4.0 Pinnacle 27 Operator Instructions 12

5.0 Pinnacle 27 EZload/Non EZ load Troubleshooting

5.5 General Troubleshooting

Malfunction corrections are based on visual obser-vations made by the operator. The causes of themalfunctions are isolated by the symptom of themalfunction and noting at which point in the operat-ing cycle the malfunction occurred. Malfunctionsmay be pinpointed to a defective electrical compo-nent or mechanical part by referring to thePrinciples of Operation, the troubleshooting guideand the wiring diagram.

5.6 Troubleshooting Chart

The troubleshooting guide chart that follows isarranged in order of the normal operationalsequence. When a malfunction occurs, read downthe SYMPTOM column until you find the appropri-ate description for your symptom. Read the corre-sponding PROBABLE CAUSE, then perform therecommended procedure in the CORRECTIVEACTION column. When replacing electrical compo-nents that have push on terminals, label the electri-cal leads that were removed, to facilitate reconnecting them. Refer to the wiring diagramsto resolve any wiring difficulties that may occur.

WARNING! Always unplug the laminator to avoid possible elec-trical shock hazard before attempting to performany repairs.

14

Pinnacle27 and Pinnacle27EZ Operation Tip!

FOOTAGE COUNTER/TEMPERATURE DISPLAY The Ready Light is ‘OFF’… the display shows ‘TEMPERATURE’

The Ready Light is ‘ON’…. the display shows ‘FEET’

There seems to be some confusion on the part of our customers, and some of our techs, regarding the footage/temp display on the Pinnacle27s. This confusion may be leading to unnecessary service calls and part replacement. The observed problem is that when the machine goes to 'ready', the temperature suddenly 'jumps' to a temp way over/under range, i.e. ‘400’ or ‘105’ on the display. What the customer does not realize is that this is not the actual temperature any more. Instead, it is the number of feet of laminate used since the last manual reset of the footage counter (the display changes from temperature to feet when the P27 goes to ready state). So ‘400’ on the display is now 400 feet of laminate used. The footage counter continues to count up until the '1, 2, 3’ button is pressed and held until it resets to '0'! It does not reset to zero when the P27 is turned off or unplugged. In this example simply resetting the footage counter gets rid of the ‘400’ display, changing it to ‘0’. The giveaway here is whether or not the green ‘Ready Light’ is illuminated. If the P27 is not ‘Ready’ and the ‘Ready Light’ is ‘OFF’, the display shows the actual shoe temperature as it approaches the set temperature. If the P27 is to temperature or ‘Ready’, and the green ‘Ready Light’ is ‘ON’, the display shows the total feet of laminate used since the last manual reset. Summing up: The Ready Light is ‘OFF’… the display shows ‘TEMPERATURE’ The Ready Light is ‘ON’…. the display shows ‘FEET’ Please refer to the operator manual features guide for clarification if necessary.

5.0 Pinnacle 27 EZ load/Non EZ load Troubleshooting

No functionality out of control panel (With main rocker switch illuminated)

Interlock disengaged

Off/Standby switch defective

Thermal fuse up /downdefective (Located in heat shoe )

Circuit breaker opened

F1 20A/125VAC fuse blown on main board

Transformer defective

Main board defective

Check tray or upper heat shoe safety inter-lock

Test and replace control panel PCB Assy If necessary

Test and replace If necessary (refer to wiring diagram)

Reset or replace If necessary

Test fuse and if necessary replace main board

Test T1 in and T1 out on main board with transformer in circuit for: (On main board) 120 VAC on T1 in and 8 VAC T 1 out 2.

Test for 120VAC across EL1 on main board. Check CN1 for +7V~11V DC on pin 1 (next to UA5) to dc ground.

Check CN1 for +5V DC on pin 4 (closest to UA5) to dc ground.

5.0 Pinnacle 27 EZ load/Non EZ load Troubleshooting

Er.1 on control display

Er.2 on control display

Er.3 on control display

Air bubbles in film

CalibrationsA. Motor jammed

B. Motor connection is loose .

C. Encoder sensor connector is loose.

D. Encoder wheel is loose.

E. Encoder sensor is damaged

F. Left hand side cover is removed. (GW)

A. Main NTC sensor loose.

B. Main NTC sensor damaged.

A. Roller NTC connector is loose.

B. Roller NTC Sensor dam-aged.

Insufficient film tension

A. Resolve loading issue.

B. Reseat connector, visually inspect motor connector termination.

C. Reseat connector, visually inspect encoder connector termination.

D. Inspect encoder wheel

E. Test and or replace if neces-sary (refer to electrical sche-matics).

F. Excess light difussing emmiter with cover removed. Install cover to resolve. A. Reseat connector, visually inspect ntc connector termi-nation.

B. Replace main ntc sensor.

A. Reseat connector, visually inspect ntc connector termi-nation.

B. Replace roller ntc if 5vdc not present on control panel board.

Adjust film tension via the tension adjustment plate on the non-ez load. For the ez load adjust via the set screws on the ez load levers (left and right hand side). Tighten equally on both sides per film roll.

.

5.0 Pinnacle 27 EZload/Non EZ load Troubleshooting120 VAC

June 12, 2006

EZ 65 Main Board AC Block

GA1

A2

G

A2

A1

Pre-Heater ControlPre-Heater

HEAT DOWN

HEAT UP

70*C OFF

HEAT2

HEAT1

US Version

EN0LINE SW

LINE SW

UP TF2

EN0

UP TF1UP TF2

LINE

LINE SW

VPO

VPO

CN2(NTC1)2.5MM/2P

12

CN3(NTC2)2.5MM/3P

12

RA16

10k

QA10

BAT26-600B

3

21

QA16

SAnRex / T16C6

3

21

RA301K

RA311KZC

UA4

TLP3063

1

2

4

6

3

ZC

UA3

TLP3063

1

2

4

6

3RA13 470 1/2W

RA12

1K

Terminal 1(PA12)(right)

2

3

4 5

6

7

QA62SC1815

31

2

RA32

470

RA14

470

ROLLER HEATER(3.96MM3PIN)

123

177+/-10

177+/-10

177+/-10

123

TF1 192*C

TF2 192*C

Terminal 2(PA12)(left)

2

3

4 5

6

7

177+/-10

177+/-10

177+/-10

TF3(Thermostat)

RA50Ohm

TFLINEAR X'FORMER

1

2

3

6

4

5

RB50OHM

T-OUT22.5MM/2P1

2

QA12

2SC18153

1

2

T1-OUT13.96MM/2P1

2

RA34

10K

RA3310K

T250

1P

IN

T250

1P

IN

H1HEATER SHINK for BAT26-600B

12

H2HEATER SHINK for TMG16C60

12

123

T1-in3.96MM3PIN 3T

123

177+/-10

177+/-10

177+/-10

177+/-10

RA154.7K

177+/-10

177+/-10

PWM

PWM2

Friday, November 10, 2006

5

1

. 8

Slide SW Function

TO MainHeater NTCsensor

8 .

LED Board June 6 2006

8

AC Buzzer 3 KHz

.

Sleep Disable = LO

TO Pre-Heater NTCsensor(503GT)

LED

CONTROL PANEL PCB

Sleep Disable

AUTO OFF PCB

MIRCO ICTEMP SETTING FOR MAIN HEATERHIGH TEMP: 300*F (150*C)LOW TEMP: 250*F (120*C)MIRCO IC TEMP SETTING FORROLLER HEATER 60*C

*

*

Actual test Value

300*F (150C*)250*F (120*C)85~90*C

+5V

7V ~ 11V

+5V

7V ~ 11V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

RC2910K

QC5 2SA1015

3

1 2

RC2210K

+

- U2BLM324

5

67

+

- U2CLM324

10

98

+

- U2DLM324

12

1314

+

- U2ALM324

3

21

411

CN1

11HEADER2.0 11PIN

123456789101112

SWC5 HI TEMPDC5 1N41481 2

RC21100

RC27100

RC28

10K

NTC22.5MM/2P

12

RC301.39k CC5

0.1U/50VCC40.1U/50V

VR110K

CC70.01U/50V

SWC6 NC1(Power)DC6 1N41481 2

RC33

10K

SWC7Motor ReverseDC7 1N41481 2

RC23100

RC32100

DC8 1N41481 2

NTC12.5MM/2P

12

CN22.0MM/2P

12

CN8SW SLIDE 3PIN

3 2 1

VR10K

CC90.1U/50V

LEDC2LED 7 SEG

3/8

910

1246

57

com

FG

EDCB

RDPA

LEDC3LED 7 SEG

3/8

910

1246

57

com

FG

EDCB

RDPA

CN22.0MM/2P

12

RC10 330

RC14 330

RC11 330

RC311.39k

RC9 330

RC16 10KX8

1 2 3 4 5 6 7 8 9

RC12 330DC3 1N41481 2

DC2 1N41481 2

CYC1 4MHZ

RC3410K

RC20100

CC230P/50V

CC130P/50V

QC12SA1015

31

2

RC26 100

SWC2 Motor Run/STOP

SWC3 Reset

RC25 100

BZC1AC BUZZER

RC1710KQC6

2SC1815

31

2

RC1810K

RC31K

CC3

0.1U/50V

QC22SA1015

31

2

QC32SA1015

31

2

RC41K

SWC4 LO TEMPDC4 1N41481 2

LEDC1LED 7 SEG

3/8

910

1246

57

com

FG

EDCB

RDPA

RC21K

RC13 330

RC8 330

LEDC1POWER

HT46R23-28U1

8

13

4

5

6

7

3

12 17

14

16

19

1811

10

15

2

1

20

21

22

24

25

27

23

28

9

26

PB2/AN2

PC1

PA2

PA1

PA0

PB3/AN3

PA3/AN3

PC0 PD0/PWM0

PC2

PC4

RES

PD1/PWM1VSS

PB0/AN0

PC3

PB4/AN4

PB5/AN5

VDD

OSC1

OSC2

PA6/SDA

PA5/INT

PB7/AN7

PA7/SCL

PB6/AN6

PB1/AN1

PA4/TMR

LEDC3HI TEMP

LEDC2READY

LEDC4LO TEMP

RC24 100

RC51K

QC42SA1015

31

2

RC6100K

RC15 330

SWSW SLIDE 3PIN

3 2 1

RC710K

CC80.1U/50V

CC60.1U/50V

PWM

Motor On/Off

VR-2

E

F

COM4

B

F

RDP

G

VR-1

COM1

Motor Reverse

PROTECTION

B

G

COM3

A

COM3

NTC1

PROTECTION

PWM2

COM5

AC BUZZER

AC BUZZER

PWM2

RANGE

COM2

RDP

COM5

Motor On/Off

COM1

PWM

COM4

C

A

C

Motor Reverse

NTC2

ED

NTC1

D

NTC2

COM2

SPEED EYE

SPEED EYE

VR-2

VR-1

SLEEP DISABLE

SLEEP DISABLE

RANGE

5.0 Pinnacle 27 EZload/Non EZ load Troubleshooting

115VAC

June 12, 2006

EZ 65 Main Board AC Block

GA1

A2

G

A2

A1

Pre-Heater ControlPre-Heater

HEAT DOWN

HEAT UP

70*C OFF

HEAT2

HEAT1

US Version

EN0LINE SW

LINE SW

UP TF2

EN0

UP TF1UP TF2

LINE

LINE SW

VPO

VPO

CN2(NTC1)2.5MM/2P

12

CN3(NTC2)2.5MM/3P

12

RA16

10k

QA10

BAT26-600B

3

21

QA16

SAnRex / T16C6

3

21

RA301K

RA311KZC

UA4

TLP3063

1

2

4

6

3

ZC

UA3

TLP3063

1

2

4

6

3RA13 470 1/2W

RA12

1K

Terminal 1(PA12)(right)

2

3

4 5

6

7

QA62SC1815

31

2

RA32

470

RA14

470

ROLLER HEATER(3.96MM3PIN)

123

177+/-10

177+/-10

177+/-10

123

TF1 192*C

TF2 192*C

Terminal 2(PA12)(left)

2

3

4 5

6

7

177+/-10

177+/-10

177+/-10

TF3(Thermostat)

RA50Ohm

TFLINEAR X'FORMER

1

2

3

6

4

5

RB50OHM

T-OUT22.5MM/2P1

2

QA12

2SC18153

1

2

T1-OUT13.96MM/2P1

2

RA34

10K

RA3310K

T250

1P

IN

T250

1P

IN

H1HEATER SHINK for BAT26-600B

12

H2HEATER SHINK for TMG16C60

12

123

T1-in3.96MM3PIN 3T

123

177+/-10

177+/-10

177+/-10

177+/-10

RA154.7K

177+/-10

177+/-10

PWM

PWM2

5.0 Pinnacle 27 EZload/Non EZ load Troubleshooting115VAC

Friday, November 10, 2006

A2

HEAT DOWN

HEAT UP

G

Main-Heater

HEAT2

A1

G

Pre-Heater

A2

HEAT1

70*C OFF

A1

T250

NN

L L

LINE

NEUTRAL

MAINBOARD

EN0

UP TF2

LINE SW

UP TF2

LINE SW

EN0

LINE SW

EN0

LINE

LINE

UP TF1

LINE SW

UP TF1

VPO

VPO

T1-in 3.96mm 3PIN 3T

123

TF1 192*C

177+/-10Terminal 2(PA12)

2

3

4 7

8

9

1 10

5 6

ZC

UA3

TLP3063

1

2

4

6

3

ZC

UA4

TLP3063

1

2

4

6

3

H2HEATER SHINK for TMG16C60

12

Heater Up170OHM

177+/-10

ROLLER HEATER(3.96mm 3PIN)

123

177+/-10

177+/-10

QA16

SAnRex / T16C6

3

21

RA311K

RA301K

TS1(Thermostat)

RA13 470 1/2W

177+/-10

177+/-10

QA10

BAT26-600B

3

21

RA12

1K

177+/-10

177+/-10

T2501 PIN

177+/-10

177+/-10

177+/-10

H1HEATER SHINK for BAT26-600B

12

T250

1 PIN

123

Heater Down170Ohm

177+/-10

T2501 PIN

T2501 PIN

CY1103/AC400V

F110A/250VAC

EC1

0.68uf/275VACT250

1PIN

T2501PIN

V1MOV

T2501 PIN

T2501PIN

EL1 JUMPER #1.3*22 X2PCS

1 2

34

CY2103/AC400V

EC21UF/250VACR1

1M 1/2WT250

1 PIN

T2501PIN

circuit breaker 10A 250VAC

S1

JA1

Power Cord

1 2

SW1

POWER SW 16A/250V

1 2

1PIN

1PIN

TF2 192*C

Terminal 1(PA12)

2

3

4 5

6

7

SW5

SAFTETY SW5 15A/250VAC

1 2SW3

SAFETY SW4 15A/250VAC

1 2SW2

SAFTETY SW2 15A/250VAC

1 2SW4

SAFTETY SW3 15A/250VAC

1 2

TF3 130*CT1

LINEAR X'FORMER

1

2

3

6

4

5

123T-OUT1

2.5MM/2P

12

T1-OUT2

3.96MM/2P

12

5.0

Pinn

acle

27

Non

EZ

load

Tro

uble

shoo

ting

EU V

ersi

on

A2

HEAT DOWN

HEAT UP

G

Main-Heater

HEAT2

A1

G

Pre-Heater

A2

HEAT1

70*C OFF

A1

T250

NN

L L

LINE

NEUTRAL

MAINBOARD

EN0

UP TF2

LINE SW

UP TF2

LINE SW

EN0

LINE SW

EN0

LINE

LINE

UP TF1

LINE SW

UP TF1

VPO

VPO

T1-in 3.96mm 3PIN 3T

123

TF1 192*C

177+/-10Terminal 2(PA12)

2

3

4 7

8

9

1 10

5 6

ZC

UA3

TLP3063

1

2

4

6

3

ZC

UA4

TLP3063

1

2

4

6

3

H2HEATER SHINK for TMG16C60

12

Heater Up170OHM

177+/-10

ROLLER HEATER(3.96mm 3PIN)

123

177+/-10

177+/-10

QA16

SAnRex / T16C6

3

21

RA311K

RA301K

TS1(Thermostat)

RA13 470 1/2W

177+/-10

177+/-10

QA10

BAT26-600B

3

21

RA12

1K

177+/-10

177+/-10

T2501 PIN

177+/-10

177+/-10

177+/-10

H1HEATER SHINK for BAT26-600B

12

T250

1 PIN

123

Heater Down170Ohm

177+/-10

T2501 PIN

T2501 PIN

CY1103/AC400V

F110A/250VAC

EC1

0.68uf/275VACT250

1PIN

T2501PIN

V1MOV

T2501 PIN

T2501PIN

EL1 JUMPER #1.3*22 X2PCS

1 2

34

CY2103/AC400V

EC21UF/250VACR1

1M 1/2WT250

1 PIN

T2501PIN

circuit breaker 10A 250VAC

S1

JA1

Power Cord

1 2

SW1

POWER SW 16A/250V

1 2

1PIN

1PIN

TF2 192*C

Terminal 1(PA12)

2

3

4 5

6

7

SW3

SAFETY SW4 15A/250VAC

1 2SW2

SAFTETY SW2 15A/250VAC

1 2

TF3 130*CT1

LINEAR X'FORMER

1

2

3

6

4

5

123T-OUT1

2.5MM/2P

12

T1-OUT2

3.96MM/2P

12

5.0

Pinn

acle

27

EZ lo

ad T

roub

lesh

ootin

g EU

Ver

sion

EZ 65 Main Board DC BlockJune 9, 2006

To Cool Fan

FOR motor speed

reverse: DC 7.2V

90*C = Lo Ohm Value

70*C = Hi Ohm Value

TO Fan NTC sensor

forword: DC 8.5V ~ DC22V

DA1031DQ06

IaIb

PCB CoolFan

31DQ06 DB7

31DQ06DB5

DA1131DQ06

31DQ06DB6

1N4004 DB1

1N4004 DB2

1N4004 DB4

1N4004 DB3

HI=Motor OnLO=Motor Off

Friday, November 10, 2006

+5V7V ~ 11V

7V ~ 11VVPO

7V ~ 11V

+5V

7V ~ 11V

+5V

7V ~ 11V

28V~38V

5V

7V ~ 11V

28V ~ 38V

20V ~ 26V

+5V +5V

20V ~ 26V

RA24

10K

- +

31DQ06 DB8

+ C3

2200U/50V

+CA2220U/16V

T1-OUT2 2.5MM/2P

12

- +

+CA1

1000U/16V

UA5

78L05/TO220

1

2

3

RA4310K

RA2847K

+

CA1510UF/25V

DA61N4148

12

QA92SC1815

13

2

+CA14

4.7UF/25V

RA254.7K

RA271.5K

RA291K

RA1722K

RA1922K

+

- U3BLM358

5

67

RA2610K

QA82SA1015

1

32

QA72SD882

13

2

T-OUT1 3.96MM/2P

12

RA2022K

DA5 1N41481 2

RA221KRA18

100

RA231K

RA2122K

DC FAN2.5MM/2P

12

DA131N4004

12

+

- U2ALM358

3

21

84

NTC12.0MM/2P

12

CA130.1U/50V

CA120.1U/50V

RA410

RA910K

QA4

2SC1815

13

2

QA13 2SA10151

3

2

RA810K

CA11470P/50V

UA1 33063AVP

2

18

45

36

7 Switch E

Switch CDriver C

GNDComp-IN

Timing CapVCC

Isensor

QA22SC

1815

3

12

RA4

0.011/2W(

RA12K

RA24.7K

QA32SC1815 1

3

2

DA11N4148

12

RA36

680

QA1IRF5305(IRF9Z34N)

1

23

+ CA16

10U/50V

H4HEAT SHINK FOR IRF5305

12

DA21N4148

12

DA8FR104

12

+

CA31000U/25V

RA354K7

L1Choke 80~100uH

CA4

0.1/50V

RA6910

RA74K7

1 2

3

ZD1 20V(OPEN)

12

DA3FR104

12

CA80.1/50V

CA100.1/50V

CA60.1/50V

L2 100UH

DA41N4004

12

CA70.1/50V

CA90.1/50V

+ CA5

1000U/25V

MOTORCONNECTOR/3.96MM 2PIN

12

KA1

SMI-SH-206D/DC6V

DA9FR104

12

RA421K

RA54.7k

RA3710K

CN1(2.0 11PIN)

123456789101112

CN62.5MM/3Pin

123

QA52SC1815

13

2

RA4010K

RA1110K

RA39 10K

RA101K

RA3810K

MMO1

DC24V

QA142SC1815

13

2

DC FAN12.5MM/2P

12

QA152SD882

13

2

DA71N4004

12

PROTECTION

VR-2

Motor ReverseMotor On/Off

PWMPWM2

VR-1

SPEED EYE

Motor Reverse

MOT VOL

SPEED EYE

VR-2

VR1

PROTECTION

Motor On/Off

5.0 Pinnacle 27 EZload/Non EZ load Troubleshooting

115VAC

Low Active

SPEED EYE PCB

5V

5V 5V

5V

RA5560

CN42.0MM/3Pin

123

CN4

2.5MM/3Pin

1 2 3

RB1560

LED1

12

LED2

1

2

RB447K

RB3 22K

RB522K

RB2100K

CN62.5MM/3Pin

123QB1

2SC1815

13

2

5.0 Pinnacle 27 EZload/Non EZ load Troubleshooting

Friday, November 10, 2006

5.0 Pinnacle 27 EZload/Non EZ load Troubleshooting

5.0 Pinnacle 27 EZload/Non EZ load Troubleshooting EU Version

EZ Load and Non EZ Load EU Heat Shoe Wiring

6

910200037320

670800003400660000002670

910200036540

910000139480

911100000030

911100000960911100000970

622000021200

670400000700

671100008800

670300013000

-------------

-------------

-------------

910000145300

910200026250

-------------

14

9

11

10

8

18

6

12

34519

7

16

15

12 13

-------------

LH Side

RH Side

91020002625020 Counter PCB assy

20

CONTROL PANEL ASSY 910000145240