (COMPLETE - SIMPLE) PL 3.5 PARTS ON THE PLOTTER (LADYBIRD) ELECTRONIC COMPONENTS PL 4.1 ELECTRONICS PWBS - POWER SUPPLY KITS PL 5.1 KITS FOR UPGRADING AND REPAIRING Butterfly Extra Spare Parts List Butterfly Folder giu 2018 Service Manual 5-1 BUTTERFLY EXTRA SPARE PARTS LIST

59 1. FAN FOLDER PL 1.1 INFEED SENSORS ITEM CODE DESCRIPTION 1,2,3,4,5 C695412X SENSOR FRONTAL OM 6,7 C695415X SENSOR LATERAL OM SENSORS CODE DESCRIPTION CA Advancing Sensor CS Start Sensor CC Conveyor Sensor C4 1 st Cross Fold Sensor C5 2 nd Cross Fold Sensor CST Tear Sensor Remove the Upper Cover (two screws) to access Feed Sensor and Motors [CS] Sensor 1 [CC] Sensor 2 [CA] Sensor Up Sn [CA] Sensor 6 From Sn on 3 [C5] Sensor [CST] Sensor 7 [C4] Sensor 4 Butterfly Folder giu 2018 Service Manual 5-2 BUTTERFLY EXTRA SPARE PARTS LIST

60 PL 1.2 INFEED MOTORS AND POSITION SENSORS ITEM CODE DESCRIPTION 1 C960411X STEPPER MOTOR 2,5 C110402X SENSOR FORK OM 3 KNIFE MOTOR 4 FLAP MOTOR [M2] Motor 1 4 [MT] Motor CODE PS3 PS4 PS9 PS10 SENSORS DESCRIPTION MT Position Sensor MT Position Sensor (Driver) MT Position Sensor MT Position Sensor (Driver) 5 [PS9-PS10] Sensor CODE M2 M4 MT MOTORS DESCRIPTION Entry Stepper Motor Knife Motor Entry Feed Flap Motor [PS3-PS4] Sensors 2 [M4] Motor 3 Remove the Upper Cover (two screws) to access Feed Sensor and Motors Butterfly Folder giu 2018 Service Manual 5-3 BUTTERFLY EXTRA SPARE PARTS LIST

61 PL 1.3 FAN FOLDER MOTORS AND SENSORS ITEM CODE DESCRIPTION 1 LOWER FLAP MOTOR 2 CONVEYOR MOTOR 3 C940401X STEPPER MOTOR 4 C110402X SENSOR FORK OM 5 BASKET MOTOR CODE M1 MEF M3 M8 CODE PS1 PS2 MOTORS DESCRIPTION Transport Motor Exit Flap Motor Fan Main Stepper Motor Basket Motor (Only Extra Version) SENSORS DESCRIPTION MEF Position Sensor MEF Position Sensor (Driver) [M8] Basket Motor 5 (Only Extra Version) Remove the Front Panel (six screws) and the Rear Panel (two screws) to access the lower part 1 [MEF] Motor [M1] Motor 2 4 [PS1-PS2] Sensors [M3] Motor 3 NOTE: these parts are not present in the versions Base, Complete and Simple Butterfly Folder giu 2018 Service Manual 5-4 BUTTERFLY EXTRA SPARE PARTS LIST

62 PL 1.4 FAN UPPER AND LOWER POCKET SENSOR ITEM CODE DESCRIPTION 1 2 C695419R SENSOR BARRIER GE 26 [C2] Sensor [C3] Sensor 24 Butterfly Folder giu 2018 Service Manual 5-5 BUTTERFLY EXTRA SPARE PARTS LIST

63 PL 1.5 FAN TRASMISSION ITEMS ITEM CODE C960507X C940503X C940504X C940502X 5 C940505X 6 G950047X G950080X C950081X C950018X DESCRIPTION BELT D 110XL037 BELT D 285L050 BELT D 124L050 BELT D 600L050 BELT D U 177.5T (Belt on M2 Motor not showed) COMPLETE TIE-ROD W/O TAG 16 ; From sn on (TAG 2) COMPLETE TIE_ROD (W TAG 16) TIE ROD PIN FLAP BRACKET TAG 14: Handle for Manual Eject on Infeed Roller Butterfly Folder Service Manual giu BUTTERFLY EXTRA SPARE PARTS LIST

64 PL 1.6 CONVEYOR (Extra - Plus) ITEM CODE DESCRIPTION 1 C940520X BELT P 27X C940519X BELT D.90XL037 3 C460505X BELT FLAT [M1] Motor Butterfly Folder giu 2018 Service Manual 5-7 BUTTERFLY EXTRA SPARE PARTS LIST

65 PL 1.7 FAN MOBILE ROLLER ITEM CODE DESCRIPTION 1 C980010X MOBILE ROLLER RIGHT LEVER 2 C960010X SPRING WASHER MOBILE ROLLER 3 C210502X BEARING 6002 ZZ X C960055X HINGE PIN 5 C980001X MOBILE ROLLER 6 C980011X MOBILE ROLLER LEFT LEVER Butterfly Folder giu 2018 Service Manual 5-8 BUTTERFLY EXTRA SPARE PARTS LIST

66 PL 1.8 FAN FOLDING ROLLERS ITEM CODE DESCRIPTION 1 C309219X WASHER 2 C960019X TOOTHED PULLEY 3 C695049X MOTOR LEFT FLANGE 4 C423504X BEARING 6202 ZZ 5 C980003X LOWER FOLDING ROLLER C940062X UPPER FOLDING ROLLER 6 C490088X LOWER FLANGE 7 C980030X SPACER Butterfly Folder giu 2018 Service Manual 5-9 BUTTERFLY EXTRA SPARE PARTS LIST

67 PL 1.9 FOLDER FAN ITEM CODE DESCRIPTION 1 C560420A FAN 24 V dc 2 C940411X FAN 24 V dc (until Sn ) 3 C560420A FAN 24 V dc (from Sn on) [FAN2] 2 1 [FAN1] (8 items) Remove the cover green highlighted to access the Fan indicated by the arrow [FAN2] (3 items) 3 Butterfly Folder giu 2018 Service Manual 5-10 BUTTERFLY EXTRA SPARE PARTS LIST

68 PL 1.10 ANTISTATIC BRUSHES AND FOAM ROLLS NOTE: this list is general and includes all items of the version Plus that may be not present in other versions Base, Complete and Simple. 2 1 ITEM CODE DESCRIPTION 1 C309566A ANTISTATIC BRUSH 900 K004729X ANTISTATIC BRUSH 1000 (Until Sn ) 2 C960096X ANTISTATIC BRUSH 900 (From Sn On) C940100X ANTISTATIC BRUSH 500 (Until Sn ) 3 C450503X ANTISTATIC BRUSH 250 (2 pcs) (From Sn On) 4 C309566A ANTISTATIC BRUSH G940069X COMPLETE ROLL Ø46 SHAFT 6 G940007X COMPLETE ROLL Ø50 SHAFT 7 G940084X 5 6 BUTTERFLY ANTISTATIC BRUSHES KIT (From Sn On) Butterfly Folder giu 2018 Service Manual 5-11 BUTTERFLY EXTRA SPARE PARTS LIST

69 2. CROSS FOLDER PL 2.1 CROSS MOTORS AND SENSORS (Extra - Plus) As Training Support see also the video: CROSS FOLDER COMPONENTS ITEM CODE DESCRIPTION 1 C690417X SOLENOID N021 2 C490409X MOTOR 24V 53 rpm (until Sn 258) C490422X MOTOR 24V 54 rpm (from Sn 259) 3 C490409X MOTOR 24V 53 rpm (until Sn 258) C490422X MOTOR 24V 54 rpm (from Sn 259) 4 C940402X MOTOR ACC24 MP 5 C110402X SENSOR FORK OM 6 C694481R SENSOR REFLECTION GE 7 C695412X SENSOR FRONTAL OM 8 C695415X SENSOR LATERAL OM 9 C694512X LOCK MOTORS 1 [E3] * C8 E3 C7 PS7/8 M7 [M7] ** 2 9 * C8 7 E3 PS7/8 M7 C7 6 5 ** CODE DESCRIPTION M5 M6 M7 E3 Main Cross Motor Lower Knife Motor Upper Knife Motor Solenoid SENSORS 4 CODE DESCRIPTION C6 C7 C8 PS7 PS8 PS5 PS6 Lower Pocket Sensor Upper Pocket Sensor Cross Exit Sensor * Plus Configuration ** Extra Configuration M7 Position Sensor M7 Drive Sensor M6 Position Sensor M6 Drive Sensor [M5] C6 M5 M6 PS5/6 3 [M6] 8 C6 M5 M6 PS5/6 5 Butterfly Folder giu 2018 Service Manual 5-12 BUTTERFLY EXTRA SPARE PARTS LIST

70 PL 2.2 CROSS BELTS AND ROLLERS (Extra - Plus) ITEM CODE DESCRIPTION 1 C940215X MOBILE EXIT ROLLER 2 C940213X MOTOR EXIT ROLLER 3 C940212X MOBILE FEED ROLLER 4 C940210X MOTOR FEED ROLLER 5 C940211X CONDUCTED FEED ROLLER 6 C940514X BELT P 220 x C960500X BELT T 4 x 605 (5 pcs) 8 C940509X BELT ROUND T 4 x 190 E3 1 E3 M7 M M5 M6 M5 M6 5 Butterfly Folder giu 2018 Service Manual 5-13 BUTTERFLY EXTRA SPARE PARTS LIST

71 PL 2.3 CROSS MOTORS PARTS (Complete) ITEM CODE DESCRIPTION 1 C940416X MAIN CROSS MOTOR 2 C695415X SENSOR LATERAL OM 3 C490409X MOTOR 24V 53 rpm 4 C110402X SENSOR FORK OM 5 C940213X MOTOR EXIT ROLLER 6 C940215X MOBILE EXIT ROLLER CODE M5 M7 PS7 PS8 C7 DESCRIPTION Main Cross Motor Knife Motor M7 Position Sensor M7 Drive Sensor Pocket Sensor 3 2 C M 1 Butterfly Folder giu 2018 Service Manual 5-14 BUTTERFLY EXTRA SPARE PARTS LIST

72 3. GENERAL PL 3.1 EXTERNAL PARTS AND SENSORS ITEM CODE DESCRIPTION 1,2 C690404X MICROSWITCH Single Contact 3 C690403X MAIN SWITCH 4 C790422X MICROSWITCH Lever 5 C961015X CASTER SHORT 6 C695508X CASTER 7 C694509X FOOT 8 C490511X HANDLE M4X10 9 C940500X BUTTERFLY KEYBOARD 10 C950502X BUTTERFLY KEYBOARD 11 C950500X BUTTERFLY KEYBOARD [DS3] Switch [DS2] Switch [DS1] Switch 2 Butterfly Folder giu 2018 Service Manual 5-15 BUTTERFLY EXTRA SPARE PARTS LIST

73 PL 3.2 PARTS ON THE PLOTTER (Plus - Base) ITEM CODE DESCRIPTION 1 G950042X PLOTTER WHEEL 2 HINGE BRACKET 3 SAFETY INTERLOCK BRACKET 4 CQ ADAPTOR ROLL KIT FOR T Butterfly Folder giu 2018 Service Manual 5-16 BUTTERFLY EXTRA SPARE PARTS LIST

74 PL 3.3 PARTS ON THE PLOTTER (Extra Extra II) ITEM CODE DESCRIPTION 1 C953303X PLOTTER RULE 2 G953310X RULER WHEEL FOR T REAR BAR 4 LEFT FOOT HINGE BRACKET 5 RIGHT FOOT BRACKET 6 FRONT CROSS BAR 7 LEFT FRONT TRAY SUPPORT 8 RIGHT FRONT TRAY SUPPORT 9 BLUE CANVAS 10 INOX BAR 11 G695313X ROTATION PLATE KIT 3 6 G953318X EXTRA COMPLETE FOOT BRACKET 7 10 G953025X TRAY KIT 12 C960087X CASTER ANTISKID Butterfly Folder giu 2018 Service Manual 5-17 BUTTERFLY EXTRA SPARE PARTS LIST

75 PL 3.4 PARTS ON THE PLOTTER (Complete - Simple) ITEM CODE DESCRIPTION 1 POSITION PLATE 2 HOOKING PLATE 3 EXIT PLOTTER ROLL 4 PLOTTER STOP KIT ASSEMBLY 5 CUT SIGNAL INTERLOCK 6 PLOTTER RULE Butterfly Folder giu 2018 Service Manual 5-18 BUTTERFLY EXTRA SPARE PARTS LIST

76 PL 3.5 PARTS ON THE PLOTTER (LADYBIRD) ITEM CODE DESCRIPTION 1 Plotter Plate 2 Support 3 Left attaching bracket 4 Central attaching bracket 5 Right attaching bracke 6 Exit ruler 7 Left & right support brackets Butterfly Folder giu 2018 Service Manual 5-19 BUTTERFLY EXTRA SPARE PARTS LIST

77 4. ELECTRONIC COMPONENTS PL 4.1 CODE 1 C940403R C960413R C960423R ELECTRONICS PWBs - POWER SUPPLY ITEM 2 1 G953402X C940413R C940404R C940405R C960403R C940406X C940412X C960422X Power Supply PWB Main Controller DESCRIPTION POWER SUPPLY 240 VAC 24 V DC PWB MAIN CONTROLLER W/O TAG 13 PWB MAIN CONTROLLER W TAG 13 CANBUS I KIT TAG 13 CANBUS II KIT TAG 15 MOTOR BRAKE FM1 ; FM2 STEPPING MOTOR DRIVE NDC 04 STEPPING MOTOR DRIVE NDC 06 DRIVE CONTROLLER IN LETPLUG FUSE 1.6 AT (N 2 EU version) FLAT CABLE Remove the Rear Panel by two screws to access the Main Controller and the Power Supply Flat Cable Motor Brakes CANBUS Remove the Front Panel by six screws to access the Stepping Motor Drive Controller 8 Drive Controller Stepping Motor Drive NDC 06 Stepping Motor Drive NDC 04 Butterfly Folder Service Manual giu BUTTERFLY EXTRA SPARE PARTS LIST

78 5. KITS PL 5.1 KITS FOR UPGRADING AND REPAIRING ITEM CODE DESCRIPTION BUTTERFLY EXTRA CARE PACK 1 G952XCPX (See contents previous Parts Lists listed with this colour) 2 G953402X CANBUS II KIT TAG 15 3 G953318X EXTRA COMPLETE FOOT BRACKET Butterfly Folder giu 2018 Service Manual 5-21 BUTTERFLY EXTRA SPARE PARTS LIST

79 1. FAN FOLDER PL 1.1 INFEED SENSORS PL 1.2 INFEED MOTORS AND POSITION SENSORS PL 1.3 FAN FOLDER MOTORS AND SENSORS PL 1.4 FAN UPPER AND LOWER POCKET SENSOR PL 1.5 FAN TRASMISSION ITEMS PL 1.6 CONVEYOR PL 1.7 FAN MOBILE ROLLER PL 1.8 FAN FOLDING ROLLERS PL 1.9 FOLDER FAN CROSS FOLDER PL 2.1 CROSS MOTORS AND SENSORS PL 2.2 CROSS BELTS AND ROLLERS GENERAL PL 3.1 EXTERNAL PARTS AND SENSORS ELECTRONIC COMPONENTS PL 4.1 ELECTRONICS PWBS - POWER SUPPLY GF 500 Spare Parts List GERAFOLD 500 Folder giu 2018 Service Manual 5-1 GF 500 SPARE PARTS LIST

80 1. FAN FOLDER PL 1.1 INFEED SENSORS SENSORS ITEM CODE C695412X C695412X C850405X C695412X DESCRIPTION SENSOR FRONTAL OM SENSOR FRONTAL OM SENSOR SENSOR FRONTAL OM CODE DESCRIPTION CS CC C5 CFAN Start Sensor Conveyor Sensor 2nd Cross Fold Sensor Fan Sensor Remove the Green Covers to access Feed Sensor 1 [CC] Sensor [CS] Sensor [CFAN] Sensor GERAFOLD 500 Folder Service Manual 2 4 [C5] Sensor 3 giu GF 500 SPARE PARTS LIST

81 PL 1.2 ITEM 1 2,5 3 4 INFEED MOTORS AND POSITION SENSORS CODE C960411X C110402X C880402X C860404X DESCRIPTION STEPPER MOTOR SENSOR FORK OM MOTOR [M2] Motor 1 4 [MT] Motor MOTOR 24V 270K 5 SENSORS CODE DESCRIPTION PS3 PS4 PS9 PS10 MT Position Sensor MT Position Sensor (Driver) MT Position Sensor MT Position Sensor (Driver) [PS9-PS10] Sensor MOTORS CODE M2 M4 MT DESCRIPTION Entry Stepper Motor Knife Motor Entry Feed Flap Motor [PS3-PS4] Sensors [M4] Motor 2 3 Remove the Green Covers to access Feed Sensor GERAFOLD 500 Folder Service Manual giu GF 500 SPARE PARTS LIST

82 PL 1.3 FAN FOLDER MOTORS AND SENSORS ITEM CODE DESCRIPTION 1 C860404X MOTOR 24V 270K 2 C940419X MOTOR 24 VDC 1/ rpm 3 C940401X STEPPER MOTOR 4 C110402X SENSOR FORK OM 5 C880402X MOTOR CODE M1 MEF M3 M8 CODE PS1 PS2 MOTORS DESCRIPTION Transport Motor Exit Flap Motor Fan Main Stepper Motor Basket Motor (Only GF500 Version) SENSORS DESCRIPTION MEF Position Sensor MEF Position Sensor (Driver) [M8] Basket Motor 5 (Only GF500 Version) 1 [MEF] Motor [M1] Motor 2 Remove the Green painted panels to access this part list parts 4 [PS1-PS2] Sensors [M3] Motor 3 GERAFOLD 500 Folder giu 2018 Service Manual 5-4 GF 500 SPARE PARTS LIST

83 PL 1.4 FAN UPPER AND LOWER POCKET SENSOR ITEM CODE DESCRIPTION 1 2 C695419R SENSOR BARRIER GE 26 [C2] Sensor [C3] Sensor 24 GERAFOLD 500 Folder giu 2018 Service Manual 5-5 GF 500 SPARE PARTS LIST

84 PL 1.5 FAN TRASMISSION ITEMS ITEM CODE DESCRIPTION 1 C960507X BELT D 110XL037 2 C940503X BELT D 285L050 3 C940504X BELT D 124L050 4 C940502X BELT D 600L050 5 C940505X BELT D U 177.5T (Belt on M2 Motor not showed) 6 G950047X COMPLETE TIE-ROD GERAFOLD 500 Folder giu 2018 Service Manual 5-6 GF 500 SPARE PARTS LIST

85 PL 1.6 ITEM CONVEYOR CODE C940520X C940519X G460505X C954032X DESCRIPTION BELT P 27X1680 BELT D.90XL037 SET 3 BELT P 27X1690 TRAY STRIP [M1] Motor 3 GERAFOLD 500 Folder Service Manual giu GF 500 SPARE PARTS LIST

86 PL 1.7 FAN MOBILE ROLLER ITEM CODE DESCRIPTION 1 C980010X MOBILE ROLLER RIGHT LEVER 2 C960010X SPRING WASHER MOBILE ROLLER 3 C210502X BEARING 6002 ZZ X C960055X HINGE PIN 5 C980001X MOBILE ROLLER 6 C980011X MOBILE ROLLER LEFT LEVER GERAFOLD 500 Folder giu 2018 Service Manual 5-8 GF 500 SPARE PARTS LIST

87 PL 1.8 FAN FOLDING ROLLERS ITEM CODE DESCRIPTION 1 C309219X WASHER 2 C960019X TOOTHED PULLEY 3 C695049X MOTOR LEFT FLANGE 4 C423504X BEARING 6202 ZZ 5 C980003X LOWER FOLDING ROLLER C940062X UPPER FOLDING ROLLER 6 C490088X LOWER FLANGE 7 C980030X SPACER GERAFOLD 500 Folder giu 2018 Service Manual 5-9 GF 500 SPARE PARTS LIST

88 PL 1.9 FOLDER FAN ITEM CODE DESCRIPTION 1 C940411X FAN 24 V dc 2 C560420A FAN 24 V dc Remove the cover green highlighted to access the Fan indicated by the arrow [FAN1] 1 [FAN2] 2 1 [FAN1] (8 items) GERAFOLD 500 Folder giu 2018 Service Manual 5-10 GF 500 SPARE PARTS LIST

89 2. CROSS FOLDER PL 2.1 CROSS MOTORS AND SENSORS C7 ** C7 ** ITEM CODE DESCRIPTION 1 C690417X SOLENOID N021 2,3 C880402X MOTOR 4 C490408X STEP MOTOR 5 C110402X SENSOR FORK OM 6 C694481R SENSOR REFLECTION GE 8 C695415X SENSOR LATERAL OM 9 C694512X LOCK MOTORS 1 [E3] * C8 E3 PS7/8 M7 [M7] 2 9 * C8 E3 M7 PS7/8 6 5 CODE M5 M6 M7 E3 DESCRIPTION Main Cross Motor Lower Knife Motor Upper Knife Motor Solenoid 7 CODE C6 C7 C8 PS7 PS8 PS5 PS6 SENSORS DESCRIPTION Lower Pocket Sensor Upper Pocket Sensor Cross Exit Sensor M7 Position Sensor M7 Drive Sensor M6 Position Sensor M6 Drive Sensor 4 M5 M6 3 M5 M6 C6 PS5/6 [M6] C6 PS5/6 [M5] 8 5 GERAFOLD 500 Folder giu 2018 Service Manual 5-11 GF 500 SPARE PARTS LIST

90 PL 2.2 CROSS BELTS AND ROLLERS ITEM CODE DESCRIPTION 1 C940215X MOBILE EXIT ROLLER 2 C940213X MOTOR EXIT ROLLER 3 C940212X MOBILE FEED ROLLER 4 C940210X MOTOR FEED ROLLER 5 C940211X CONDUCTED FEED ROLLER 6 C940514X BELT P 220 x C960500X BELT T 4 x 605 (5 pcs) 8 C940509X BELT ROUND T 4 x 190 E3 1 E3 M7 M M5 M6 M5 M6 5 GERAFOLD 500 Folder giu 2018 Service Manual 5-12 GF 500 SPARE PARTS LIST

91 3. GENERAL PL 3.1 EXTERNAL PARTS AND SENSORS ITEM CODE DESCRIPTION 1,2 C690404X MICROSWITCH Single Contact 3 G890404R TOUCHSCREEN CONTROL PANEL 4 C850404X POWER SWITCH 5 C695508X CASTER (npm 4) 6 C954023D PLASTIC HANDLE [DS2] Switch 1 [DS1] Switch GERAFOLD 500 Folder giu 2018 Service Manual 5-13 GF 500 SPARE PARTS LIST

92 4. ELECTRONIC COMPONENTS PL 4.1 ELECTRONICS PWBs - POWER SUPPLY ITEM CODE DESCRIPTION 1 C340419X RELAY 24Vdc DOOR INTERLOCK 2 C960421X PS2 POWER SUPPLY 230VAC -48VDC 3 C940403R PS1 POWER SUPPLY 230VAC -24VDC 4 C695457R INPUT / OUTPUT PWB 5-6 G695456R LOGIC AND MAINBOARD PWB 8 C953400X CAN BUS - RS 232 CONVERTER 9 C850401R STEPPER MOTOR DRIVE CONTROLLER 10 C940410X RELAY SOCKET 11 C890401X FLAT CABLE 11 GERAFOLD 500 Folder giu 2018 Service Manual 5-14 GF 500 SPARE PARTS LIST

93 6. General Procedure 6. GENERAL PROCEDURE FLOOR SPACE REQUIREMENTS (BUTTERFLY) FLOOR SPACE REQUIREMENTS (GERAFOLD 500) TECHNICAL SPECIFICATIONS FOLDING SPECIFICATIONS CONFIGURATIONS CONTROL PANEL ELECTRONIC PWB Main Controller PWB Drive Controller PWB Power Supply DIAGNOSTIC POWER ON INPUT / OUTPUT TEST GERA DIAGNOSTIC TOOL PROCEDURE DIAGNOSTIC with TOOL Rev DIAGNOSTIC with TOOL Rev MAINTENANCE SERVICE Folder Adjustment Utility Rev Butterfly Utility Rev CHANGE TAG INDEX (BUTTERFLY) CHANGE TAG INDEX (GERAFOLD 500) CONTROL PANEL GERAFOLD ELECTRONIC PWB (GF500) Logic Board PWB Stepper Motor Drive Power Supply Unit PS1 PS I/O Logic PWB DIAGNOSTIC (GF500) Power On Input/Output Test Diagnostic Procedure Input Test Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-1 GENERAL PROCEDURE

94 FLOOR SPACE REQUIREMENTS (BUTTERFLY) Version Extra with Hewlett Packard T7000 A = 600 mm B = 600 mm C = 500 mm D = 1250 mm Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-2 GENERAL PROCEDURE

95 FLOOR SPACE REQUIREMENTS (GERAFOLD 500) Version GF 500 with Hewlett Packard HP T1200 A = 600 mm B = 600 mm C = 600 mm D = 1000 mm Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-3 GENERAL PROCEDURE

96 TECHNICAL SPECIFICATIONS CONFIGURATIONS Voltage Requirements: 230 Vac ± 5% (50Hz) Max. Power Consumption: 1.6 A ; 0.3 A (standby) The GERA Butterfly Folder is available in the standard configuration with the capability to be modified with field installable performance and feature options: Audible Noise Impulse Average Continuous 48-dBA max. 46-dBA max. ( run ) NEGLIGIBLE NEGLIGIBLE (Stand by) Environmental: Relative Humidity: 35% to 85% Temperature 60 to 90 Fahrenheit (15 to 32 Celsius) Paper: Bond (ordinary), 18-22lbs (75-100gsm) Folder Weight: Kg according the version Extra II version : This configuration is compatible for DesignJet HP T7100/7200 for automatic fan and cross folds, the folded copies delivered to the top tray Folder with Tag 13 and fw 2.## on can handle protocol communication with the printer for enhanced integration and feature beyween the two devices GeraFold 500 version: This configuration is able to fold 4A0/Min only 1 st Fold and is provided with only longitudinal section. This configuration is compatible with the HP plotter PageWide XL4000/4500/5000. FOLDING SPECIFICATIONS Print sizes GeraFold 500S version: This configuration is able to fold 7A0/Min only 1 st Fold and is provided with only longitudinal section. This configuration is compatible with the HP plotter PageWide XL4000/4500/5000. DIN, sizes: A4, A3, A2, A1, A0 Longitudinal folding panel: 190 mm, 210 mm Cross folding panel: 297 mm, 305 mm GeraFold 500X version: This configuration is able to fold 4A0/Min 1 st and 2 nd Fold and is provided with both longitudinal and transversal section. the finished copies come out in the collection tray situated on the top of the folder This configuration is compatible with the HP plotter PageWide XL4000/4500/5000. GeraFold 500XS version: This configuration is able to fold 7A0/Min 1 st and 2 nd Fold and is provided with both longitudinal and transversal section. the finished copies come out in the collection tray situated on the top of the folder This configuration is compatible with the HP plotter PageWide XL4000/4500/5000. Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-4 GENERAL PROCEDURE

97 CONTROL PANEL The Butterfly Folder Control Panel is provided with two keys and four led. The Red Light means a failure like jam or folder busy and the four led show the current folding program. The four leds corresponding P1, P2, P3 and P4 indicate the current folding program differently according the Folder version. To identify Px with a fold program selection refer to the Final Test Report data sheet and the Quick Guide. ELECTRONIC PWB Main Controller PWB The Main Controller is located inside the back panel of the folder. It contains one serial port (J7), the CPU and Firmware that controls the input components and drives all the output solenoids and the dc motors. Selection Key Reset Key If the red light is off the key allow to select the folding program; press the Selection key to change the program; to assign P1, P2 or P3 led a fold style refer to NVM adjustment. If the red light is on the key performs the manual feed to eject the copies jammed through the folding rollers. By pressing the Reset Key, the folder performs a check at power on of all sensor and motors; if the folder emits 4 beeps 1 or more sensors are covered (Extra II see codes 41, 42, 43 ) otherwise folder is ready to receive the copies. ITEM DESCRIPTION TYPE J1 Input Fan sensors AMP 12x2 J2 Input Fan Sensors AMP 12x2 J3 Input Cross Sensors AMP 12x2 J4 Input Flap Sensor PS10 AMP 4x1 J5 Key Reset AMP 4x1 J6 Input C3 AMP 4x1 J6/ V CANBUS 12 Vdc AMP 4x1 J7 Diagnostic & Adjustment Tool connection AMP 4x1 J8 RIP(Extra I) / Debug (ExtraII) AMP 4x1 J9 Serial Port for Gera Download software 4x1 J10 Output Cross 10x1 J11 Output M5 24 Vdc 4x1 J12 Fan Output 8x1 J13 Alarm Printer 2x1 J14 Voltage Power Supply to Drive Controller 8x2 J15 Output M8 24 Vdc 2x1 J17 Input 24 V dc from Power Supply AMP 2x1 J18 Input 24 Vdc from Power Supply AMP 2x1 J19 Input Flap Sensor PS10 4x1 J20 CANBUS AMP 4x1 Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-5 GENERAL PROCEDURE

98 Drive Controller PWB The Butterfly Folder is available with two different Stepper Motor Drives. The PWB Drive Controller is located inside the back panel of the folder. It contains the CPU and firmware that controls the stepper motors: - Entry Fan Folder Motor [M2] - Main Fan Folder Motor [M3] The PWB Drive Controller consists of the Stepper Motor Controller PWB C2 Board and the two Stepper Motor Driver PWB s. NDC 04 NDC 06 CN2 CN3 GENERIC FEATURE: NDC 04 NDC 06 Vdc nom. (V) Inf. min. (A) Inf. max. (A) 2 6 Dimensions (mm) 93.5 x 101 x 25 Working Temp. +5 C +45 C Chart Terminology Used CN1 CN4 Vdc nom. = DC nominal value Vac nom. = AC RMS voltage value Iinf. = Phase nominal voltage (peak value). The voltage, can be set by the technician in four different values through DIP-SWITCHES. Inf min and max = Minimum and maximum voltage values are set through DIP-SWITCHES Step Inf = Sets voltage spacer value. Power Supply Drive Controller PWB C2 ITEM DESCRIPTION TYPE CN1 Communication Port 8x2 CN2 + 5V Keyboard 10x1 CN3 M3 output 10x1 CN4 M2 output 10x1 The Power Supply mounted is a separate unit. PS1 distributes the power: 24Vdc to the Main Controller and 24 Vdc to the Drive Controller PWB. Connection 1 AC L 2 AC N 3 AC FG 4 - V out 5 - V out 6 + V out 7 + V out TRIMMER to adj. 24 Vdc out. Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-6 GENERAL PROCEDURE

99 DIAGNOSTIC Diagnostic function allows to check the working of each single folder component both in input test (sensors and safety interlocks) and output test (motors, solenoids, sound signal). DIAGNOSTIC with TOOL Rev 2.3 Run the GERA diagnostic and adjustment tool program and select the correct Serial port used. POWER ON INPUT / OUTPUT TEST In the Butterfly Folder the input / output test operation is performed through the Power On Self Test This procedure can be done without running the Diagnostic and Adjustment program INPUT TEST: It s a procedure when we cover the sensor, switch Off and then switch On the folder if there is 4 beeps the sensor work, this procedure will be done for all the sensors one by one. And by checking the sensor LED status we can identify the one covered by paper. OUTPUT TEST: It s a procedure when we check for properly motor position and rotation: By pressing the selection key on the folder (more than 3 sec.) the motors M2, M3, M5 and MT will be activated. By covering the position sensor of MEF, M6, M7 and M4 the motors goes to work position after that switch Off and On the folder if the motors turn on home position there are work correctly. GERA DIAGNOSTIC TOOL PROCEDURE Turn on folder when POST is completed press CONNECT TO FOLDER button. if connection is not performed use a USB- SERIAL 232 adapter, check cable and perform again waiting the Power cycle completed. If the problem persist check serial driver serenum.sys Other tool designed for better diagnostic folder input /output failure is the GERA Diagnostic and Adjustment Tool downloadable from the Gera web site technical page and requiring external PC connection. Turn off the folder and swing out from Connect the folder port P5 with a serial cable to a PC serial port Move the internal cable from J9 connector on the Main Controller PWB to J7 select Diagnostic key (default indication = green) Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-7 GENERAL PROCEDURE

100 Input Test (Utility Rev 2.3) The sensors default status is like the screen below, it change status from colour green to red or from red to green when covered discovered. Refer to the page below for recognize the input items.. Output Test (Utility Rev 2.3) The motors and the solenoids can be actuated through the button on the folder layout and stopped by pressing it again; for the stepper motors use button to actuate and button for stop Refer to the page below for recognize the output items. Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-8 GENERAL PROCEDURE

101 DIAGNOSTIC with TOOL Rev 2.5 REQUIREMENTS for Tool Rev 2.5: Operating System XP, VISTA, W7 W8 32,64 bit with NET Framework version 4.0 or higher; USB to Serial cable converter with driver. With Folder swiched on and on PWB Main Controller connected on J7 run the GERA diagnostic and adjustment tool program and select the correct Serial port used. OUTPUT TEST (Utility Rev 2.5) There s a folder only for the Stepper Motors M2 Infeed Motor (Step Motor 1) and M3 Main Motor (Step Motor 2) OUTPUT TEST (Utility Rev 2.5) Choose the folder output and will appear all the items that can be actuated through the button. To actuate an item press the button, the icon will become green while the corresponding output is actuated; to stop it press again the icon. Press the Start Button,; will be enabled Trim and Test Buttons Press Test Buttons and choose, when asked, the ini file previously downloaded. INPUT TEST (Utility Rev 2.5) Choose the Input Folder The sensors default status is like the screen below, it change status from colour green to red or from red to green when covered discovered. Refer to the page below for recognize the input items. Motor Rotation In the example to the right the circular arrow shows a CCW rotation relative to the viewing direction shown by the straight arrow. This means that the rotation direction CW or CCW is defined by looking from the output shaft of the motor towards the motor. The words CW or CCW, are always intended as depicted in the illustration. AFTER COMPLETE THE FOLDER OUTPUT TEST TURN OFF- ON THE FOLDER IN ORDER TO RESET ALL OUTPUT ACTIVE Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-9 GENERAL PROCEDURE

102 Fan Folder (ALL) Cross Folder (ALL) Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-10 GENERAL PROCEDURE

103 MAINTENANCE The folder demands activity of cure and maintenance apt to maintain good functionality and performance. In order to estimate which type of action is necessary to realize, it s necessary to know the linear meters proceeded by the folder and the jam s frequency, these elements will be able to give you a panorama of the activities for clean up, calibration and substitution. Since the paper passage worn out folder parts or path is necessary to verify the expected life for rollers, antistatic brushes, belts transport or paper guides. Before the limit is reached and folder functionality may be reduced it s important to perform the maintenance activities and replace these parts near or over the estimated life When the limit is reached the CSE needs to identify part or components worn out and perform the maintenance activities. Here below parts are listed with description of reason and or explanation of relative folder failure PART DC Motors Belts Bushing Bearing Static Brushes REASON Possible motor malfunction due to carbon brushes wear, unexpected noise on the electrical circuit Poor drive or paper transportation, folded prints with toner signs Poor shafts rotation, noise Poor shafts rotation, noise High paper static load, paper stick on folder guides Poor folding quality Every meters folded: Maintenance activities Check & Clean Every meters folded: Maintenance activities Life Part Replacement The CSE has to perform other activities every multiple of and meters folded. The folder does not provide a folder life counter, for the operator the folder visualize the number of copies folded since the folder is switched on, this is only and informative counter, it does not generate any message or recall maintenance activity. The identify the number of copies handled by the folder considers all the copies folded, as well all the prints manually fed and the copies or transparencies bypassed. The folder counter is erased each time when the folder is turned off, in order to estimate the number of copies folded read the linear meters printer counter. The folder after meter of paper folded needs operations designed for to remove paper dust that can damage or reduce the folder functionality PART All Sensors Fan & Cross Folder flat Belts The pressure of the Rollers Cross Folder Roller Clean all the sensors from paper dust TASK Clean the all the Flat Belts from toner and paper dust. (Avoid strong solvent, can be used product like Lixton GT1) Clean guide from dust and oxidation Check and adjust ADJ 1.1 Mobile Roller Pressure Check and adjust ADJ 2.1 Cross Mobile Roller Pressure Clean the Conducted Feed Roller (PL 2.2 item 5) with alcohol especially if the surface is sticky Driving Roller Rubber rollers Sensors Poor print transportation, lack of pressure Poor print transportation Poor print sensing, resulting in lower fold quality Cams / bearing / bushing lubrication Cross Folder Conducted Feed Roller C940211X (item 5 Part List Section 5) Check the cams and lubricate them with grease (use the type of grease you would use for bearings) Check the bushing and clean or lubricate them with light oil Clean the Roller Surface using a detergent that does not contain solvent (advised is the rubber roll cleaner sold by GERA code K009519X) then sprinkle talcum powder on the roller surface. Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-11 GENERAL PROCEDURE

104 SERVICE Folder Adjustment Utility Rev 2.3 For service Operation the application Gera Diagnostic & Adjustment Utility 2.1 operating on OS: XP 32 bit, enable engineer to modify fold panel values. Run the Gera Diagnostic & Adjustment Tool (refer to the Diagnostic Section) and select the Adjustment key A window will open asking for INI file, this file is a description of the NVM value retrieved from the folder, this is file is available at tech support page of GERA website,once the INI zipped file relative to the folder firmware is downloaded, un zip it and use it to open the below window. Select on the VALUE column the number required to be changed ; the current value is displayed and can be changed through - and + bottoms or writing directly the value. Click on SAVE bottom in order to get effective the value modified. Default Values When the value column is not correct ( all empty or 1) the folder does not work. To restore the factory default values from the default firmware, open the INI file relative to the folder firmware, press the Restore Default button, all values will applied, then press SAVE. If the operation does not enable the folder to work proceeds with the download tools and download from the Gera web site the Parameter bank, extract them from the compressed folder and the download t the Parameter bank. HEX by selecting the green button of the GERA download utility. Below are listed the Adjustment values after the firmware release 1,07 Adj Adjustment description Value Plus Value Extra To make the panel /time longer 01 Adjust 1 st Panel 210 mm Increase the value +1 step = + 1mm 02 Adjust 1 st Panel 190 mm Increase the value +1 step = + 1mm 03 Adjust 2 nd Panel 210 mm Increase the value +1 step = + 1mm 04 Adjust 2 nd Panel 190 mm Increase the value +1 step = + 1mm 05 Set Folder type: only fan folder or with cross folder 06 Fan Finger Guide Assembly Engage: (base) 1 (plus) 1 0 = Butterfly Base 1 = Butterfly Plus, Extra 0 = w/o Finger Guide Assembly 1 = with Finger Guide Assembly 0 = w/o table 07 Support table for off line mode: = with table Adjust print guide time against mobile 08 roller Increase the value 1 step = 1 msec Adjust print guide position against 09 mobile roller Increase the value 1 step = 1 msec Max number of fan folded Panels for 10 active the Cross Folder 9 9 Increase the value 11 Adjust 1st Fan Folded Panel in off line mode Increase the value +1 step = + 1mm 12 Adjust 2nd Fan Folded Panel in off line mode Increase the value +1 step = + 1mm 13 Adjust last Panel 190 Margin < Increase the value +1 step = + 1mm Adjust last Panel 210 or 190 with 14 support table Increase the value +1 step = + 1mm Adjust last Panel 210 or 190 with 15 support table Increase the value +1 step = + 1mm 16 Adjust 1 st 1 (W/O TAG 3) Cross Folder Panel 297 mm 380(W TAG 3) 380 Increase the value +5 step = + 1mm 17 Adjust 2 nd 1 (W/O TAG 3) Cross Folder Panel 297 mm 210(W TAG 3) 210 Increase the value +10 step = + 1mm 18 Max number of fan folded panels Increase the value 0 = cross folder exit 19 Upper exit roll 297 mm = fan folder exit Adjust print guide position against 20 mobile roller impulse No Fold 3850 Increase the value 1 step = 1 msec Fan last Panel Margin 190 M between and Increase the value +1 step = + 1mm 22 Fan last Panel Margin 190 M > Increase the value +1 step = + 1mm 23 Controller Extension 0 1 0= until release = from release 1.07 Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-12 GENERAL PROCEDURE

105 Butterfly Utility Rev. 2.5 REQUIREMENTS for Tool Rev 2.5: Operating System XP, VISTA, W7 W8 32,64 bit with NET Framework version 4.0 or higher; USB to Serial cable converter with driver. Connect the folder port P5 with a serial cable to a PC serial port: Folder Adjustment With Folder switched on, run the Gera Butterfly Tool 2.5, choose the right COM and press start ; on butterfly tools windows appears the model and Trim and Test will be activate. Press Trim and choose when asked, the ini file previously downloaded; a Butterfly Trim window will show the property name of even adjustment, the folder values and the defaul value saved on ini file. On Main Controller according to the operation to be performed pay attention to the Main Controller connector position (Firmware-parameter download must be on J9 while in diagnostic-adjustment must be on J7): Firmware-Parameter download With Folder switched off, run the Gera Butterfly Tool 2.5, choose the right COM and select the Download key ; second window will ask to press start Switch on the folder; if connection is complete it will ask to press Program or Parameter Choose the appropriate firmware downloaded previously. After finishing the firmware upgrading Switch off/on the folder: 1) If one green LED is lit on, the upgrading was successfully done. 2) If two LED is lit on, do the upgrading procedure again. After each modification it is necessary to press Save All Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-13 GENERAL PROCEDURE

106 CHANGE TAG INDEX (BUTTERFLY) TAG: 01 CLASS: Optional MFG SERIAL N : NAME: Cross Folder Flat Belts Guides PURPOSE: Avoid Flat Belt in Cross Folder Lateral Swinging KIT NUMBER: N/A REFERENCE: N/A TAG: 02 CLASS: Optional MFG SERIAL N : NAME: Fan Folder Mechanical Enhancement PURPOSE: General Improvement of Fan Folder performances through mechanical modifications and Mobile Guide Earth connection. KIT NUMBER: N/A REFERENCE: N/A TAG: 03 CLASS: Optional MFG SERIAL N : NAME: Automatic Cross Folding Panel Size PURPOSE: In On Line Mode the Cross Folding Panel size is adjusted automatically by the software. The layout of the Cross Folder pockets sensors [C6] and [C7] has been modified in order to recognize the size starting the sensor reading. Only from firmware release 1.35 on. KIT NUMBER: N/A REFERENCE: Folder Adjustment Addresses TAG: 04 CLASS: Optional MFG SERIAL N : NAME: Copy Convey Enhancement PURPOSE: Cross Folder entry knife shape modified for prevent jam; Cross Folder exit rolls with smooth surface that do not damage the folded copy. KIT NUMBER: N/A REFERENCE: N/A TAG: 05 CLASS: Optional MFG SERIAL N : NAME: Mobile Exit Roller PURPOSE: Improve the Mobile Exit Roller performance using an external softer rubber in order to obtain a most market fold KIT NUMBER: C940215X REFERENCE: PL 2.2 TAG: 06 CLASS: Optional MFG SERIAL N : See Purpose NAME: Copy Convey Improve PURPOSE: Fan Conveyor guide modified for enhancement the Cross Folder Entry (from Serial Number ); The Fan Finger Guide Assembly is modified in order to increase moving range and avoid jams (from Serial Number ). KIT NUMBER: N/A REFERENCE: N/A TAG: 07 CLASS: Optional MFG SERIAL N : NAME: Anti-tear Sensor PURPOSE: Avoid that the Folder pulls and tears the paper if the Plotter stops for any reason (for example door opened or end of media roll) KIT NUMBER: N/A REFERENCE: N/A TAG: 09 CLASS: Optional MFG SERIAL N : NAME: Kit enabling Folder to pause print process PURPOSE: Enable the Folder in alarm status to pause the print process, allow the alarm removing and restart after a Folder reset with the job queue. KIT NUMBER: G002184X REFERENCE: IS TAG: 10 CLASS: Optional MFG SERIAL N : NAME: Cross folder entry roller pulley with one way bearing PURPOSE: Prevent the Cross Folder Entry roller slipping and avoid that the roller gets sticky with fold quality problems. KIT NUMBER: G940288X REFERENCE: N/A TAG: 11 CLASS: optional MFG SERIAL N : NAME: Controller extension PURPOSE: To replace old PWB handling printer cut signal KIT NUMBER: C940417R / C960412R REFERENCE: N/A Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-14 GENERAL PROCEDURE

107 TAG: 12 CLASS: optional MFG SERIAL N : NAME: 3 Fans extension PURPOSE: to flatten the copies to be more easy to enter in the cross folder part KIT NUMBER: C953315X REFERENCE: N/A TAG: 13 CLASS: optional MFG SERIAL N : NAME: CAN BUS communication PURPOSE: Cut signal comes from CANBUS protocol see P.L4.1 KIT NUMBER: REFERENCE: N/A TAG: 14 CLASS: optional MFG SERIAL N : NAME: Foot Brackets ; Second handle for Manual Eject PURPOSE: Improve the Manual Eject from Fan Folder, the Folder and Printer assembly fixing and the Full Bin Stop KIT NUMBER: N/A REFERENCE: PL 1.5 TAG: 15 CLASS: optional MFG SERIAL N : NAME: CANBUS II PURPOSE: The CANBUS option TAG 13 is improved with a simplified cabling where is not any more necessary remove the T7100 printer covers. KIT NUMBER: G953402X REFERENCE: PL 4.1 TAG: 16 CLASS: optional MFG SERIAL N : NAME: Flap Tie Rod PURPOSE: The Tie Rod of the Entry Flap in Fan Folder is improved with a new design assembly that prevents breakdown. KIT NUMBER: G950080X REFERENCE: PL 1.5 TAG: 17 CLASS: optional MFG SERIAL N : (except Sn and ) NAME: PWB Motor Brake PURPOSE: The Relais assembled on Motor Brakes PWB FM1 and FM2 has been replaced with a 16 A one that avoid failures under heavy duty. KIT NUMBER: C940413R REFERENCE: PL 4.1 TAG: 19 CLASS: Mandatory MFG SERIAL N : NAME: Cross Folder Sensor Fixing PURPOSE: The lower Cross Folder sensor fixing avoids the cross folding step manual setting. Changed the Entry Flap support. KIT NUMBER: N/A REFERENCE: N/A TAG: 20 CLASS: Mandatory MFG SERIAL N : NAME: MEF;MT;M4;M6;M7;M8 PURPOSE: Replace Motors for Improvement of folder performances KIT NUMBER: N/A REFERENCE: N/A TAG: 21 CLASS: Mandatory MFG SERIAL N : NAME: Stepper Motor Controller PURPOSE: Replace old Stepper Motor Controller NDC04/06 for Improvement of folder performances KIT NUMBER: C850401R REFERENCE: N/A TAG: 22 CLASS: Mandatory MFG SERIAL N : NAME: Mobile Roller PURPOSE: Replace old Mobile roller with new one with deepest gorges KIT NUMBER: C940062X REFERENCE: N/A Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-15 GENERAL PROCEDURE

108 TAG: 0 CLASS: Mandatory MFG SERIAL N : NAME: Butterfly Extra III PURPOSE: Adapting T7200 KIT NUMBER: N/A REFERENCE: N/A TAG: 1 CLASS: Mandatory MFG SERIAL N : NAME: Main Cross Motor PURPOSE: Improve M5 Cross Motor Performance (only for B6 Extra III) KIT NUMBER: C850401R REFERENCE: N/A TAG: 2 CLASS: Mandatory MFG SERIAL N : NAME: Folder Entry Flap Tie Rod PURPOSE: Restore the Entry Flap Spring Tie Rod KIT NUMBER: G950047X REFERENCE: PL 1.5 CHANGE TAG INDEX (GERAFOLD 500) TAG: 0 CLASS: Mandatory MFG SERIAL N : NAME: GeraFold 500 PURPOSE: Adapting PW XL 4000/4500/5000 KIT NUMBER: N/A REFERENCE: N/A TAG: 1 CLASS: Mandatory MFG SERIAL N : NAME: Cross Exit Assembly PURPOSE: Improve the exit cross guide to push thickness paper KIT NUMBER: G REFERENCE: N/A TAG: 2 CLASS: Mandatory MFG SERIAL N : NAME: Mylar Tray strip PURPOSE: Flat exit copy to fall correctly into the bascket collection KIT NUMBER: C954032X REFERENCE: N/A TAG: 3 CLASS: Mandatory MFG SERIAL N : NAME: Transparent tubes PURPOSE: Prevent conveyor rollers from A2/A3 tearing edge KIT NUMBER: N/A REFERENCE: N/A TAG: 4 CLASS: Mandatory MFG SERIAL N : NAME: PVC Grey Roller PURPOSE: More thrust for small size A2/A3 KIT NUMBER: N/A REFERENCE: N/A Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-16 GENERAL PROCEDURE

109 CONTROL PANEL GERAFOLD 500 The circular button has 2 functions : ELECTRONIC PWB (GF500) Logic Board PWB 1. Press & Hold for 2 seconds turn on the folder. 2. Press during the folding process it stops the engines movement. 1st Fold panel dimension 2nd Fold panel dimension Margin size dimension ITEM DESCRIPTION TYPE Bin Capacity Operator Menu Settings Menu J1 POWER 24 V AMP 2x1 J3 OUTPUT 5, 12, 24 V AMP 6x1 J3A LOGIC MAINBOARD PWB AMP 24x1 J3B LOGIC MAINBOARD PWB AMP 24x1 J4A MOTOR SIGNAL AMP 4x1 J4B MOTOR SIGNAL AMP 4x1 J4C MOTOR SIGNAL AMP 4x1 J6 INTERLOCK AMP 2x1 J8 SENSOR SIGNAL AMP 12x2 COM1 CANBUS AMP 4x1 COM2 SERIAL AMP 4x1 KEYB TOUCH SCREEN AMP 10x2 Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-17 GENERAL PROCEDURE

110 Power Supply Unit PS1 PS2 Stepper Motor Drive The Folder is provided with three Stepper Motor Drive one for each stepper motor [M2], [M3] and [M5] The GeraFold 500 is provided with two Power Supply Units: PS1 24 Vdc for the I/O logic and Touch Screen and PS2 48 Vdc for the Stepper Motor Drive I/O Logic PWB The Folder is provided with two PWB: one for the Fan Folder and the other for the Cross Folder if present GENERIC FEATURE: Vdc nom. (V) Inf. min. (A) Inf. max. (A) Dimensions (mm) Working Temp x 85 x C +45 C Chart Terminology Used Vdc nom. = DC nominal value Vac nom. = AC RMS voltage value Iinf. = Phase nominal voltage (peak value). The voltage, can be set by the technician in four different values through DIP-SWITCHES. Inf min and max = Minimum and maximum voltage values are set through DIP-SWITCHES Step Inf = Sets voltage spacer value. Butterfly Extra III GERAFOLD 500 Folder Service Manual 13-Jun ITEM P1 P2 P3 P4 J3 J5 DESCRIPTION INPUT 5, 12, 24 V INPUT 5, 12, 24 V OUTPUT FAN - MOTOR OUTPUT FAN - MOTOR INPUT FROM LOGIC BOARD PWB SENSOR SIGNAL TYPE AMP 4x1 AMP 4x1 AMP 6x1 AMP 4x1 AMP 24x1 AMP 12x2 GENERAL PROCEDURE

111 DIAGNOSTIC (GF500) Diagnostic function allows to check the working of each single folder component both in input test (sensors and safety interlocks) and output test (motors, solenoids, sound signal). Power On Input/Output Test Input Test The input test screen shows the sensors with default status, it change status when covered or discovered and on the screen the name of the sensor will appear or disappear In the GeraFold 500 the input / output test operation is performed through the Power On Self Test This procedure can be done without running the Diagnostic and Adjustment program INPUT TEST: It s a procedure when we cover the sensor, switch Off and then switch On the folder if there is an error code message (40-->49) on the Touchscreen panel the sensor work, this procedure will be done for all the sensors one by one. And by checking the sensor LED status we can identify the one covered by paper. OUTPUT TEST: It s a procedure when we check for properly motor position and rotation: By selecting the "clean" option and pressing the arrow key on the Touchscreen folder the motors M2, M3, M5 will be activated. By covering the position sensor of MT, MEF, M6, M7 and M4 the motors goes to work position after that switch Off and On the folder if the motors turn on home position there are work correctly. Output Test Diagnostic Procedure Other option for better diagnostic folder input /output failure is through the Diagnostic option selectable from the Touchscreen panel. The motors and the solenoids can be actuated through the arrow button and stopped by pressing the square button Refer to the page below for recognize the output items AFTER COMPLETE THE FOLDER OUTPUT TEST TURN OFF- ON THE FOLDER IN ORDER TO RESET ALL OUTPUT ACTIVE Butterfly Extra III GERAFOLD 500 Folder 13-Jun-2018 Service Manual 6-19 GENERAL PROCEDURE