COUNT-WISE

1, M, & BANTAM

April 2008 Revision

U.S. PAPER COUNTERS

138 Elizabeth Terrace
P0Box837
Cairo, NY 12413
Tel: (518) 622-2600
Fax: (518) 622-2695
e.. mail: uspc@wecount.com
website: www.wecount.com
 U.S. PAPER COUNTERS•
COUNT-WISE I, COUNT-WISE M & BANTAM
COUNTING MACHINES

Table of Contents

SECTION# 1: WARRANTY .................................................................................................................................... 3

SECTION #2: TECHNICAL DETAIL & INSTALLATION INSTRUCTIONS .................................................. S

INSTALLATION INSTRUCTIONS ............................................................. ;.......................................................... 6
MAX-BANTAM SHEET COUNTER .................................................................................................................. 6-7
DIAGRAM-BANTAM .................................................................................................................. ........................ 7
COUNT-· WISE I SHEET COUNTERS ......................... ~ ......................................................................................... 8
DIAGRAM -RECEPTACLE GUARD .................................................................................................................... 9
COUNT-WISE M SHEET COUNTERS ......................................................................................................... 10-11
AIR FLOTATION SYSTEMS ............................................................................................................................... JO
DIAGRAM CW-M ............................................................................................................................................... ll
COUNT-WISE I, M & BANTAM TECHNICAL DETAILS ................................................................................. 12
SUCTION BLADE GUIDE FOR RANGE OF PAPER TO BE COUNTED ........................................................ 12
SECTION #3: OPERATING INSTRUCTIONS & SEQUENCE OF EVENTS DURING OPERATION ....... 13
OPERATrNG INSTRUCTIONS ............................................................................................................................. IS
DIAGRAM-BREATHERS .................................................................................................................................... 14
BREATHERS ....................................................................................................................................................... 15
DIAGRAA1-SELF DIAGNOSTIC LEDS .............................................................................................................. J6
SEQUENCE OF EVENTS • LOGIC BOARD S-3170 ........................................................................................... 17
DIAGRAM-LOGIC BOARD ................................................................................................................................ 18
SECTION #4: COUNTING HEAD & MAINTENANCE SCHEDULE .............................................................. 19
LOADING OF INSERTTAPE ............................................................................................................................. 20
DIAGRAM-TAPE LOADING .............................................................................................................................. 2I
RESET ADJUSTMENT WIDIAGRAM................................................................................................................. 22
COUNT ADJUSTlvfENT WIDJAGRAM............................................................................................................... 22
COUNTING HEAD REMOVAL .......................................................................................................................... 23
REMOVING COUNTING HEAD CENTER PLATE..·.......................................................................................... 23
REPLACING COUNTING HEAD ....................................................................................................................... 23
HEAD INSTALLATION AND ALIGNMENT....................................................................................................... 24
HOW TO CHANGE A SUCTION BLADE........................................................................................................... 25
SETTING VERTICAL RISE SWITCH............................................ ...................................................................... 25
SETTING THE COUNTER POISE SPRING ....................................................................................................... 25
DIAGRAM-ORBIT ADJUSTMEJVT...................................................................................... ............................... 26
ORBIT ADJUSTMENT........................................................................................................................................ 27
DRAWING: COUNTING HEAD CENTER PLATE/TAPE CHUTE .................................................................... 28
HOW TO REMOVE A TAPE JAM ...................................................................................................................... 29
TAPE CHUTE REMOVAL .................................................................................................................................. 30
REPLACING TAPE CHUTE ............................................................................................................................... 30
CHANGING THE TAPESOLENOID ................................................................................................................. 32
REMOVAL OF KNIFE ASSEMBLY.................................................................................................................... 32
REPLACING KNIFE ASSEMBLY....................................................................................................................... 32
PHOTO-COUNTING HEAD, RIGHT SIDE ....................................................................................................... 33
PHOTO- COUNTING HEAD, LEFT SIDE......................................................................................................... 35
MAINTENANCE SCHEDULE .............................................................................................................................. 37
SECTION #5: TROUBLE SHOOTING ........................................................................................................... 39-46

Page# 1
 SECTION #6: ELECTRICAL SYSTEM ............................................................................................................... 47
LOGIC CONTROLLER.......................................................................................................................................... 48
PHOTO & PARTS LIST- REAR, TOP OF MACHINE ........................................................................................ 49
COUNTWISE SPEED CONTROL 15DV PARTS PLACEMENT & LIST ........................................................... 50
PHOTO & PARTS LIST- FACEPLATE COUNTWISE -M. ................................................................................ 51
BANTAM CONTROL PANEL 2001 TO PRESENT ............................................................................................. 52
CONTROL PANEL KEY-BANTAM 2001 AND AFTER ...................................................................................... 53
BANTAM CONTROL PANEL PRE-200 ! .............................................................................................................54
CONTROL PANEL KEY-BANTAM PRE-2001 ................................................................................................... 55
SECTION #7: BASIC ADJ1JSTMENTS ................................................................................................................ S7
VACUUM SYSTEM ............................................................................................................................................... 58
PHOTO-& PARTS LIST: POWER SUPPLY & VACUUM AREA ....................................................................... 59
SEITI1VG VACUUM SWITCHES ........................................................................................................................ 60
VACUU1Yf SWITCH ADJUSTi\1ENT ................................................................................................................... 61
SPEED CONTROL ADJUSTMENT SEQUENCE ............................................................................................... 62
ACE MICRO CUSHION ADJUSTMENT............................................................................................................ 63
SECTION #8: WffiiNG DIAGRAMS .................................................................................................................... 65
LOGIC BOARD WIRE CONNECTIONS....................................................................................................... 66-67
LOGIC BOARD PLUGS...................................................................................................................................... 68
COUNTING HEAD ............................................................................................................................................. 69
VERTICAL RISE MOTOR ................................................................................................................................... 70
LOGIC CONTROLLER ....................................................................................................................................... 71
ELECTRONIC COUNTING UNIT (ECU) BASIC COMPONENTS.................................................................... 73
ELECTRONIC COU1VTING UNIT (ECU) .................................................................................................... 74-75
POWER SUPPLY ASSEMBLY ON ECU............................................................................................................. 77
COMPUTER ECU......................................................................................................................................... 78-79
PRE-2001 BANTAM WIRING DJAGRAM .......................................................................................................... 80
SECTION#9: PARTS LISTS, PHOTOS & DIAGRAMS .................................................................................... Sl
TAPE RETAININ"G BLOCK .................................................................................................................................. 82
RECOMMENDED SPARE PARTS .............................. :........................................................................................ 83
PHOTO-COUNTING HEAD .................................................................................................................................. 84
PARTS LIST-COUNTING HEAD ........................................................................................................................ 85
PHOTO-FRONT VIEW COUNTING HEAD ....................................................................................................... 86
PHOTO & PARTS LIST-PRE-SELECT & START SWITCH AREA .................................................................... 87
PHOTO & PARTS LIST-POWER SUPPLY & VACUUM AREA ........................................................................ 88
PHOTO & PARTS LIST-INSIDE CONTROL PANEL ......................................................................................... 89
LASER SYSTEM OPERATION, DIAGRAM & PARTS LJST............................................................................... 90
INDEX .................................................................................................. ,.. ,............ ,, .. & ....................... , •••••••••••••••••••••••••••• 91

DIAGRAMS & PHOTO LISTINGS ....................................................................................................................... 94

NOTE: U.S. Raper Counters reserves the right to change the price, appearance, specifications or design
of lts products at any time without notice or incurring the obligation either to modify units previously
manufactured or to furnish products with previously published specifications.

Revised: APRIL 2008 (CWlMBTM-042008)

Page # 2
SECTION# 1: WARRANTY

Page# 3
Page # 4
SECTION #2: TECHNICAL DETAIL &
INSTALLATION INSTRUCTIONS

Page# 5
 INSTALLATION INSTRUCTIONS
MAX-BANTAM SHEET COUNTER

1. Remove carton containing mount bolts, table supports, insert tape, power cord,
receptacle guard, bag of hardware and manual.

2. Place machine on workstation, or optional base cabinet.

3. Remove hex head screws from left and right sides of front panel and install table
support brackets using same screws.

4. Place table onto brackets and into the "throat" of the counter.

5. Place the small silver hex-bolt through the table at the 11 pointu near the counter of
the table. Tighten the bolt so that the table is approximately 1/32" above the
table flap.

6. Install the remaining two (2) small silver hex-bolts through the table and the
brackets. You may have to move the brackets into position.

7. Open back panel access door by pulling out, then lifting up. There are two (2)
white plastic holders on the side panels that the access door slides into.

8. Remove all packing material from interior of machine. This includes cardboard
under counting head, two rubber bands holding tape cover closed and counting
head down, and white plastic wire ties holding counting head down.

9. Install receptacle guard to rear of machine. (Refer to Diagram, page 9)

10. Remove shipping bands from the counting head. Plug power cord securely into
the socket located on the rear panel. MUST BE INSERTED FIRMLY.

·NOTE: REAR BACK PANEL MUST BE CLOSED FOR MACHINE TO OPERATE.

*****SEE OPERATING INSTRUCTIONS***** {Page 13)

Page # 6
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 INSTALLATION INSTRUCTIONS
COUNT-WISE 1 SHEET COUNTERS

1. Remove table mount bolts, jogging plate, table supports, insert tape, breathers
(wood inserts), power cord, receptacle guard, and bag of hardware from back of
machine. Remove manual.

2. Place machine on workstation, or optional base cabinet. SECURING THE

COUNTER IS ESSENTIAL TO ELIMINATE ·nPPING OF THE MACHINE.
BOLTS ARE SUPPLIED WITH BASE CABINET.

WARNING: BOLTING MACHINE TO CUSTOMER•s TABLE OR TO BASE CABINET

IS ESSENTIAL TO ELIMINATE TIPPING FORWARD OF THE MACHINE.

3. Remove hex head screws from left and right sides of front and install table
support brackets using same screws.

4. Place table onto brackets and into the "throat" of the counter.

5. Place the small silver hex-bolt through the table at the "point" near the throat of
the table. Tighten the bolt so that the table is approximately 1/32" above the
table flap.

6. Install the remaining two (2) long hex-bolts through the table and the brackets.
You may have to move the brackets into position so they support table.

7. Open back panel access.

8. Remove all packing material from interior of machine. This includes cardboard
under counting head, two rubber bands holding tape cover closed and counting
head down, and white plastic wire ties holding counting head down.

9. Install receptacle guard to rear of machine. See page 8 for more details.

10. Plug power cord into rear of machine. MUST BE INSERTED FIRMLY!

NOTE: REAR BACK PANEL MUST BE CLOSED FOR MACHINE TO OPERATE.

*****SEE OPERATING INSTRUCTIONS, SECTION 3***** (Page 13)

Page # 8
 TO INSTALL RECEPTACLE GUARD
LOOSEN LOWER LEFT #8. -32
BUTTON HEAD SCREW ON PUMP
BOX AND INSERT GUARD AS SHOWN.
TIGHTEN SCREW SECURELY.
DO NOT USE GUARD AS PULL HANDLE.

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 INSTALLATION INSTRUCTIONS
COUNT-WISE M SHEET COUNTERS Diagram#3, Pagell
1. Open wings on the cabinet until each wing wedges into its corner of the cabinet.

2. Remove table mount bolts, jogging plates, insert tape, breathers (wood inserts), power
cord, bag of hardware, receptacle guard and manual from back of machine box.

3. Lift the counter and place it into the cups on the base cabinet. Slide the counter all the
way foiWard into the wings.

4. Place the table into the wings and into the 11throat" of the counter.

5. Place the small silver hex bolt through the table at the 11 point.. near the throat of the table.
Tighten the bolt so that the table is approximately 1/3211 above the table flap.

6. Install the remaining four (4) long·hex-bolts through the table and the wings. You may
have to move the wings into position.

7. Install the two (2) jogging plates (available on Count-Wise M only) insuring the plates
are parallel with the throat of the machine.

8. Open back panef access door.

9. Remove all packing material from interior of machine. This includes cardboard under·
counting head, two rubber bands holding tapa cover closed and counting head down,
and white plastic wire ties holding counting head down.

10. Install receptacle guard to rear of machine. See page 8 for more detail.

11. Plug power cord into back of machine. MUST BE INSERTED FIRMLVI

AIR FLOTATION SYSTEM

1. Connect the pfug coming out of the top of the base to the receptacle coming out of the
bottom of the machine.

2. Install the hose connector to the underside of the table. Connect the hose coming from
the base cabinet to this connector and tighten.

NOTE: REAR BACK PANEL MUST BE CLOSED FOR MACHINE TO OPERATE.

*****SEE OPERATING INSTRUCTIONS~ SECTION 3***** (Page 13)

Page # 10
 DIAGRAM #3 COUNTWISE-M

Page#·u
 COUNT-WISE I, M & BANTAM TECHNICAL DETAILS
COUNT~WISE I COUNT-WISE M BANTAM
DIMENSIONS:
Weight: 185 lbs /84 kg 275 lbs /125 kg 1601bs/ 72kg
Height: 30 11 /75cm 5511 /138cm 28u /70cm .
Width: 3811 /95cm 42" /105cm 1811 /45cm
Depth: 54n /135cm 5611 /140cm 36"/90cm
*Stack Size: 811 /20cm au I 20cm 611/15cm
Table Dimensions: 27" X 27" 3211 X 32u 1511 X 1811
68cm x68cm 80cm x 80cm 38cm x45cm
(unless special ordered)
SHEET SIZE:
Minimum: 2 1/4" X 511 2 1/411 X 5't 2 1/4" X 511
5.5cm x 13cm 5.5cm x 13cm 5.5cm x 13cm
Smaller sheets can be counted using optional
coupon tray (2 1/4" x 2 3/4"} (57mm x 70mm).
Maximum: Limited only by size of table selected.

*PAPER RANGE: 20 up to 250 G/M2

20 lb Book up to .010 Stock
4 lb Bond up to .010 Stock

SUCTION BLADE GUIDE FOR RANGE OF PAPER TO BE COUNTED

(Choice of 2 with the purchase of any of these three counters.)
2 2
Blade #70: 30 - 75 G/M Blade #71: 50-90 G/M
20 - 50 lbs Book 33 - 60 lbs Book
8 - 20 lbs Bond 13- 241bs Bond

Blade #72: 75 - 110 G/M2 Blade #73: 110-220 G/M2

50 - 73 lbs Book 73 -1131bs Book
20 - 30 lbs Bond 29 - 45 lbs Bond

Blade#74: 20 -30 G/M 2 *Blade #75: 110 up to 250 G/M2

Tissue thru onion skin 00611 up to .010

COUNTING SPEED: CW-l & M: Variable up to_2500/sheets per minute according to texture of paper.
Bantam: Variable up to 2000/sheets per minute according to texture of paper.

*TAB INSERTION: CW-1 & M: 3 TO 9999· Bantam: 5 to 999

ELECTRICAL: 120V AC 60 Cycle, 15 Amps or 230V AC, 15 Amps @ 50/60 Hz (lf you can not
maintain a steady power source, please call us to purchase an optional line
conditioner to insure accuracy.)

CE: Standards to which conformity is declared: CW-1 & M: EN 55022 Class A, EN

55024:1998 & EN 60950 (1992). BANTAM: EN 55011, EN 50082-1 & EN
60204~1.

*NOTE: ACCORDING TO THE HEIGHT OF THE PAPER TO BE COUNTED, BREATHERS {WOOD

INSERTS) MAY BE NECESSARY ON THE CW-1 OR M (SEE PAGE 15). STACK SIZE AND
COUNTING ABILITY MAY VARY DUE TO THE SUBSTANCE AND TEXTURE OF THE PAPER BEING
COUNTED AND THE TABBING RANGE SELECTED. A CURL OF THE CORNER COUNTED IS TO
BE EXPECTED DUE TO THE MECHANICAL OPERATION THAT SEPARATES THE SHEETS.

Page # 12
 SECTION #3: OPERATING
INSTRUCTIONS & SEQUENCE OF
EVENTS DURING OPERATION

Page# 13
 DIAGRAM-BREATHERS

MACHINE
TOP VIEW

BREATHER

Page :It 14
 OPERATING INSTRUCTIONS
1) Counting head should be set up with a suction blade suitable for the paper. Suction
blade chart located on Page 6. (Refer to Page 24 for how to change a suction blade.)

2) Activate main switch at rear of machine to .. ON" position.

3) Turn tab selector to the required insert number.

CAUTION: PRESELECT SHOULD NEVER BE SET LOWER THEN 0005111 Check that reset
on-off and tape length switches are in "ON" position. Where applicable, manually
reset batch and totalizer counters.

4) Load paper on table, locating it firmly against guides; insert breathers (wood inserts) if
necessary.

5) Press ~~start Switch" when lit.

6) At completion of count, clamp will release. Remove paper; counters will reset
automatically.

IMPORTANT
Count-Wise 1 & M: According to the height of the paper to be counted, ~~breathers"
(wood inserts) may be necessary. (See notes below.)

Stack size, counting speed and counting ability may vary due to the substance and
texture of the paper being counted and the tabbing range selected.

A slight curl of the corner counted is normal. The thickness of the stock determines
the amount of curL

BREATHERS -WOOD INSERTS

(REFER TO DIAGRAM PAGE 14)

l'Breathersll (wood inserts) are specially shaped lengths of wood inserted into the stack at
inteNaJs (as shown in figure on page 14) to "loosen" the corner by creating an air space. This
space allows the counting head to operate without damaging the paper or the machine.

The inter'ials at which breathers (wood inserts) should be inserted in the stack follow no hard
and fast rule. Papers vary in weight. texture and finish which wm effect the breather spacing.
Through experience it will be found that, while spacing at 3 in. (76mm) intervals for one type of
paper gives excellent results, another type will require spacing at 4-6 in. (100mm to 150mm),
and yet another type will only be counted with the spacing closer at the bottom than at the top.

Overuse of breathers (wood inserts) must be avoided; an excessive number inserted in the
stack will loosen the corners so much that the 11 FOLLOW-UP 11 of the counting head will bend
them back and give erratic counting.

On thin paper, care should be taken not to damage the sheets when inserting breathers.
Page# 1~
 DIAGRAM-SELF DIAGNOSTIC LEDS ·
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Page 4f 16
 SEQUENCE OF EVENTS- LOGIC BOARD S-3170

1) Plug machine into AC service.

2) Main switch to "ON" position with Safety Switch closed (cover down):

a) Power applied to all circuits

b) Red Power LED activated on Logic Board

3) Material inserted, green Table Sensor/Laser LED #7 activatedJ and Vacuum Pump
turns "ON". Green Vertical Rise Switch LED #8 needs to be an. Red Count Valve
LED #5 activates momentarily to bleed vacuum off system.

4) Pressing Start Switch:

a)· Green Start Switch LED #11 activates an Logic Board

b) Red Clamp Valve LED #16 activates
c) Red 24V DC Relay LED #1 activates

5) Clamp comes down:

a) Red Vertical Rise LED #3 lights

b) Counting Head rises to meet paper
c) LED #1 0 lights
d) When Head tips off Vertical Rise Switch, RED Count Valve LED #5 activates and
vacuum is applied to Suction Blade
e) When vacuum reaches 1911 HG, GREEN Motor Start Vacuum Switch LED #15
turns, activating the RED Speed Control LED #4; AC is applied to Speed Control
via SSRI. Counting Head counts as long as a minimum of 20"HG is maintained.

6) At completion of count, vacuum breaks and AC is turned off to Speed Control. The
Counting Head will rise 2"-3" above the stack of paper and stop.

7) Removing paper from Table Sensor/Laser deactivates Pump Control Relay and the
C_ounting Head lowers to bottom position.

8) Upon reaching bottom position, the Reset Circuit is energized; the ~red Reset LED #2
activates until the Counting Head is in the reset position.

Page# 17
 DIAGRAM #6 LOGIC BOARD

S-3170
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f'LUG1 • PLUG2 PLUG3 PLUG 'I

BLOW UP OF RESET SPEED PINS

Vertical Rise Delay Reset Speed
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Page# 18
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SECTION #4: COUNTING HEAD &
MUUNTENANCESCHEDULE

Page# 19
 LOADING INSERT TAPE

CAUTION: Use extreme care when installing tape so as to not bend or distort
the looper wire. After loading tape, make sure looper switch wire has not been
distorted out of shape and that it is not rubbing against the tape reel cover when
closed. Switch wire must operate freely for proper loop follow-up when tabbing I

or the loop will not keep up and will cause a tape jam or no tape will come out.

1. When back access door is opened power is automatically turned off.

I

2. Loading Insert Tape:

a. Place a roll of insert tape on the counting head as shown in the illustration
on Page 20.
b. Make sure that tape roll is flat (not coned) and center cardboard support is
not "egg-shaped ... Spool must spin and float freely when cover is closed.
c. Close magnetic tape cover.
d. Pull out a 12u to 1411 length of tape.
e. Spread tape loop rollers using tape-loading lever.
f. Place tape between looper rollers.
g. Push end of tape through the chute until it exits the front of the counting
head.
h. Open tape cover; place remaining loop inside. Close cover.
i. Close back access door; turn on power.

3. To cut the excess tape, press the cut tape button located on the front panel.

Page # 20
 DIAGRAM- LOADING..OF INSERT TAPE

4-TAPE LOADING LE

3-INSERT TAPE
S-1036

2-DOWEL PIN

Page# 21
 RESET ADJUSTMENT W /DIAGRAM·

6.

1. Remove counting head from machine. (See instructions, page 23.)

2. Remove both counting head covers.
3. Place ohmmeter on #9 reset switch leads with magnet, #8, away from switch. Meter should
register closed).
4. Position wiper pin #3 as shown above.
5. Loosen allen screw #6; turn reset magnet carrier #7 until meter registers 11 0pen11 • See figure
above.
6. Tighten screw #6. Check tightness - allen screw #1 0.

COUNT ADJUSTMENTW/DIAGRAM

(-~-~------"") : 0

7 6.

1. Remove counting head from machine. (See instrudtions, page 23.)

2. Remove counting head left cover.
3. Place ohmmeter (#9) on count switch leads (with magnet (#8)
away from ~witch; meter should register .open).
4. Position wiper pin #3 as shown above.
5. Loo~en allen screw #6; turn count magnet carrier #7 until
meter registers closed. See figure above.
6. Tighten screw#6. Check tightness- allen screws #10.

Page 41= 22
 COUNTING HEAD REMOVAL

1. Pull plug from counting head. (NOTE: Grasp plug (not wires) when unplugging
cable and hook into white clip).

2. Pull off vacuum hose~

3. Loosen wing nuts on left and right pivot bearing housing, and lift hinged top off
bearing.

4. Remove counterpoise spring by unhooking "8 11 clip from dashpot bracket.

5. Grasp front of counting head by vacuum shaft housing and the back of counting
head. Carefully lift head out.

REMOVING COUNTING HEAD CENTER PLATE

1. Remove counting head from Machine; remove counting head covers and insert tape.

2. Unscrew vacuum line from suction blade housing ..

3. Place screwdriver on the outer side top of 15-pin plug. Press down and in. Plug wilt
disconnect from plate. (Plug should hang free inside counting head.)

4. Disconnect 3-pin motor plug.

5. Remove 2 allen head screws from bottom of base plate connecting center plate.
Carefully lift center. plate out.

NOTE: When replacing center plate, positior.l on steel guide pin and gently push
into position. Take care that drive gears are properly meshed before tightening allen
head screws.

REPLACING COUNTING HEAD

1. Place counting head into pivot bearing housing. Take care to position left side
bearing squarely between guide pins located in left side housing. Close hinged
top onto pivot bearing and tighten wing nuts.

2. Connect counterpoise spring "S" clip into hole provided in rear of dashpot
bracket.

3. Plug cable into counting head and reconnect vacuum hose.

Page# 23
 COUNTING HEAD INSTALLATION AND ALIGNMENT**

1) Raise carriage assembly approximately halfway. Loosen pivot block bolts from
carriage base plate.
2) Mark center of suction blade directly behind suction hole.
3) Lower carriage assembly and stop when suction blade is level with tabletop
surface.
4) Insert paper squarely into throat or jog of machine over suction blade.
5) Viewing from top, adjust counting head until corner of paper is on centerline mark
on blade ~nd approximately 1/16" (1.59mm) from back edge of blade.
6) Move right pivot block 1/16 to 1/4 of an inch forward, causing right side of head to
be closer to paper.
7) Raise counting head again approximately halfway and tighten pivot blocks to
carriage base plate.
8) Hook counterpoise spri~g to dash pot bracket.
9) Insert a 3/8u (9.54mm) spacer block between carriage base bracket and counting
head base to level head.
10) Loosen set screw on dash pot assembly (setting to be at #5 or mid range) and
adjust dash pot plunger so that a 1/16 to 1/8-inch gap exists between the plunger
and suction blade· housing. Tighten nuts.
11) Remove 3/8 .. (9.54mm) spacer and lower counting head leveling bolt on rear of
dash pot bracket to give approximately 1/16n (1.59mm) gap between dashpot
plunger tip and base of suction blade housing. Tighten.
12) To set vertical rise setting: Turn mushroom cap bolt into vertical rise switch
button until you hear click. When it clicks, adjust approximately 1/16th of a turn
into vertical rise switch, hold and tighten.
13) Adjust counterpoise spring tension to lightly pull counting head down.
Approximately half the length of the bolt or less is satisfactory.

**Refer to photos on pages #84 and 86.

ADJUSTMENT IS CRITICAL FOR PROPER FOLLOW-UP THRU PAPER.

Page # 24
 · HOW TO CHANGE A SUCTION BLADE**

1) Turn off power receptacle and disconnect cord.

2) Remove counting head from machine (Refer to instructions, Page 23).
3) Holding the link arm, loosen the allen cap screw in the center of the blade and
remove the blade from the holder.
4) Take the blade required, line up the locator pin with the slot in the holder and install
I

1he blade.
5) Again holding the link arm, tighten the allen cap screw in the blade.
6) Reinstall and connect counting head.
Turn on power. The machine is ready to count.

SETTING VERTICAL RISE SWITCH**

1) With Counting Head in machine, loosen "locking nuf' on Vertical Rise Actuator.

2) Adjust the Vertical Rise Actuator so it lifts off the Vertical Rise Switch.

3) Screw the Vertical Rise Actuator onto the Vertical Rise Switch until you hear the
switch click or switch close. ·

4) Turn the Vertical Rise Actuator no more then 1/16" (3.175mm).

5) Tighten the Locking Nut.

SETTING THE COUNTER POISE SPRING**

1) Loosen wing nut on Counter Poise Spring Bolt.

2) Adjust tension of spring by turning the Counter Poise Spring Bolt so that there is
sufficient tension on Counter Poise Spring to ensure that the head of the Vertical
Rise Actuator will engage into the Vertical Rise Switch.

3) Secure bolt by locking wingnut.

**(Refer to photos on pages #84 & 86)

Page# 25
 DIAGRAM-ORBIT ADJuSTl\1ENT

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Page 41= 26
 ORBIT ADJUSTMENT

CAUTION: Read and understand all instructions before attempting this adjustment.

1) Remove counting head from machine. *

2) Remove both covers and tape spooL

3) Disconnect small vacuum line from suction blade housing, 15-pin plug from side
plate and disconnect 3 pin motor plug. *

4) Remove 2 screws from bottom of base connecting center plate and carefully lift
plate out.*

5) Loosen Allen screw on small crank arm #1. Rotate and hold crank arm at
maximum forward position so that allen screws are facing downward.

6) Loosen allen screw on large crank arm #2, and raise back edge of suction blade
#5 approximate 2 degrees above level. Lightly tighten screw.

7) While holding small crank arm (#1), at maximum forward position) rotate main
shaft (#9) until top of wiper pin (#3) is flush and parallel with front surface of
suction blade (#5) afld approximately 1/8n (3.18mm) away from front edge.

NOTE: Adjustment of push rod (#8) may be required to obtain this setting. (Loosen 2
screws (#13) on orbiter assembly to adjust)

8) Lightly tighten all screws.

9) Continue rotating wiper pin (#3) under suction blade {#5) and around back
edge. Set clearance of approximately 1/811 (3.18mm) between wiper pin (#3)
and back edge of suction blade (#5) by loosening screw (#14) and rotating
rocker arm adjustor (#15). Lightly tighten screw.

10) Continue rotating wiper pin (#3) across top surface of suction blade (#5) to
achieve approximate 1/1611 (1.59mm) clearance. Set this by adjusting push rod
(#8) length. (Refer to note in step 7.)

11) Rotate wiper pin (#3) around blade (#5) observing all clearances. Repeat
procedures·s through 10 if necessary to obtain uniform orbit.

12) Tighten all screws securely.

*Refer to procedures on Page 23.

Page# 27
 DRA~G:CO~GHEADCENTERPLATEITAPECHUTE

11
Tape Cora·
Support
12
Low Tape~
Switch ~
10
Tape Guida

·i
i
Page # 28
 HOW TO REMOVE A TAPE JAM

1) Remove head from machine. (Refer to ~~counting Head Removalu Page 23.)
2) Remove both head covers.
3) Push small knurled wheel against large knurled wheel and rotate the main shaft
to 11 back-out" the jam in the chute.

***NOTE: On 2000 + models, the internal size of the chute has been
increased and the slot has been extended for easier removal of tape jam.

4) If step 3 doesn't work, use a small pair of needle-nose pliers or tweezers, grasp
the tape and pull the jam from the chute. Do not damage knurled wheels by
"picking11 at the tape with a screwdriver and be careful to not damage the tape
chute by scoring or burring where the tape travels.

5) If step 4 did not work, removal of knife assembly is necessary. Do not pick at
tape thru knife or serious damage will result to knife assembly.

a) Unhook black connecting link S-6283 from teardrop.

b) Loosen the #1 0-32 nut and remove #1 0-32 allen cap screw. (#1)
c) Carefully lift knife assembly (#13) off of tape chute.(#3)
d) You will now see the tape protruding from end of chute. Grab tape with
small needle nose pliers and pull straight out.
e) While you have knife assembly out, this is an excellent time to internally
clean the knife. Remove anvil from barrel and clean both pieces with a Q-
tip and acetone.. DO NOT OIL THIS ASSEMBLY.
f) Reassemble knife and carefully place back onto tape chute.
g) Replace #1 0-32 allen cap screw until it "bottoms ourll in knife. Do not over
tighten or damage will result to end of tape chute.
h) Adjust screw so the tape will exit from center of slot. Hold and tighten nut
securely.
i) Reattach connecting link S-6283.

6) If step 5 did not work, the tape chute will have to be removed. (See directions on
following page.) Using a small torch. heat area of tape to "burn oue the tape
jam. Pass a new piece of tape thru the chute to clear. Or, you may order a new
s.
chute, 6Q56-1, if necessary.

Page# 29
 TAPE·CHUTE REMOVAL
(Refer to drawing on Page 28)

1) Remove screw #1.

2) Loosen nut #2. (Do not remove).
3) Slide Tape Chute carefully out of Knife Assembly and 11 L" bracket, #14.

REPLACING TAPE CHUTE

1) Replace chute carefully into Knife and "L" bracket, #14.

2) Replace screw #1 (Do not tighten).
3) Insert tape into chute until tape comes through Knife Assembly smoothly. If
restrictions are felt, move the Chute out of the Knife Assembly slightly until the
tape passes smoothly through the knife. Tighten nut #2.
4) Reinsert tape into chute and push tape to the tape chute slot #15.
5) Position chute so that tape lightly brushes bottom knurled drive wheel while
passing over slot #15.
6) Secure screw #1.

Page ·if 30
NOTES

Page# 31
 CHANGING THE TAPE SOLENOID
<Part S-3103,

(These instructions reference Photo and parts on pages 33 & 35.)

1) Remove Center Plate (Refer to instructions~ Page 23).

2) Remove 11Tape DrivelJ (#R9) by removing 2 allen screws.
3) Using 1/211 (12.7mm) socket, remove nut holding the Tape Solenoid to the Center Plate.
4) Push back the sleeve over the solenoid wires and cut the wires.
5) Take the wires of the new solenoid and solder them to the cut wires. Use shrink tube or
electrical tape to cover solder connections.
6) Replace the 1/2" nut that holds the solenoid to the center plate.
7) Replace Tape Drive with the 2 allen screws. Before tightening, make sure the·gear of
the top tape drive is engaged with the gear of the bottom tape drive.
8) Push the top tape drive so that both knurled wheels touch.
9) Turn the solenoid plunger into the solenoid while holding down the top tape drive until
you feel the top tape drive being pushed away.
10) At this point, turn the plunger one full turn away from the Tape Solenoid.
11) Tighten plunger nut.

REMOVAL OF KNIFE ASSEMBLY (S-6285-1)

1) Remove connector link arm (#R17) from tear drop (#R14) of knife.
2) Loosen locking nut and remove allen screw.
3) Remove Knife assembly from the end of tape chute and adjusting plate.

***DO NOT USE OIL ON KNIFE ASSEMBLY.***

REPLACING KNIFE ASSEMBLY (S-6285-1)

1) Position knife on tape chute. Turn allen head screw into knife adjusting plate until screw
"bottoms out".
2) Attach knife connecting link arm (#R17) to tear drop (#R14).
3) Push tape through until it comes through the knife anvil. (Tape must travel smoothly
through anvil.) Slightly turn the aUen head screw clock~wise or counter-clockwise until
tape flows smoothiy.
4) Lock down the locking nut. (#R15).
5) Depress knife solenoid and ascertain knife blade completely passes over anvil slot with
over travel not to exceed 1/32.. (.79mm). This adjustment is made via the connector link
arm (R#17).
6) Place counting head in a flat position. Push tape through chute until tape hits bottom of
blade, approximately mid~way. Adjust the angle of the knife anvil using the allen head
screw.

DO NOT USE OIL ON KNIFE ASSEMBLY.

Page # 32
 PHOTO-COUNTING HEAD CENTER PLATE, RIGHT SIDE

Rl R2 R3 R4 R5 R6

Rl3

R12

RlO

R15

Rll

R14

R1- Vacuum Switch (S-3043-1) R10- Knife (S-6285-1)

R2- Tape Loading Lever (Ass'y- S-6045) R11- Knife Linkage (S-6283)
R3- Looper Stop Switch (SM31 05) I R12- Allen Screws
R4- Looper Driver Motor (S-3106-1) R13- Nut
R5- Looper Drive Belt (S-6062) R14- Tear Drop
R6- Knife Solenoid (S-3102) R15- Locking Nut
R7- Reset Reed Switch (S-3107) R 16- Knife Adjusting Plate
R8- Tape On I Off Switch (S-3140) R17- Connecting Link Arm
**If equipped**
R9 - Tape Drive (S-6250)

Page# 33
 NOTES

Page # 34
 Photo Counting Head Center Plate Left Side

11- Low Tape Actuator 15- Tape Chute (S-6056-1)

12- Looper Drive 0-Rings (S-6054) 16- Count Reed Switch (S-31 08)
13- Looper Drive Wheels 17- Knurled Wheels (S--6250-E)
(S-6021, Not Shown)
14- Tape Solenoid (S-3103) L8- Looper Stop Actuator (S-3105-A)

Page# 35
 NOTES:

Page # 36
 NUUNTENANCESCHEDULE
1. Filter Assemblies (vacuum manifold & counting head): Remove jars and clean fitters
daily. Depending on dust and paper material, more frequent cleaning or replacement of
filters may be necessary. Be sure jars are tight to avoid vacuum leaks.

2. Wiper Pin Bearings (*Critical): Due to the extreme load placed on the wiper pin
assembly. it must be checked daily for free spinning and !1Q excessive up and down
movement To lubricate: Remove brass end cap using a large tipped, flat screwdriver
and push assembly through housing. Use either Teflon based oil, any high-grade motor
oil or lithium or teflon grease and place directly onto bearings. It is not recommended to
use multi-oil or light household oil because it will not adhere to the ball bearings.
Lubricate weekly or every 40 hrs of operation.

NOTE: Depending on usage and material dust, more frequent lubrication may be required. Be
sure end cap is tight.

3. Knife Assembly (*Critical): The knife assembly should be checked daily for free
movement. If knife appears sluggish, use a high-pressure contact cleaner and spray
directly onto knife. Disassembly of the knife may be required to clear barrels internally if
sluggishness persists. Do not use any oil on knife assembly. This will attract dust and
cause knife malfunction.

4. Tape Loop Drive (*Critical): To ensure proper tape loop and tabbing, the tape loop
drive must always spin freely. Check that all a-rings are in place. If tape loop drive is
binding, it may have to be disassembled and lubricated using a light oil. When
reinstalling, do not sandwich pieces together tightly. Remember that it must move
freely. Inspect and check monthly (every 30 days).

5. Counting Blade: The wiper pin must orbit the blade without coming in contact with it.
Any scoring of the blade can cause tearing, miscounts, or marking of the stock being
counted. If blade shows signs of wear, it must be replaced. If paper chips or dust
becomes lodged in blade, it must be removed and cleaned. When reinstalling, make
sure housing seat and bottom of suction blade are clean and be sure blade is tight to
avoid vacuum leaks.

6. Additional lubrication points (lubricate weekly, or every 40 hrs of operation, using a

light oil):
Pivot bearings (on sides of head)
Connecting ling bearings (dog bone assembly)
Rocker arm assembly (in head; remove covers)
Tape drive assembly (in head: remove covers)

NOTE: Do not spray lubricant inside mechanical parts on head; this action can and will cause
head failure. If you have any questions, contact the factory.

7. Inspect upper and lower knurled wheels and gears. Check all mechanical and electrical
connections for tightness.

8. Machine: General cleaning of machine may be done using a store bought glass cleaner
or aU-purpose cleaner.

NOTE: Remove any tabs from bottom of machine that could block the laser pick-up assembly.

Page# 37
NOTES:

Page =IF 3&

SECTION #5: TROUBLE SHOOTING

Page# 39
 CALL U.S. PAPER COUNTERS

SERVICE DEPARTMENT

AT 5.18-622-2600

FROM 8:30 AM TO 5 PM EST,

MONDAY THRU FRIDAY

YOU CAN ALSO

FAX TO 518-622-2695

OR
-
E-MAIL TO uspc@wecount.com

Page # 40
1. No power. Power switch in the off
position.
2. Power LED on a) Main power fuse blown.
logic not lit. b) Safety switch (EMO) not
set/reset.
c) Bad interlock.
d) Bad logic.
a) No power.
3. Vacuum pump
doesn't start.
b) LED #7 on logic board
not lit.
c) Solid state relay (SSR)
on pump plate not turning
on (LED 7 is lit).
d) Lower laser receiver bad.
4. Vacuum pump a) Obstruction (tabs) over
doesn't stop. lower laser receiver.
b) Laser not aligned.
c) Laser dim or not lit.
d) Bad logic board.
5. Decade (overage) a) F2 fuse blown.
not lit. b) No voltage going to ECU.
c) Bad ECU.
·Turn switch to the on position.
a) Replace fuse.
b) Set (EMO) to correct position.
c) Close rear cover~ check cover safety
switch.
- Check AC pins 3 & 4 on interlock. If no
AC, check plug 1 pins 8 & 9 on logic
board.
d) Check for broken wires.
- Replace logic board.
a) Check procedure for 'No power• (#1
above).
b) Check plug on receiver.
c) Check for DC voltage on SSR pin 1 & 2
-If you have voltage, jump relay.
Replace SSR.
-If no voltage, check for broken wires.
d) Replace receiver.
a) Clean lower laser of obstructions.
b) Check alignment.
c) Replace laser diode assembly (test witt
flashlight).
d) Check DC voltage on plug 4 pins 6 & 7
on logic.
-Replace logic board.
a) Replace fuse.
b) Check ECU 9 pin-plug pins 8 & 9 for
AC.
c) Replace ECU.
Page# 41
 a) Broken wire.
6. Counts fail to
register while machine
b) Bad count reed switch.
is running.
c) Vacuum switch out of
adj. or bad.
d) Defective ECU.
7. Count registers,
a) Tape length too short.
but no tabs in stack.
b) Knife sticking.
c) No tape loop.
d) Loose connection on
ECU/ broken wire.
e) Tape chute out of
adjustment or jammed.
f) Bad solenoid/ECU.
g) Bad totalizer board.
h) Bad in-line fuse I Blown
F3 fuse.
8. Count registers a) Sticky knife.
but no knife or batch b) Loose connection of
counts. ECU.
c) Broken wire.
d) Bad ECU.
9 . Decade and batch a) Sticky knife.
counter register but b) Broken wire.
no knife. c) Broken knife linkage.
Page ff 42
* Use a non-residue electronic cleaner (do not use a silicone spray)
a) Check continuity of coax cable from
ECU (9-pin plug pins 1 & 2 to head
cable).
b) Replace switch.
c) Check vacuum switch settings ( 17
%J) hg). Jump vacuum switch; if
counts register, replace.
d) With power on, jump between 9-pin
plug on ECU pins 1 & 2.
-Replace ECU.
a) Adjust length.
b) Clean knife.*
c) Check loop follow up, a-rings, looper
switch and motor.
d) Check pin 3 &6 on 9 pin plug.
e) Adjust chute or clean.
f) Check continuity from ECU pins 3
and 6 to counting head cable.
- Jump pins 3 & 6; listen for click
from knife.
g) Replace ECU.
- Unplug totalizer board; if decade
runs and tabs, replace total
board.
h) Replace fuse.
Refer to steps under ~~count registers,
but no tabs in stack~~ (#7 above).
a) Clean knife*.
b) Check connections of white/brown
wire in head cable.
c) Check knife linkage from knife to
solenoid.
Replace parts as needed.
10. Tape and/or knife Bad ECU.
operate continuously.
11. Miscounts, a) Wrong suction blade for
undercounts, or stock being counted.
overcounts. b) Bad count reed switch.
c) Vacuum switch bad,
clogged or out of adj.
d) Bad pre-select
e) Vertical Rise out of
adjustment.
11
12. Decade fails to a) Reset switch in 0ff,
reset position.
b) Broken wire on "Start
Switchn.
13. Insert tape not a) Tape length too short.
entering stack or . b) Counting head alignment
falling out. (depth of corner) not
correct.
c) Tape retaining springs
out of adj.
d) Head timing is out of adj.
(count reed).
*Use a non-residue electronic cleaner (do not use a silicone spray)
Replace ECU
(May need to replace solenoid)
a) Refer to counting blade chart for
correct blade.
b) Test reed switch for proper function;
replace if needed.
c) Clean, adjust or replace vacuum
switch.
d) Test 4 corners of the stack without
tabbing; if all corners are the same,
replace pre-select.
e) Check VR switch settings.
a) Move switch to correct position or
replace.
b) Test blue wire from start switch to
reset switch.
a) Adj. tape to a 2 % -2%, length.
11
b) Check depth of corner.
c) Set retaining springs.
d) Set timing with meter (call factory).
(Refer to 'Tearing or chipping
corners• at #24 below for more info.)
Page# 43
14. Knife partial cutting a) Sticky knife.
or half cuts. b) Linkage sticking.
c) Weak pulse from ECU.
d) Bad ECU.
e) Bad cutting edge on
knife.
. a) Laser out of alignment or
15. Clamp not blocked by tabs.
lowering.
b) Vertical rise switch out of
adjustment.
c) Bad start switch.
d) Blown fuse.
16. Clamp lowers as a) Bad start switch.
soon as paper is placed b) Bad clamp valve.
in throat of counter. c) Bad logic board.
a) If logic board was
17. Counting head replaced, check VR
does not rise. jumper settings on board.
b) VR switch out of Adj.
c) Blown F1 or F3 fuse.
d) Bad 24 VDC directional
relay.
e) VR sprocket loose.
f) Bad logic board.
a) Laser obstructed, out of
18. Counting head alignment or dim.
does not lower.. b) Down limit switch out of
adjustment.
c) Blown F1 fuse.
19. Counting head fails a) Filters. counting head or
to stop after- counting is Vacuum lines clogged.
complete. b) Motor Start Vacuum
switch out of adj. or bad.
c) Bad logic board.
Page # 44
a) Clean knife & linkage*.
b) Check for binding or worn parts.
c) Adj. uKn pot on ECU.
d) Replace ECU.
e) Replace knife.
a) Align laser.
b) Set VR switch.
c) If LED 11 doesn't light when start
switch is pressed, replace switch.
d) Replace F3 fuse on logic board.
Refer to sequence of events.
Replace parts as needed.
a) Move jumpers to match VR motor
in machine.
b) LED #8 on logic must be lit; check
and adjust VR switch.
c) Check fuses; replace if needed.
d) LED 1 should be lit when relay is
energized; replace if needed.
e) Tighten setscrew or replace roll
pin.
_f) Replace logic board.
a) Clear. adjust or replace.
b) Check 24VDC relay on logic
board.
- Check LED #1 0 on logic. Must
be in up position (adjust switch).
c) Replace fuse.
a) Clean vacuum filters. head and
line.
b) Check switch settings.
c) Replace logic board.
20.. Counting head fails a) Vacuum pressure too low a) Adjust vacuum relief valve.
to start counting. (min. 22hg on gauge
needed to start).
b) Vacuum leak.
c) Motor start vacuum
switch out of adj. or bad.
d) Blown F4 or F5 fuse.
e) Speed control set to off. e) Increase speed.
f) Bad counting head motor. f) Check voltage at counting head
g) Wrong suction blade for
stock.
21. Counting head a) Wrong counting blade.
stops counting before b) Stack being counted is
counting is complete. not jogged properly.
c) Stack too loose.
d) Speed too fast or too
slow.
e) VR switch travel not set
correctly.
f) Counter poise spring not
adiusted correctly.
22. Continuous reverse a) Bad reset switch.
rotation of wiper pin for
reset. b) Weak magnet or magnet
broken or missing.
c) Bad logic board.
23.. Counting head fails a) Bad logic board.
to reset after counting.
b) Bad counting head motor.
b) Check for vacuum leak (filters,
lines. etc.).
c) Set Vacuum switch to 19nhg or
replace.
d) Replace fuse(s).
motor: replace if needed.
g) Install correct suction blade.
(Refer to "Suction Blade GuideJI)
a) Check blade chart for correct
counting blade.
b) Check jog of paper.
c) Check spring blade and blade
stop for proper adjustment.
d) Adjust coun~ing speed.
e) Adjust VR switch and counter
poise spring.
f) Adjust Counter poise spring.
a) Test Reed Switch and replace if
needed.
b) Check magnet and replace if
needed.
c) Move reset speed jumper on logic
board; or
Replace logic board.
a) Check LED #2 on logic; if not
flashing replace logic.
b) If it is flashing~ check voltage at
motor. 1f voltage at motor, replace
motor.
Page# 45
 a) Orbit out of adj.
24. Tearing or chipping b) Wiper pin not spinning
of corners. freely or bad wiper pin
bearings.
c) Bent wiper pin.
d) Incorrect suction blade.
e) Counting speed set too
fast for stock being
counted.
f) Vertical rise (VR) switch
not set properly.
g) Depth of corner off.
h) Bad spring b1ade or blade
stop set to wrong angle.
i) Stack too high for
quantity tabbing in.
a) Orbit out of Adj.
25. Folding corners. b) Bad Wiper pin bearings
or wiper pin (pin needs to
spin freely).
c) Depth of corner off.
a) No tape loop or not
26. Erratic tape keeping tape loop.
lengths ..
b) Bad Looper motor or bad
looper stop switch.
c) F2 fuse blown.
d) Tape chute out of
alignment.
Page # 46
a) Reset orbit.
b) Replace bearings.
c) Replace wiper pin and bearings.
d) Install correct suction blade.
e) Reduce counting speed.
f) Set VR switch.
g) Set depth of corner.
h) Replace spring blade;
- Adj. spring blade stop
(stop should have·slight downward
bend).
i) Shorten stack height or insert
"breathers. fJ
a) Reset orbit.
b) Replace bearings and/or wiper pin
c) c. Set depth of corner.
a) Set actuator wire on looper switch.
- Check and replace drive o..rings,
if needed.
b) Check for AC at pins 7 & 9 on
head cable; if voltage is present,
check looper switch for continuity.
c) Replace F2 fuse.
d) Adjust tape chute.
SECTION #6: ELECTRICAL SYSTEM

Page# 47
 ELECTRICAL SYSTEM

LOGIC CONTROLLER
24DCRELAY

_ De-Energized switches Vertical Rise motor leads to "down11 position.

Energized switches Vertical Rise motor leads to uup" position.

SSRl

Supplies 120V AC ± 5% to speed control.

SSR2

Supplies 120V AC ± 5% to vertical rise motor via 24V DC relay.

F3 (Page 49)

Fuses for counter function

***Also See page 18. ***

Page # 48
 E

A B c D

FO- F5 Fuses
FO- *A & *B Fuse 10Amp.5X20mm- Mains (*16 Amp with air
table)
F1 -. 75 Vertical Rise Motor for Dayton Motors
2Amp. SLO/BLO for Bodine Motor
F2- 1Amp. ECU I Looper
F3 - 3Amp. + 42V DC
F4- 5Amp. Speed Control AC In
F5 - 5Amp. Speed Control AC Out

* - Different styles available depending on machine

Page# 49
 . COUNTWISE SPEED CONTROL
15DV PARTS PLACEMENT "&-LIST

RESISTORS* CAPACR'QRS DIODES

R1 100K C1 .1ufSJV 01 1N91-4B
A2 150K C2 ..tl.lfSOV DZ 1M4005
A3 33KW C3 .otuf1(X]V D3 1N4005
Fl4 22K C4 2..21lf !rJV N..Pw 04 1l'l40tl$
. fl5 1Q cs 2.2ufsrN D5 S&\4
Ra
J17
33K
5I< SPeDPOT cs .o1uf10lV D6 D4C15L
Fl8 2-2M D7 D4015L
D8 ·1NS638
mo
R11
R12
=::zw
220K
1K~ · ·
MJSCBJ.ANEOUS
D9
010
1N4005
1N4005
R13 .D6206W
~~:· =~~COM?.)
R16 ~1111MPOT (MIN.)
Fl17 ~

ACTIVE DEVICES
01 S07JW'$ G-MOV
02 2N6!t7
03 2N6520
04 $401$1... SCR
OS S40t!LSCA
06 2N412S
U1 W3581C

Page # 50
 PHOTO & PARTS LIST-FACEPLATE CW-M

GHIJKL

A Emergency Stop (EMO) (S-3188) H Tape Cut Switch (S-3119)

B Low Tape Indicator (S-3111-A) I Tape Length (S-3048)
c Batch Counter (S-3062-*) J Blower On I Off (S-3058)
D Reset On I Off Switch (S-3056) K Speed Control (S-3047-*)
E Totalizer wl Memory (S-3062-*) L Pre-Select (S-3065-*)
F LED Display (S-3067)
G Start I Stop Switch Ass'y (S-3049-*)
Start I Stop Switch (S-3049-*)
* - Different styles available depending on machine

Page# 51
 Control Panel Key- Max Bantam: 2001 to present.

1. FACEPLATE
2. I LED DISPLAY Displays paper count
3. PRE-SELECT lays batch number selected by user
4. LOW-TAPE DC voltage supplied by the electronic counting unit via the
INDICATOR (S-3111-A) low-tape switch located in the counting head, behind the
tape reel.
5. RESET ON-OFF· "ON" position: overage display on the electronic counting
SWITCH (S-3056) unit will zero when start switch pushed.
"OFF'' position: display will maintain number from
previous batch and continue from that number/
6. TAPE LENGTH 500K with ON/OFF switch. Controls length of tape as it is
POTENTIOMETER being inserted into pile. "OFF" disconnects power to tape
(S-3048) and knife solenoids, low-tape indicator and batch counter.
7. START SWITCH -
Supplies 5 volts DC to the Logic Controller
START SWITCH LAMP - 5 volts DC supplied from Laser Sensor
(CALL FOR PART#)
8. N/A N/A
9. RUBBER FEET Support faceplate against chassis

10. N/A N/A

11. BATCH COUNTER Function: counts tabs inserted. Powered from electronic
counting unit; knife pulse 42V DC. Will not operate with
tape length potentiometer in "OFF" position. Reset
accomplished with button on "Batch Counter".
12. TOTALIZER WITH Voltage supplied by 42V DC power supply; count input
MEMORY from count proximity and count vacuum switch located in ·
counting head, via coax cable. Reset accomplished with
button on "Totalizer".
13. COUNT SPEED Supplies up to 90 V DC to counting head motor. Speed
CONTROL control is supplied from output ofSSRl. NOTE: Speed
control can be turned "OFF" for circuit testing.
14. KEY LOCKS (S-1 0 17) Secures face plate. (Keys included.)

15. TAPE CUT (S-3119) Manual tape cut (after changing roll of tabbing paper).
16. EMERGENCY STOP Emergency Stop Switch. Push to cease operation and stop
(EMO) (S-3118) power to the machine.
Page # 52
MAX BANTAM CONTROL PANEL 2001 & AFTER

,Qa
1Cnu
·uJ;;!;t

Page# 53
 Control Panel Key- Max Bantam: Pre-2001.

1. FACEPLATE

2.' PRE-SELECT Display~ batch number selected by user.

DO NOT SET PRE-SELECT TO "000" UNLESS
TAPE LENGTH POT IN TURNED TO "OFF".
3. LED DISPLAY Displays paper count.

4. RESET ON-OFF "ON" position: overage display on the electronic

SWITCH counting unit will zero when start switch pushed.
"OFF" position: display will maintain number from
previous batch and continue from that number.
5. NYLATCH FASTENER Secures face plate

6. COUNT SPEED Supplies up to 90 volts DC to counting head motor via

CONTROL Solid State Relay# 1 (SSRl)

?. START SWITCH - Supplies 5 volts DC to the Logic Controller

8. LOW-TAPE LED DC voltage supplied by the electronic counting unit

via the "Low-Tape" switch located in the counting
head behind the tape reel.
9. TAPE LENGTH 500k with ON/OFF switch; controls length of tape.
POTENTIOMETER "OFF,, disconnects power to tape and knife solenoids,
"Low-Tape'' indicator, and batch counter.
10. LOCK Secures faceplate; prevents unauthorized access to
control panel.
11. TOTAL I BATCH Counts total sheets - OR- number of tabs inserted.
COUNTER. (Reset accomplished by pressing button located on
counter.)
12. TOTAL/BATCH If switch is set to '.'TOTAL'', the total number of
SELECTOR SWITCH SHEETS COUNTED will be displayed. If switch is
set to "BATCH", the total number of"BATCHES", or
number of tabs inserted.
13. TAPE CUT SWITCH After install new roll of insert tape, this switch is used
to cut off excess tape at the knife.

Page # 54
 12 2 3

MAX-BAN AM 4

I~
5

~I TOTAL@ BATCH ~RESET~N

~
818
OFF o:;
~~
PRE-SELECT

10
~
{]
11 I
0 0
z
13
Ttef

(i) 10*
OFF"-..~
100/ \""
LDVI

0
STAR\
TAPE

~
o/oFF
.. ""100
1

6
I~
~
10
~
~
/ TAPE LENGTH COUNT SPEED

~~
BY U.S. PAPER COUNTERS, INC. IN U.S.A. I 1r
1-d
·/ '7
9 ~
.. I
~
0

.,
AX BAN AM FAC PLAT c
)o-ol
C>
~
,=#::
VI
VI
NOTES

Page # 56
SECTION #7: BASIC ADJUSTMENTS

Page# 57
 VACUUM SYSTEM

Manufactured by Thomas Industries; standard voltage 11 OV AC or

VACUUM PUMP 230V AC, 50/60 Hz; optional voltage is available. Powered by "Time
"E,, Delay" relay. Maximum output 29 Y2» HG.
(110- S-3004-3)
(220 - S-3004-4) NOTE: Vacuum may vary due to altitude and barometric pressure.

CLAMP VALVE Four-way vacuum valve, operates clamp cylinder.

(S-3041-1)
(Not Shown)
Applies vacuum to suction blade when counting head tips off vertical
COUNT VALVE rise micro switch. Valve de-energizes when clamping circuits released.
"I"
(S-3042)
START Manually adjusted to operate at 19" HG. When hole on suction blade is
VACUUM SWITCH exposed to atmosphere, counting head vacuum switch opens breaking
"H" circuit to counting head.
(8..3043-1)
(Refer to page 60, "Setting Vacuum Switches',)

COUNT CONTROL (PAGE 33, KEY #Rl) Manually adjusted to operate at 17 Y2" HG.
VACUUM SWITCH Wired series with Count Reed Switch. Assures the accuracy of the
count. Open when last sheet is counted.

Page # 58
 PHOTO & PARTS LIST-POWER SUPPLY & VACUUM AREA

B C D E F G H I J
A Power Supply Assembly .-.:G, Filter Housing Assembly (S-4018)
' ·-_

(S-3008-1) Plastic Rivet (S-4018-A) Glass Filter Jar (S-4006)

6 Vacuum Pump Cut-off (S-3132-2)
' 'Vacuum Pump Cut-Off w/ Air 18-3132-*)
:(~> Vertical Rise Motor (S-3005-*)
D Startin_g Cap. VIR Motor (S-3007)
E Vacuum Pump 110 (S-3004-3)
Vacuum Pump 220 18-3004-4)
F Vertical Rise Switch (S-3114)
* - Different styles available depending on machine
FUter Stem (S-4018-B)
Filter Element 2 (S-4019)
Art- Vacuum Switch (S-3043-1)
~-1 Count Vacuum Valve (S-3042)
J Cover Safety Switch (S-3165)
-K Lower Laser System (8 . .3079-l)

Page# 59
 SETTING VACUUM SWITCHES

Adjusting your vacuum s\-vitches does not change the output of vacuum frotn your
pump. Adjustment occurs when the switch closes. For instance, setting the count
control vacuum switch to 17-1/2 Hg allows the machine to register a count when
this vacuum is achieved. To set your switches> use the following method:

1. Turn off power, remove counting head (refer to Page 23) and place on table
in front of machine.
•·.

2. Hook up an extended hose to the counting head from the hose in the back.

3. Remove the main cover from the counting head and put a meter across the
first and last lead of the count control vacuum switch.

4. Remove white/grey wire from tnotor start vacuum switch.

5. Apply power.

6. Put something over your Laser Sensor so that the pump comes on. While
holding down the "Vertical Rise Switch", press the "Start Switch"
momentarily. The clamp should come down and the carriage \Vill rise.
Release the "Vertical Rise Switch". Vacuum should be coming through the
blade. Gauge should read approximately 15" Hg.

7. Slowly cover up the Suction Blade hole. Watch the vacuum gauge and,
when it reaches 17-l/2lf Hg, there should be continuity through the count
control vacuum switch. If continuity is reached before the gauge reaches 17-
1/2" Hg, count control switch should be adjusted clockvvise. If it is above
17-1/2 19 Hg, adjust counter clockwise to lower setting (see Page 56). Repeat
step until desired reading is achieved.

8. For the ''Motor Start Vacuun1", place the leads of the meter across the first
and last lead of that switch. Slowly cover up Suction Blade hole, observing
the vacuum. When the vacuum reaches 19 11 Hg, this switch should have
continuity.

9. Put machine back together. Remember to put wire back on motor statt
vacuum switch.

Page # 60
 VACUUM SWITCH ADJUST1\1ENT
VACUUM SWITCH SETTINGS:

MOTOR START VACUUM SWITCH...... 1911 !Jg.

COUNT VACUUM SWITCH........... 17-1/211 Hg.

ALLEN SCREW

Turn allen screw clockwise; this increases vacuum required to activate.

Page# 61
 SPEED CONTROL ADJUSTMENT SEQUENc;;E

1. Turn speed control knob to "0" on faceplate. (Do not attempt to tab at th~s time. Turn
tape pot "OFF".)
2. Bottom out the center pot (B) by turning it completely count~r-clock:wise.
3. Set the slow speed pot (C) to "OFF'' position by turning it completely counter-clockwise.
4. Insert a stack of paper into the machlne. Press-the "START' switch and turn pot (C)
clockwise until count starts; then back off until it stops.
5. Tum "Speed Control Knob', on faceplate to full "ON" position. Ins_ert a stack of paper into
the machine; press "Start Switch..,,. Using a stopwatch, counter should read 425 in 15 seconds
be
(or 1700 spm). Adjustment of pot (A) may required to obtain this.

Page# 62
 ACE 1\fiCRO CUSHION ADJUSTMENT

ADJUSTING KNOB
MOUNTING STRUCTURE

NUT

INDICATOR

ADJUSTMENT

Proper adjustment is important to the efficient operation of the ACE Micro Cushion. All units are preset at the
factory at 50°. To adjust deceleration, loosen the lock screw located in adjusting knob at rear of shock absorber
with hex wrench (.050 inch or 1.27mm). Tum toward "011 for more cushioning. When desired setting has been
determined, tighten lock screw. The shock absorber is now ready for use.

Page# 63
Page # 64
SECTION #8: WIRING DIAGRAMS

Page# 65
 LOGIC BOARD WIRE CONNECTIONS
PLUGl

PLUG2

Black AC line to ECU (On old version w/interface board. ECU gets power
from lo motor on 3.

Page# 66
PLUG3

Page# 67
 ,.-----
,..------
.-------
"'"0
~
C§ . 9· 18 9 1"8 9 1.8
::;:!::
9 18
0\
00

i·
~
~
>
~
~

..
8
~
Cj

10 1 10' O:J
. 1 10 1 10 1 - 0
-

~
~

PLUG 1 PLUG 2 PLUG 3 PLUG I~

4~
oo.

LOGIC BOARD PLUGS

 WlRING DIAGRAM-COUNTING HEAD
80
lO
I
(f)

0
<t
w
I
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z
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z
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.. . .. .. . - 0 0 .. ...
' Page# 69
~- ·---:.~---_:;n___ ~ ..... ;_.... ,.~~-- . ~- g
----- ---N·-·

~ ~
:::! 61.
........
-
,0')_,,

- -
-~ Ll1
 VERTICAL RISE MOTOR

1. The Logic Controller S-3170 is compatible with either the Bodine or Dayton
vertical rise motor.

2. The board has 2 jumpers that determine which motor the board will drive.
Refer to the picture to determine the proper jumper position. ·

COllNT-WISE ECU HEADER PINOUT

9-PIN HEADER ON MAIN ECU BOARD

1. Count Input Coax

2. Count Ground Shield
3. Ground White/Black
4. Reset White/Blue
5. +42VDC White/Orange
6. Tape White/Green
7. Knife White/Brown
8. Line Brown/Whlte
9. Neutral White

S-PIN HEADER ON MAIN ECU BOARD

A. External Tape Pot Orange

B. External Tape Pot Orange
c. Ground White/Black
D. Ground N/C
E. Ground N/C

ADJUSTl\1ENT POTS:
11
T 11 =Internal Tape Adjustment
"KD 11 =Knife Delay
"K" = Knife Adjustment
Center Pot on Board is Equal Input Delay.
Set Adjuster Pointer towards Transformer.

***DO NOT TURN ANY OF THESE POTS TO THE FULL END OF THEIR ROTA-
TIONAL TRAVEL, AS TIDS WOULD CAUSE AN OPEN CONDITION.

Page# 70
WIRING DIAGRAM- LOGIC CONTROLLER

L L
0 0
+J +J
Q) 0
lUI

c. .g:L
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Page# 71
Page # 72
 ELECTRONIC COUNTING
" :.:
~ . .
UNIT
.
cECID. BASIC COMPONENTS
. ~ ' ...

·····:··ual
I:~
.........I
} ~~ _.un
•••••••• ······~·

.}..........
~=:~1
••••••••
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as~.
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R?~~tw
:

.
·· e · •co
cm

..............
.
~
Rm~-! U1
tu&~ .••·· PU ~ ~·m.a:t. :I
ata944 ~ Qi --
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Rl4~~
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ml . -~~ ..~--~·~~·· i
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•. f

ELECTROHIC
, .. : .. ,: ·-
COUNTING UNIT
Page# 73
 o4i
ICOUNf
INPUT ..
} "" r~Ku~G DIAGRAIVJS..ELECTRONIC COUNTING UNIT
Rll
~\~ Ul3 lOOK
.
~ 56 . ,.-
4~28
.L
Ub
"J.sr -"·... l
r .......
U-ta

-
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T.
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ttifdo7 .. I.02 4(f93

l
l
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1
>,- ~ .Tl -.a ....2.. TO TmllO

~
t Tl-'-\
~' OF 114 ..
UNITS. 4~\
~~ ~9 ~~
~ ;:~~
~
CNTl
--- ~"!l:i h
-~
.
~~ _;11-22
.n-.w
1"1
tnb ~~.0.

~
~· ~Jl-')d
....
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.... --
TENS ..
t-.l-'14
,.... us ~
4~2
18

4
·n
CNTO --
n r
~~ -
:n-1,a ..
.i.-.
.>~ ....Tl-J'";J'
>> .•.Jr-n'
UlOa
-
r7•.

~
»'"' "l .... f~
~

HUNDREDS .. ll~1,
~Uli~
~N!2
_.
M
; .... ~
-....

_,,_ jl1_.... 1 CJ 1,3 1_110

UlOti ',_
~> .J -~ll JZl
»--,ll.-l'l ~ ...t.n
>>
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~
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tHOUSANDS. ·- -
-.:--:' Ull ~'
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~ONIC cotnr.r Ultt1'.. f/M S-3064

Page # 74

Dat-e% 19-JA:R-99 -
RESET/SSLSC'l'
OPTION. Cl
I.1s
U6 ..

KNIFE
.SOLENOID.
R4
2.21(

12
+V

U5
4017

sus
lOOK

SL~N'lC cotnr:r t)!ti:T ,.. PIN s.- .3064

-
seu t>.i\M: 2
' - .
ReV m
Page# 75 e
._
5 CIRCUI~ WIRED FQR 120VJ\C; 60Jt~ ~·

1N4007 ~ 4 ..

1?/N S-3064B

:$1
ASS~Y . PIN S~4

POWER $UPPLV .ASS'V ON E.C.U.

.. -
B.LE~.NIC ~ING UNIT .. E/N s- 3064
.
Eet1 eow&R SU9et,Y ..

Pag~ # 76 Rev lD
e
Tl.£-t'.Ai> ~1-.nv-rul JiriurA1 t of r
Page# 77
 COMPUTER ECU

11-PIN HEADER ON MAIN ECU BOARD

1. Count Input Coax

2. Count Ground Shield
3. CJround White/Black
4. Reset White/Blue
5. 24VDC White/Orange
6. Tape White/Green
7. Knife White/Brown
8. Line Brown/White
9. Neutral White
10. 12V DC White/Red
11. Ground White/Black

NOTE: Pin 3 and Pin 11 are connected.. 12V DC comes from own main ECU.

5-PIN HEADER ON MAIN ECU BOARD

A. External Tape Pot Orange

B. External Tape Pot Orange
c. Ground White/Black
D. Ground NIC
E. Ground N/C

AUTOSTOP ECU BOARD

10-PIN HEADER ON AUTOSTOP ECU BOARD

Jl- +SV DC Start Switch Blue

J2- N/C
J3- · Autostop Relay Board Green/Black
J4- N/C
J5- N/C
J6- N/C
J7- N/C
J8- Logic Ground White/Black
J9- N/C
Jl 0- Batch Signal White/Purple

NOTE: J8 & JlO come from the total and batch board..

Page # 78
 1
n"tsv sm~ ors-rut swrr<;:B I
,1' S60· L. J

.,_

.£Ctt aoARI)

lfOI)l

12?
~.,..
D.PJ:l.T,

13
A=op
,_'
!.CU

. . .
' f "•

Nate : +tiVDC & OR."D.. F~ crimput!r ECt1 Bad Yus ·tO"·~ ~:1

Page#79
 .::::~::::so!.~,~: .'
0 0
[ ,]
· ~· .
Jl •_ ·...lrBCD·
-
J1 .
~

7. •~I,

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IJt'O'S

t~,·· r·Cl.R lATCH./

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'f... !4pf 'lenfth

hlr Knift Dtfay
K·Kaift .
J. t-tl(Q Pots- Ctockwi&e
tce'~lncretits•
•ll
F.wtlons

.. I
~

MAX·BANTAM..ECU
,,
SS·33·16A

~
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$CAli Jcmct<Ut av . lDti-Wf\14YO Owv:er-
OMS: V./9/9:i t· J ...
_StZE I' e~AWING NQ.. _
-· ~~~ .............
SECTION #9: PART LISTS, PHOTOS &
DIAGRAMS

(Part #'s may change; please call to verify)

Page# 81
 . TAPE RETAINING BLOCK

(Refer to Photo on Page #86, K~y #13)

TAPE RETAINING
SPRING. RooKs
S-ea91

•O

Page # 82
 RECOI\IIMENDED SPARE PARTS

Wiper Pin w/ Bearings

(Includes Wiper Pin, 2 bearings
small & large spacer, & E-Ciip)

1 Knife Solenoid

*-Different styles available depending on machine~-

Page# 83
 PHOTO-COUNTING HEAD

11

~~-----10

12

13

2 3 4 5 6

Page # 84
 PARTS LIST- COUNTING HEAD

Tape Loading Lever Assembly S-6045

Suction Blade House Assembly S-6269
- Seals Suction Blade (2) S-6132
- Bearin s Suction Blade & Orbitor S-6135
3 Suction Blade Shaft S-6133
4 Suction Blade S-627X*
(#70- #75- See Page 6 for specifications)*
Wiper Pin Assembly Complete S-6234
5 Wiper Pin w/Bearings S-6236-2
- Includes wiper pin, 2 bearings, small & large
spacer, and E-Ciip)
6 Wiper Pin Housing S-6235
- End Cap ._ S-6235-a
- Spacer- small (not shown) s.6238
- Spacer- large (not shown) S-6232
- Wiper Pin Bearings (2) (not shown) S-6237
- Sna Rin Cli S-6239
7 Hose Barb Connector S-4032-A
8 Cable Clamp- Black Plastic S-3073
Not shown in this hoto
9 Lock Buttons, Relieved S-6151
10 Pivot Bearing S-6106
11 Receptacle 15 Pin S-3032
12 Mainshaft Bearing Retainer (2) S-6320
Mainshaft Bearing Snap-ring (2) S-6318
Mains haft Snap-Ring (2) (not shown) S-6321
Orbitor Bearing (not shown) S-6332
Orbitor Bearing Retainer (not shown) S-6330
Orbitor Bearing Housing (not shown) S-6331
13 Push Rod 5-6233

Page# 85
 PHOTO-FRONT VIEW COUNTING HEAD

2 1

3
7

4 8

10
6
~------- 13
------11

12a
12

1- Counting Head Motor (S-3100-B) 8- Orbitor (S-6230)

2- Counter Poise Spring (S-6173)
3- Vertical Rise Actuator (S-6175)
4- Magnet Can·ier Count Reed (S-6316)
5- Connecting Link Arm (S-6100)
6- Counting Head Filter (S-4062)
7- Drive/ Timing Belt (S-6011)
9- Magnet CarrierReset Reed (S-6316)
10- Lower Tape Drive Ass 'y (S-6020)
11- Suction I Counting Blade (S-627-.. )
12- Wiper Pin w/bearings (S-6236-2)
12a- Wiper Pin wlhousing (S-6234)
13- Tape Retaining Block (S-6290)

Page # 86
 PHOTO & PARTS LIST-PRE-SELECT & START SWITCH AREA

A M

B L

E F G H I J
A Pre-Select Assembly (S . . 3065 . . *) G Reset On I Off (S-3056)
B Speed Control Pot (S-3047-*) H Batch Counter (S-3062-*)
c Tape length Pot (S-3048) I Emergency Stop Switch
(EMO) Assembly (S-3188)
lncfudes:
Contact Block (S-3188-A)
Red Stop Switch (S·3188-C)
Terminal Protector (S-3188-C)
D Tape-Cut Switch (S-3119) J Speed Control (S-3047-*)
E Main Blower Switch (S-3058) K Totalizer Counter (S-3062-*)
F Start Switch Assembly (S-3049-*) L Decade Board (S-3067)
Includes: M Totalizer I Batch Driver P.C.
Start Switch (S-3049-*)
Splash Guard (S-3049-20) Board (5 . .3145-*)
lamp (S-3050-*)
lens Cap (S-3051-•)
* - Different styles available depending on machine
Page# 87
 PHOTO & PARTS LIST-POWER SUPPLY & VACUUM AREA

B C D E F G H I J
A Power Supply Assembly G Filter Housing Assembly (S-4018)
(S-3008~1) Plastic Rivet (S-4018-A) Glass Filter Jar (S-4006)
Filter Stem (S-4018~8)
Filter Element 2 (S-4019)
B Vacuum Pump Cut-off (S-3132-2) H Vacuum Switch (S-3043-1)
Vacuum Pump Cut-Off w/ Air (S-3132 .. *)
c Vertical Rise Motor (S-3005-*) I Count Vacuum Valve (5~3042)
D Starting Cap. V/R Motor (S-3007) IJ Cover Safety Switch {S-3165)
E Vacuum Pump 110 (S-3004-3) K Lower Laser System (S-3079-L)
Vacuum Pump 220 (S-3004-4)
F Vertical Rise Switch (S-3114)
* - Different styles available depending on machine

Page # 88
 PHOTO & PARTS LIST-INSIDE CONTROL PANEL

A B c D

A 14 Pin Ribbon Cable (S-3066-1) c Clamp Cylinder (S-4023-*)

B' 24 Pin Ribbon Cable (S-3068) D Electronic Control Unit
(ECU) {S-3064)
* - Different styles available depending on machine

Page# 89
 LASER SYSTEM OPERATION, OIAGRAM & PARTS LIST

The upper laser system contains a laser diode, which, projects light down on the lower laser
system. When the laser beam is broken, a signal is sent to the S-3170 Logic Controller, which
activates the vacuum pump atld enables the start switch. The machine will ngw clamp and count
the :paper when the start switch is depressed.

The laser beam must fall on the lens cap located on the lower laser system. Adjustments to the
beam's position can be made by loosening the left to right or the front to back adjustment screws
located on the upper laser system. The laser mounting bracket can now be moved, so that the
beam is in its correct pqsition, and the screws re-tightened.
LEFT-R..::j:GHT
ADJUSTING SCREWS

FRONT-SACK
ADJUSTING SCREWS

2-----.. e
----3

LIGHT BEAM

1 Laser Mountirtg Bracket s ..1o12-A

2 Laser Mounting Block S-1072-8
3 Cellomating Lens S-3080
Upper Laser System S-3079-U
ove 3 items + Laser Dio
4 Lower Laser System S-3079-.L
Page # 90
 INDEX
A
Ace Micro Cushion .......................................................................................................................................63
Adjustments ........................................................................................................................................... 57-63
Air Flotation ..................................................................................................................................................10
B
Batch Counter ..............................................................................................................................................51
Breathers ................................................................................................................................................14, 15
c
CE Certification ............................................................................................................................................12
Center Plate: Removal ................................................................................................................................23
Center Plate: Drawing with Tape Chute ......................................................................................................28
Center Plate, Right Side: Photo ...................................................................................................................33
Center Plate, Left Side: Photo .....................................................................................................................35
Clamp Cylinder ............................................................................................................................................88
Cia mp Plate ................................................................................................................................................49
Computer ECU ............................................................. ~ ..............................................................................78
Computer ECU Board ..................................................................................................................................79
Connecting Arm Link .............................................................................................................................33, 86
Count Adjustment w/Diagram ......................................................................................................................22
Count Reed Switch .. Photo Reference .......................................................................................................35
Counter Poise Spring, Setting .....................................................................................................................25
Counter Poise Spring, Photo .......................................................................................................................86
Counting Head. Photo & Parts List ........................................................................................................84, 85
Counting Head: Photo, Front View & Parts List ..........................................................................................86
Counting Head: Installation & Alignment. ....................................................................................................24
Counting Motor ............................................................................................................................................86
Counting Head: Removal & Replacing ........................................................................................................23
Counting Head, Wiring Diagram ..................................................................................................................69
Counting Speed ...........................................................................................................................................12
Count-Wise 1. lnstallation ..............................................................................................................................8
Count-Wise M, Diagram ..............................................................................................................................11
Count-Wisa M, Installation ...........................................................................................................................10
Cover Safety Switch ...............................................................................................................................59,88
D
Decade Board ....................................................................................:............................................. 41, 42.87
Down Limit Switch .......................................................................................................................................49
Drivell"iming Belt .........................................................................................................................................86
E
Electronic Counting Unit {ECU) Wiring Diagrams ................................................................................. 73..75
Electronic Counting Unit (ECU) Basic Components....................................................................................73
Electronic Counting Unit (ECU) Power Supply Assembly
Electrical ......................................................................................................................................................12
Emergency Stop Switch .........................................................................................................................51,87
Electrical System ................................................................................................................................... 47,..56
F
Filter, Counting Head ...................................................................................................................................86
Filter Housing Assembly ........... ,..................................................................................................................59
Page# 91
Filter Jar, Glass ............................................................................................................................................59
Filter Element* Stem ...................................................................................................................................59
Fuses ...........................................................................................................................................................49
I
Insert Tape: Loading & Diagram ............................................................................................................20,21
Insert Tape: Removing a Tape Jam ...........................................................................................................29
Installation ............................................................................................................................................... 5 ~ 11
K
Knife Assembly: Maintenance Scheduel .....................................................................................................37
Knife Assembly: Removal, Replacement, Diagram .............................................................................. 32, 33
Knife Linkage ...............................................................................................................................................33
Knife Solenoid ..............................................................................................................................................33
Knurled Wheels .....................................................................................................................................28, 35
L
Laser System, Operation, Diagram & Parts List.. ........................................................................................90
Laser System, Lower ..............................................................................................................................59,88
Laser System, Upper ...................................................................................................................................49
LEOS~ Self Diagnostic, Diagram ................................................................................................................16
Logic Board: Sequence of Events & Diagram ....................................................................................... 17, 18
Logic Board Wire Connections ........................................................................................................ 66, 67,68
Logic Controller..................................................................................................................................48,49,71
Looper Driver Motor .....................................................................................................................................33
Looper Stop Switch, Photo reference ..........................................................................................................33
Looper Stop Actuator ...................................................................................................................................35
Low Tape Indicator .......................................................... ,...........................................................................51
Low Tape Actuator ......................................................................................................................................35
Lower Tape Drive Assembly (Photo) ...........................................................................................................86
M
Maintenance Schedule ................................................................................................................................37
Max-Bantam, Control Panel, Prior to 2001 .............................................................................................54,55
Max-Bantam, Control Panel, 2001 & After .............................................................................................53,54
Max-Bantam, Diagram ...................................................................................................................................?
Max-Bantam, Installation ...............................................................................................................................6
Max-Bantam, Pre-2001 Wiring Diagrams ....................................................................................................80
0
Operation .....................................................................................................................................................13
Orbit Adjustment & Diagram ...................................................................................................................26,27
p

Paper Range ................................................................................................................................................12

Parts Lists, Photos, & Diagrams ..................................................................................................................81
Parts, Recommended Spare Parts List .......................................................................................................83
Pre-Select ...............................................................................................................................................51,87
Photos & Drawings ................................................................................................................................ 81-90
Power Supply Assembly ..............................................................................................................................88
R
Receptacle Guard ................................ :.........................................................................................................9
Reset Adjustment w/ Diagram .....................................................................................................................22
Reset On/Off Switch ....................................................................................................................................51
Reset Reed Switch ......................................................................................................................................33
Ribbon Cable (14 & 24 Pin) .........................................................................................................................88

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s
Service .........................................................................................................................................................40
Spare Parts, Recommended .......................................................................................................................83
Speed Control Adjustment Sequence .........................................................................................................62
Speed Control, Count-Wise ....................................................................................................................50,51
Speed Control, Pot ......................................................................................................................................87
Start/Stop Switch .................... ,....................................................................................................................51
Start Switch Assembly .................................................................................................................................87
Suction Blade: How to change ....................................................................................................................25
Suction Blade Guide ....................................................................................................................................12
T
Tape Chute, Diagram, Photo .................................................................................................................28, 35
Tape Cut Switch .........................................................................._ ...........................................................51.87
Tape Drive ...................................................................................................................................................33
Tape Jam, Tape Chute Removal and Replacement .............................................................................29, 30
Tape Length .................................................................................................................................................51
Tape Loading Lever, Photo, reference ........................................................................................................33
Tape Retaining Bfock ............................................................................................................................32, 86
Tape Solenoid, Photo ..................................................................................................................................33
Tape SolenoidChanging ..............................................................................................................................32
Tearing or Chipping of Corners ...................................................................................................................46
Technical Details. Count..Wise 1, M, & Max-Bantam .................................................................................. 12
Totalizer .......................................................................................................................................................51
Trouble Shooting ................................................................................................................................... 39-46
v
Vacuum Pump .......................................................................................................................................41,58.
Vacuum Switch Adjustment ..............................................................................;..........................................61
Vacuum Switches, Setting ...........................................................................................................................60
Vacuum System .......................................................................................................................... 41,58,59,99
Vertical Rise Motor .......................................................................................................................... 43, 63,59
Vertical Rise Switch ................................................................................................................................25,59
w
Wiper Pin Bearings, Maintenance ...............................................................................................................37
Wiper Pin w/bearings & Housing (PHOT0) ..............................................·................................................... 86
Wiring Diagrams .................................................................................................................................... 65-80
Warranty ....................................................................................................................................................3, 4

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 DIAGRAMS & PHOTOS FOR REFERENCE

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21 ACE MICRO CUSHION ADJUSTMENT 63

4 BREATHER 14
28 COMPUTER ECU BOARD 79
8 COUNT ADJUSTMENT 22
32 COUNTING HEAD- FRONT VIEW 86
31 COUNTING HEAD PHOTO 84
10 COUNTING HEAD/CENTER PLATE & TAPE CHUTE 28
11 COUNTING HEAD/CENTER PLATE- RIGHT 33
12 COUNTING HEAD/CENTER PLATE-LEFT 35
3 COUNT-WISE M 11
25 ELECTRONIC COUNTING UNIT {ECU) BASIC COMPONENTS 73
15 FACE PLATE- COUNT-WISE M 51
35 INSIDE CONTROL PANEL 89
36 LASER SYSTEM OPERATION & DIAGRAM 90
7 LOADING INSERT TAPE 21
6 LOGIC BOARD 18
1 MAX BANTAM 7
16 MAX BANTAM CONTROL PANEL- 2001 & AFTER 53
17 MAX BANTAM CONTROL PANEL- PRIOR TO 2001 55
29 MAX-BANTAM- PRE 2001 -WIRING DIAGRAM 80
9 ORBIT ADJUSTMENT 26
'
18 POWER SUPPLY & VACUUM AREA 59 & 88
1 34 POWER SUPPLY & VACUUM AREA 88
27 POWER SUPPLY ASSEMBLY ON ECU 77
33 PRE-SELECT & START SWITCH AREA 87
13 REAR- TOP OF MACHINE; AMPS & FUSES 41
2 RECEPTACLE GUARD 9
8 RESET ADJUSTMENT 22
5 SELF DIAGNOSTIC LEOS 16
14 SPEED CONTROL- COUNT WISE 50
15D- PARTS PLACEMENT & LIST
20 SPEED CONTROL ADJUSTMENT 62
30 TAPE RETAINING BLOCK 82
19 VACUUM SWITCH ADJUSTMENT 61
22 WIRING DIAGRAM- COUNTING HEAD 69
26 WIRING DIAGRAM- ELECTRONIC COUNTING UNIT (ECU) 74-75
23 WIRING DIAGRAM - LOGIC BOARD PLUGS 68
24 WIRING DIAGRAM - LOGIC CONTROLLER 71

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