Powis Photopress ServiceManual VB

PHOTOPRESS
POWIS PHOTOPRESS S E R V I C E M A N UA L
www.powis.com
fax: 510 848 2462
phone: 510 848 2463
toll-free: 800 321 BIND
775 Heinz Ave, Berkeley, CA 94710
COPYRIGHT INFORMATION
Copyright Information
This document contains proprietary and confidential information of Powis Parker Incorporated (“Powis Parker”).
Copyright Powis Parker Incorporated 2010

All Rights Reserved.
No part of this document may be photocopied, reproduced in any form, or translated into another language without prior
written consent of Powis Parker, except as allowed under the copyright laws.
Warranty
The information contained in this document is subject to change without notice.
Powis Parker makes no warranty of any kind with respect to this information. Powis Parker specifically disclaims the
implied warranty of merchantability and fitness for a particular purpose.
PPI shall not be liable for any direct, indirect, incidental, consequential, or other damage alleged in connection with the
furnishing or use of this information.
Notice
Changes are periodically made to this document. Revisions, changes, any technical inaccuracies, and typographical
errors will be corrected in any subsequent editions.
PhotoPress Service Manual, Rev. B 8/26/11 i

CONTENTS
1 SAFETY
1.1 Safety discussion
1.2 Notes, Cautions, and Warnings
2 DEFINITIONS
3 THEORY OF OPERATION AND OVERVIEW

3.1 Theory of operation
3.2 Front view
3.3 Back view
3.4 Back internal view
3.5 Front internal view
3.6 Left internal view
3.7 Right internal view
3.8 Controller circuit board
3.9 Specifications
3.10 Contacting Powis Parker service
4 TROUBLESHOOTING
4.1 General troubleshooting
4.2 Error and status codes
5 SERVICE AND CALIBRATION PROCEDURES

5.1 Required tools
5.2 Removing rear panel
5.3 Removing electronics tray
5.4 Replacing power supply
5.5 Replacing circuit board
5.6 Replacing counter
5.7 Replacing power entry module
5.8 Replacing platen interlock switch
5.9 Replacing platen flag and mid-travel and home sensors
5.10 Replacing lid flag and sensor
5.11 Replacing operator panel
5.12 Removing front and right cover
5.13 Replacing latch sensor switch
5.14 Replacing latch motor
5.15 Replacing encoder
5.16 Replacing lid
5.17 Replacing motor brushes
5.18 Replacing platen motor
6 UPGRADING FIRMWARE
6.1 Upgrading Firmware Procedure
7 SERVICE KIT PART NUMBERS

7.1 Service kit part numbers
7.2 Service kit photographs
APPENDIXES
Appendix A - Old motor conversion
Appendix A - Early platen motor conversion
ii PhotoPress Service Manual, Rev. B 8/26/11

1 SAFETY
1. 1 Sa f e t y d i s c u s s i on
The PhotoPress machines use pressure (not heat) to bind photographs to signatures, and this brings new challenges for
the service technician compared to other Powis Parker products. There are two primary safety concerns that the service
technician must always be aware of; the press force produced by the machine, and the weight of the machine.
The PhotoPress machine produces 10,000lbs of force to activate the Pressure Sensitive Adhesive (PSA) of the signa-
tures to bond photographs to the signatures. A DC motor driving high mechanical advantage gearing and chain system
produces this force. You must practice care when one or more covers have been removed from a PhotoPress machine,
and never place fingers inside the PhotoPress unit when running the PhotoPress with the covers removed. Operating the
PhotoPress without the covers installed can cause serous personal injury. Your finger will be severed if you get it caught
in the chain and sprocket while they are moving. Your finger will be crushed if it is in the way of the platen. Do not allow
your finger between the platen and the lid or between the platen and the frame plate (just below the platen), see section
3.4. There is no power inter-lock switch in the PhotoPress.
The PhotoPress weighs almost 200lb (90Kg) and is top heavy. Powis Parker Inc. strongly recommends that four people
are employed to lift the PhotoPress machine. When lifting a PhotoPress machine, be sure that the lid is closed and
latched and that the people doing the lifting coordinate before the move so as to not trip over each other or the Photo-
Press shipping palette. The area where the PhotoPress is being moves must be clear of any obstructions. Do not lift
from the base plate as you may injure your fingers.
Read all of the Notes, Cautions and Warnings in part 1.2 before moving or working on a PhotoPress machine.
PhotoPress Service Manual, Rev. B 8/26/11 Page 1

1 SAFETY
1. 2 N OTE S , CAU TI O NS , A ND WARNINGS
This manual includes three types of supplemental and important information, they are:
NOTE: The information given here is useful to the service technician while performing a procedure.
CAUTION: The information given here indicates proper procedures which, in NOT followed, may cause damage to the
PhotoPress machine.
WARNING: The information given here indicates proper procedures which, in NOT followed, may cause injury to you.
WARNING: The weight of the PhotoPress machine is approximately 200lb. Do not lift it yourself.
WARNING: The PhotoPress machine must be placed on a solid service capable of holding at least 400lb.
WARNING: Operating the PhotoPress without the covers installed can cause serous personal injury. Your finger will be
severed if you get it caught in the chain and sprocket while they are moving. Your finger will be crushed if it is in the way
of the platen. Do not allow your finger between the platen and the lid or between the platen and the frame plate (just
below the platen).
WARNING: You must read the PhotoPress User’s Manual before operating or servicing the PhotoPress. There is impor-
tant operating and safety information in that manual.
WARNING: Unplug the PhotoPress before cleaning, or performing maintenance on it.
WARNING: Connect all electrical equipment to properly grounded power outlets.
WARNING: Place the PhotoPress on a flat surface. Do not allow the PhotoPress machine to “hang” over the edge of a
table.
WARNING: Do not attempt repairs other then ones explained in this manual.
Page 2 PhotoPress Service Manual, Rev. B 8/26/11

2 DEFINITIONS
This manual is a guide for performing basic maintenance, software updates and repairs to the PhotoPress. This manual
includes a troubleshooting chart to help you diagnose and solve common problems.
It is assumed that the maintenance technician is experienced in electronic and mechanical repair.
DEFINITIONS
AUTO CYCLING
The PhotoPress can be set to run continuously for 1,000 press cycles. This is helpful for testing. Auto cycling is started
by pressing the SMALL, MEDIUM or LARGE buttons for five seconds. The LED for that button will blink at a fast rate
indicating that Auto Cycling mode is ready, then press the bind button to start. Auto Cycling may be stopped by letting the
lid open after a completed cycle. You must carefully place a heavy book on the lid to prevent the lid from opening to let
cycling continue. After the PhotoPress completes 1,000 cycles the unit will stop and will beep continually. Cycle the line
power to stop beeping.

3. 1 T h e o r y o f op erati on
The service technician is advised to read the PhotoPress user’s manual and to become expert at assembling and binding
photo books. Often customers will have questions or concerns about the process of making a photo book or operation of
the PhotoPress machine.
Refer to the photos on the following pages as you read thought this guide.
The PhotoPress is controlled by a circuit board which detects button presses on the operator panel. The controller also
reads a number of sensors that detect movement of key components of the machine. Finally, the controller operates two
motors; the latch and platen motors. The controller constantly compares inputs from the sensors with expected actions.
If they don’t match an error condition is signaled by blinking the operator panel LEDs in a binary pattern to indicate one of
several error conditions. The buzzer will also sound. Using the “Error and status codes”, in section 4.2, you may deter-
mine a problem with the PhotoPress by comparing the blinking LEDs with codes in the chart.
Most of the major mechanical components of the PhotoPress are mounted to the bearing plate. The platen motor and
chain drive mechanism are mounted below the bearing plate. On the top surface of the bearing plate, and just visible
when the rear panel is removed, are the four large bearings which the low friction lead screws assemblies ride in. The
bearing plate also holds the side frame plates, which in turn hold the hinge, lid and latch assemblies.
The platen motor is a DC motor. The output of this motor goes through several stages of gearing to produce approximate-
ly 10,000 pounds (4,500Kg) of force required to bind photo books. First there is internal gearing in the motor unit itself.
The output of the motor/gear unit drives a two gear set which, in turn, drives a chain mechanism, both of which also have
mechanical advantage. Finally, four, low friction, ball bearing screws convert rotary motion to linear motion.
The platen motor encoder is mounted above the platen motor and consists of two photointerrupter sensors. An encoder
“cup” is mounted at the end of the platen motor unit, and consists of a series of slots and posts. The posts block the two
photointerrupters of the encoder in a certain order, and the controller interprets these signals and calculates the relative
position, direction and speed of the platen motor.
There are two photointerrupter sensors that tell the controller of the absolute physical position of the platen at predefined
locations. The platen home travel sensor is blocked by the platen flag as the platen moves to its home, or lowest, posi-
tion. The controller always moves the platen to the home position when the PhotoPress is turned on. The controller
reads the platen mid-travel sensor to also verify the platen’s absolute position during operation. The controller constantly
counts the number of posts that interrupt the platen motor encoder and verifies that a predicted count should have oc-
curred each time the home or mid-travel sensors have been interrupted. The controller signals an error, by blinking the
front panel LEDs, if this count does not verify.
The controller board also measures the current supplied to the platen motor and uses this to calculate motor torque. This
is how the controller knows how hard to drive the platen motor to produce the required platen force.
(Continued on next page)

3 THEORY OF OPERATION AND
Finally, the platen interlock switch is wired in series with the motor and acts as a safety to cut power to the motor in the
unusual event that the controller accidently runs the platen up to far.
The latch mechanism performs several operations; holding the lid closed during binding, tilting the lid and opening the
latch. A feature of the PhotoPress is to tilt the lid so that the front and back edge of the book receives an extra firm bind
pressure. The latch mechanism is driven by a step motor and drives an axel shaft through a belt. The other end of the
axel shaft drives the latch shaft though a gear set. A pair of eccentric bearings are mounted on the latch shaft, and are
offset by 0.062 inches. A pair of rocker arms ride in these bearings and are attached to the lower latch plate. The lid will
be even with the platen when the latch shaft is in its mid-level position. When the latch shaft is rotated clockwise (as seen
from the back of the PhotoPress) by 90 degrees from the mid-level position, the latch will move 0.062 inches in the down
direction. This will cause more bind pressure on the right side edge of the photo book. Conversely, when the latch shaft
is rotated counter-clockwise, by 90 degrees from the mid-level position, the latch will move 0.062 inches in the up direc-
tion. This will cause more bind pressure on the left side edge of the photo book. The latch is opened when the latch shaft
is rotated an additional approximately 45 degrees counter-clockwise from the up position. The latch shaft home sensor is
interrupted by the latch shaft flag to indicate the home position of the latch. You can manually open the latch by inserting
a large flat blade screwdriver through the hole in the back cover and turning the latch shaft counterclockwise.
The plunger of the latch sensor switch is closed by the upper latch plate when the lower latch plate closes onto it. This
indicates to the controller that the lid is latched and ready for compression.
The lid flag interrupts the lid photointerrupter sensor when the lid is open. When the lid is closed the upper latch plate
strikes the lid flag and moves it out of the lid photointerrupter indicating to the controller that the lid (but not necessarily the
latch) is closed.

3. 2 Fro n t vi ew
ITEM # DESCRIPTION
1 Lid
2 Lid handle
3 Hinge spring
4 Operator panel
5 Foot plate

3. 3 B a c k v i ew
2 3 4
ITEM # DESCRIPTION
1 Manual latch release
2 Line receptacle, line switch and
fuses
3 Counter
4 Label with serial number

3. 4 B a c k i n tern al v i ew
3
1 4 5 6
9
11
10
8
12
18
17
13 14 15 16
ITEM # DESCRIPTION ITEM # DESCRIPTION

1 Latch Sensor Switch 10 Back Frame Plate
2 Latch Return Spring 11 Bearing Plate
3 Lid Flag 12 Platen Motor
4 Lid Sensor 13 Power Entry Module
5 Platen Interlock Switch 14 Counter
6 Platen Flag 15 Power Supply
7 Platen Mid Travel Sensor 16 Controller Circuit Board
8 Platen Home Travel Sensor 17 Electronics Tray
9 Back Axle Cap 18 Wire Tie

3. 5 Fro n t in tern al v i ew
1 2
6 8
7
ITEM # DESCRIPTION
1 Lid
2 Platen
3 Left Tapping Plate
4 Front Tapping Plate
5 Front Axle Cap
6 Base Plate
7 Latch Motor
8 Latch Belt

3. 6 L ef t i n tern al v i ew
5
4
ITEM # DESCRIPTION
1 Hinge Spring
2 Hinge Spring Hold Down Bar
3 Left Side Plate
4 Reprogramming Port
5 Hinge Spring Anchor Bar

3. 7 R igh t i n tern al v i ew
2 6
ITEM # DESCRIPTION
1 Platen Motor Encoder
2 Upper Latch Plate
3 Lower Latch Plate
4 Front Rocker Arm
5 Back Rocker Arm
6 Latch Shaft
7 Right Side Plate

3. 8 C o n t rol l er c i rc u i t b o ard a sse m bly
3 4
1 2
7 9 11 12 13 14 15
8 10
ITEM # DESCRIPTION ITEM # DESCRIPTION

1 Test Point 6 - VBUS (motor power) 9 Test Point 9 - GND
2 Test Point 4 - +5V (logic power) 10 J10 - Counter, Buzzer, Latch mo-
3 J6 - Jumper Header tor
4 J7 - Sensors 11 F3 - Fuse protects motors
5 USB connecor 12 F2 - Fuse protects counter
6 J2 - Serial port 13 J8 - Power
7 Mounting holes (4) 14 F1 - Fuse protects logic
8 J12 - Platen motor 15 J3 - Operator panel

3. 9 Sp e c i f ic ati on s
Power Requirements: PHP: 115V (110-125VAC) 50-60 Hz, 3 Amps

PHPE: 220V (220-240VAC) 50-60 Hz, 1.5 Amps
PHPJ: 100V (90-110VAC) 50-60 Hz, 3 Amps
Power Consumption: PHP: 300 Watts max

PHPE: 300 Watts max
PHPJ: 300 Watts max
Recommended Operating 15 to 35 degrees (C), 59 to 95 degrees (F)

Temperature and Humidity Range: 5 to 80% RH non-condensing
Humidity:
Maximum Weight: approx. 200lbs
Dimensions: 23.5”W x 22.5”H x 19.6”D

Bind Capacity: 0.040” to 0.500” (1mm to 19mm)
Bind Speed: Small: 70 sec

Medium: 100 sec
Large: 135 sec
Safety Certifications: UL, CE, CUL

3. 1 0 C o n t ac ti n g tec h n i c al suppor t
If there are any questions not answered in this manual, please contact the Powis Parker Technical Sup-
port Dept: 510-848-2463.
e-mail: techservice@powis.com

4 TROUBLESHOOTING GUIDE
4. 1 Gen e ra l tro u bl es h oo ting
• PHOTOPRESS IS POWERED ON BUT DOES NOT OPERATE

PhotoPress is turned on, Latch Motor is heard running for a few seconds after power on, platen does not move, BIND
LED blinks.
Possible Cause Solution
Lid is open. Close lid.
Lid sensor disconnected or broken. Repair or replace as needed. Refer to Sec. 5.10
• PHOTOPRESS WILL NOT AUTO CYCLE

When set for auto cycling, PhotoPress will only run one cycle then stop.
Lid opened at end of first cycle. Auto cycling will stop if the lid opens at end of a
bind cycle or when completing 1,000 auto cycles.
To keep PhotoPress auto cycling carefully place a
heavy book on the lid.
• PHOTOPRESS WILL NOT POWER UP OR WILL NOT OPERATE

Line Cord is not securely plugged in. Check that the line cord is securely plugged into
the machine and into the wall outlet. Check the
line cord with an ohm meter for open conductors.
Electrical outlet is not functioning. Plug the machine into another power outlet.
Line fuse(s) may have blown. Test line fuses. If blown, determine reason for
blown fuse then replace line fuse(s).
Power supply may have failed. (Line fuse(s) OK.) Unplug line cord. Remove rear cover (see
procedure 5.2). Reconnect line cord and turn on
line switch.
Observe power supply LED, it should be on when
line switch is on.
Verify power supply output is 45Vdc +/-1.0Vdc.
Replace power supply if needed. Refer to section
5.4.
Circuit board fuse(s) may have blown. With line switch off (and rear cover removed),
(Power supply OK.) test fuses F1, F2 and F3 on circuit card. If blown
determine reason for blown fuse then replace.
F1 protects logic circuit.
F2 protects counter.
F3 protects motors.
Firmware may be corrupted. With line power on (and rear cover removed)
(Power supply and circuit card fuses OK.) observe circuit card LED . A blinking LED
indicates firmware and CPU are OK.
Reprogram circuit card if LED not blinking. Refer
to section 6.1.
Circuit card may have failed. Replace circuit card. Refer to section 5.5.
(Power supply, circuit card fuses and firmware all OK.)

• PLATEN MOTOR RUNS INTERMITTENTLY OR NOT AT ALL

Platen motor brushes may be worn. Replace platen motor brushes. Refer to section
5.17.
• PLATEN MOTOR MAKES EXCESSIVE NOISE WHILE RUNNING

Platen motor (or internal gears) may be worn. Replace platen motor if needed. Refer to section
5.18.
• COUNTER NOT WORKING

Fuse F2 (located on circuit card) may be blown.. With power off, test fuse. If blown determine
reason for fuse blowing and replace.
Counter not working (fuse F2 OK). Replace counter. Refer to section 5.6.
NOTE: You can manually open the latch by inserting a large flat blade screwdriver through the hole in the
back cover and turning the latch shaft counterclockwise. See section 3.3.

4. 2 E rro r an d s tatu s c o d es
If the PhotoPress encounters an error condition during operation the beeper will sound repeatedly and the
front panel LEDs will blink in a binary pattern, indicating an error number. Note which LEDs are blinking if
you call Powis Parker Inc. for assistance.
In the following chart, a blinking LED is represented in BOLD type.

Example:
If the PhotoPress signals Error# 10, (circuit card over temperature) the small and large LEDs would blink.
This is represented in the text below as follows: OPEN SMALL MEDIUM LARGE BIND
• Error# 1 - OPEN SMALL MEDIUM LARGE BIND - Latch opened during compress.
The latch sensor changed state while the platen was moving up and compressing the book
Latch sensor switch needs adjustment. Check and, if necessary, adjust latch sensor
switch. Refer to section 5.13.
Latch switch or cable is broken. Replace latch sensor switch. Refer to section
5.13.
Latch opened during compress. Latch components may be worn. Call service.
• Error# 2 - OPEN SMALL MEDIUM LARGE BIND - Latch opened during dwell.
The latch sensor changed state while the platen was in the dwell state.
Latch sensor switch needs adjustment. Check and, if necessary, adjust latch sensor
switch. Refer to section 5.13.
Latch switch or cable is broken. Replace latch sensor switch. Refer to section
5.13.
Latch opened during dwell. Latch components may be worn. Call service.
• Error# 3 - OPEN SMALL MEDIUM LARGE BIND - Lid opened during compress.
The lid sensor changed state while the platen was moving up and compressing the book.

Lid sensor or cable is broken. Replace Lid sensor. Refer to section 5.10.
Lid opened during compress. Latch components may be warn. Call service
• Error# 4 - OPEN SMALL MEDIUM LARGE BIND - Lid opened during dwell.
The lid sensor changed state while the platen was in the dwell state.
Latch switch is broken. Replace latch sensor. Refer to section 5.10.
Latch opened during dwell. Latch components may be warn. Call service.

• Error# 5 - OPEN SMALL MEDIUM LARGE BIND - Vmbus too high (>52Vdc).
Vmbus is located on the circuit card, TP6 is the test point. This power buss supplies the platen motor,
latch motor and counter. Normal voltage for this buss is 45Vdc. This error condition will activate if this
voltage goes above 52Vdc
Power supply set to high. Measure power supply voltage and, if necessary,
adjust the small potentiometer on the power
supply to 45Vdc +/-1.0Vdc
Power supply may be faulty. If power supply resists adjustment, replace. Refer
to section 5.4.
• Error# 6 - OPEN SMALL MEDIUM LARGE BIND - Vmbus too low (>40Vdc).
Vmbus is located on the circuit card, TP6 is the test point. This power buss supplies the platen motor,
latch motor and counter. Normal voltage for this buss is 45Vdc. This error condition will activate if this
voltage goes below 40Vdc

Power supply set to low. Measure power supply voltage and, if necessary,
adjust the small potentiometer on the power
supply to 45Vdc +/-1.0Vdc.
Fuse F3 on circuit board blown. Determine cause of blown fuse and replace.
Excessive current being drawn. Determine cause of excessive current draw and
repair.
Power supply may be faulty. Replace power supply. Refer to section 5.4.
• Error# 7 - OPEN SMALL MEDIUM LARGE BIND - +5V bus too high (>5.2Vdc).
+5V bus is located on the circuit card, TP4 is the test point. This power buss supplies the logic circuitry
on the circuit board. Normal voltage for this buss is 5Vdc. This error condition will activate if this
voltage goes above 5.2Vdc
If this error condition happens repeatedly then the 5 Replace if circuit card if necessary. Refer to
volt regulator circuit on the circuit board may be faulty. section 5.5.
• Error# 8 - OPEN SMALL MEDIUM LARGE BIND - +5V bus too low (>4.8Vdc).
+5V bus is located on the circuit card, TP4 is the test point. This power buss supplies the logic circuitry
on the circuit board. Normal voltage for this buss is 5Vdc. This error condition will activate if this
voltage goes below 4.8Vdc
There may be a short in the wiring of one of the Investigate wiring and sensors for shorts and
sensors. repair as necessary.
If this error condition happens repeatedly then the Replace if circuit card if necessary. Refer to
circuit board may be faulty. section 5.5.

4T R O U B L E S H O O T I N G G U I D E
• Error# 9 - OPEN SMALL MEDIUM LARGE BIND - Platen motor drive power fault.
Platen motor or wiring shorted to ground. Determine and repair.
Circuit card failure. Replace circuit card. Refer to section 5.5.
• Error# 10 - OPEN SMALL MEDIUM LARGE BIND - Circuit card over temperature (>60 deg Celsius).
PhotoPress unit exposed to high ambient Refer to specifications section of PhotoPress
temperature. owner’s manual for ambient operating
requirements..
PhotoPress overheating. Determine cause of excessive internal heat and
repair as needed.
• Error# 11 - OPEN SMALL MEDIUM LARGE BIND - Platen motor direction error.

Wrong platen motor installed. Early PhotoPress units used a different platen
motor compared to later units. See appendix A for
details.
• Error# 12 - OPEN SMALL MEDIUM LARGE BIND - Platen exceeded lower or upper travel limits.
Platen home and/or mid position sensors broken. Replace as needed. Refer to section 5.9.
Encoder board faulty. Replace encoder board. Refer to section 5.15.
• Error# 13 - OPEN SMALL MEDIUM LARGE BIND - Platen motor running longer then needed for
press cycle.
Internal gears in motor may be broken. Remove back cover and examine encoder cup by
looking through the gap between the platen and
base plate while motor is running. If encoder cup
is not moving, then internal gears in motor may
be broken. Replace motor as needed. Refer to
section 5.18.
Broken drive train. Locate problem and repair as needed.

• Error# 14 - OPEN SMALL MEDIUM LARGE BIND - No compression detected by CPU board.
Internal gears in motor may be broken. Remove back cover and examine encoder cup by
base plate while motor is running. If encoder cup
is not moving, then internal gears in motor may
be broken. Replace motor as needed. Refer to
section 5.18.
Broken drive train. Locate problem and repair as needed.
• Error# 15 - OPEN SMALL MEDIUM LARGE BIND - Machine unable to initialize correctly.
- Call service.
• Error# 16 - OPEN SMALL MEDIUM LARGE BIND - Generic error.

- Call service.
• Error# 17 - OPEN SMALL MEDIUM LARGE BIND - Quadrature Encoder error.

Grease contaminating quadrature encoder cup and/or Remove back cover and examine encoder cup by
photo-interrupter. looking through the gap between the platen and
rear frame plate. If encoder cup is contaminated
with grease, remove motor and clean encoder
cup. Refer to section 5.18. Examination and
cleaning the photo-interrupter requires removing
the encoder assembly. Refer to section 5.15.
Internal motor gears broken. Remove back cover and examine encoder cup by
rear frame plate while motor is running. If encoder
cup is not moving, then internal gears in motor
may be broken. Replace motor as needed. Refer
to section 5.15.
• Error# 18 - OPEN SMALL MEDIUM LARGE BIND - FACTORY USE

- Call service.
• Error# 19 - OPEN SMALL MEDIUM LARGE BIND - FACTORY USE

- Call service.

• Status# 20 - OPEN SMALL MEDIUM LARGE BIND - Small size auto-cycling completed.
PhotoPress has completed 1,000 small size auto-cycles.
• Status# 21 - OPEN SMALL MEDIUM LARGE BIND - Medium size auto-cycling completed.
PhotoPress has completed 1,000 small medium auto-cycles.
• Status# 22 - OPEN SMALL MEDIUM LARGE BIND - LARGE size auto-cycling completed.
PhotoPress has completed 1,000 small size auto-cycles. .
• Error# 23 - OPEN SMALL MEDIUM LARGE BIND - Latch slippage exceeded 2 degrees.
- Call service.
• Error# 24 - OPEN SMALL MEDIUM LARGE BIND - Latch open while platen moving up.
- Call service.
• Error# 25 - OPEN SMALL MEDIUM LARGE BIND - Lid open while platen moving up.
- Call service.

5. 1 R e q u i red to ol s
When servicing a PhotoPress the following tools are required:
HAND TOOLS
Phillips screwdrivers #1 and #2
Large flat blade screwdriver
Ratchet offset driver with medium size flat blade bit and #2 Phillips bit
3/32” Hex driver
5/32” ball Hex driver, screwdriver type (MSC pn# 05050109 is recommended)
5/32” ball Hex “L” driver key, modified as follows:
Modify a 5/32” ball ended, Hex “L” driver key by cutting off the “L” part.
Use an appropriate grinding tool. This modified Hex driver is helpful to start the
motor mounting screws. See the figure below.
Needle nosed pliers
Diagonal cutters
DVM meter
Ground strap
Flashlight
Dental mirror
TOOLS FOR UPGRADING OF FIRMWARE

USB cable
PC with either Windows 2000, XP, or ME
Internet access
CLEANING SUPPLIES
Paper towels
Modified 5/32” ball Hex “L” driver.

5. 2 R e mov i n g rear c over
TOOLS REQUIRED:
#2 Phillips Screwdriver
1. Turn off the PhotoPress and unplug the line cord.

2. Remove 13 Phillips screws with star washers and remove the rear
cover, see fig. 1 and 2.
Fig. 1 - Removing 13 screws.
Fig. 2 - Removing the rear cover.

3. When reinstalling rear cover be sure that cables are not pinched.
Reinstall the cover screws with the star washers.

5. 3 R e mov i n g el ec tro n i c s tray

TOOLS REQUIRED:
Ground strap
1. Remove the rear cover as described above in part 5.2.
2. As when working with any static sensitive electronic circuitry, use a

wrist grounding strap.
3. Carefully unplug the following connectors from the circuit card:

Platen Motor in line connector.
Platen Motor cable to circuit card.
Unlock the cable clip. (See figure 2) Fig. 1 - Disconnecting connectors.
Counter in line connector.
Buzzer in line connector.
Step motor cable to circuit board.
Sensor cable to circuit board.
User panel cable to circuit board.
Fig. 2 - Disconnecting the cable clip.
5. Remove two screws holding the electronics tray to the base of the
PhotoPress.
6. Carefully cut the cable tie located at the upper part of the electronics
tray.
Fig. 3 - Removing the two screws that hold the

electricians tray.
7. Finally, carefully slide the electronics tray out of the PhotoPress.
8. Reinstallation is the reverse of the above procedure. Fasten a new

cable tie to hold cables to the upper part of the electronics tray.
Fig. 4 - The electronics tray is slid out.

5 SERVICE AND CALIBRATION
5. 4 R e p la c i n g th e p ower supply (K -205129)
TOOLS REQUIRED:
Ground Strap

3. Remove the rear cover and electronics tray as described in parts 5.2
and 5.3.
4. Remove the wires connected to the power supply. Note the arrange-
ment of the wires before removing them; you will need to reinstall them
in the same order later. See fig. 1.
Fig. 1 - Unscrewing wires from power supply.

Note their placement for reassembly..
5. Remove one screw and lift out the power supply from the electronics
tray. See fig. 2 and 3.
Fig. 2 - remove one screw.
6. Installing the replacement power supply is the reverse of removal. Be-

fore returning the PhotoPress to service, test the power supply in the
following way:
Fasten the power supply to the electronics tray and reattach the HOT,
NEUTRAL and GND wires. DO NOT attach the +V and –V wires yet.
Plug the line cord into the power entry module and turn on the line
switch.
The LED in the power supply should light.
Verify that there is 45 volts +/-1.0 volts at the output.
Fig. 3 - The power supply is removed from the

7. If the power supply verifies, turn off the line switch and unplug the line electronics tray.
cord, connect the remaining wires and reinstall the electronics tray and
rear panel.

5. 5 R e p la c i n g th e c i rc u i t boa rd (K -205139)
TOOLS REQUIRED:
#1 and #2 Phillips Screwdriver
Ground Strap

and 5.3.
4. Disconnect connector J8 “PWR IN”.
Fig. 1 - Disconnecting the power cable.
5. Remove four screws and lift out the circuit board assembly (with the
metal backing plate) from the electronics tray.
Fig. 2 - Lifting out the circuit board with

backing plate.
6. Installing the new circuit board assembly is the reverse of the above
Fig. 3 - The circuit board is removed.
procedure.
7. Verify the firmware on the new circuit board before returning the Pho-
toPress to service.
Visit the Powis Parker web site (www.powis.com) for firmware revision
information and to download firmware, and see part “Reprogramming
the PhotoPress using Atmel’s SAM-BA” for information about repro-
gramming the PhotoPress. See section 6.

5. 6 R e p la c i n g c ou n ter (K-205872)
TOOLS REQUIRED:
and 5.3.
4. Clip one wire tie.
Fig. 1 - Clip the wire tie.
5. Remove one screw, and....
Fig. 2 - Remove one screw.
6. Remove the counter.
Fig. 3 - The counter is removed.
7. Installing a new counter is the reverse of the above procedure.

5. 7 R e p la c i n g p ower en tr y m odule (K -205857)

TOOLS REQUIRED:
and 5.3.
2. Clip one wire tie, see fig. 1.
Fig. 1 - Clip one wire tie.
3. Remove the clear plastic safety cover from the power supply termi-
nals, and unscrew the ground and line voltage cables from the power
supply, see fig. 2. Note there placement for reinstallation.
Fig. 2 - Removing line wires from power supply.
4. Unscrew the nuts to remove the ground wire from the grounding post,
see fig. 3.
Fig. 3 - Removing wires from the grounding post.
5. Remove the two screws holding the power entry module to the elec-
tronics tray, see fig. 4.
6. Reinstallation is the reverse of the above procedure. Fasten a new

cable tie to hold cables. Do not over tighten the screws holding the
power entry module or the terminal screws of the power supply.
Fig. 4 - The electronics tray is slid out.

5. 8 R e p la c i n g p l aten i n terlock switch ( K -205160)

TOOLS REQUIRED:
1. Remove the rear cover as described in part 5.2.
2. Remove two connectors as shown in fig. 1. Use caution - the connec-

tors are firmly attached to the switch.
Fig. 1 - Disconnecting connectors.
3. Remove two screws, see fig. 2, and...
Fig. 2 - Removing the mounting screws.
4. Remove the switch.
Fig. 3 - Removing switch.
5. Reinstallation is the reverse of the above procedure. Do not over

tighten the screws.

5. 9 R e p la c i n g p l aten fl ag a nd se nsors ( K -205017, K -200384)

TOOLS REQUIRED:
2. Remove the two screws holding the platen flag. Use a right angel
Phillips driver to break the screws free.
Fig. 1 - Removing the two screws of the platen

flag.
3. Remove the flag.
Fig. 2 - Removing the platen flag.
4. Remove the sensor connector.
Fig. 3 - Removing the sensor connector.
5. Remove the screw holding the platen mid-level sensor. Repeat this
step with the platen home sensor.

tighten the screws holding the sensors.
Fig. 4 - Removing the mid-level sensor screw.

5. 1 0 R ep lac i n g th e l i d fl a g a nd se nsor (K -205015)

TOOLS REQUIRED:
Flat blade screwdriver
2. Carefully unhook the lid flag return spring, see fig. 1.
Fig. 1 - Disconnecting the lid flag return spring.
3. Carefully remove the circle clip, see fig. 2.
Fig. 2 - Removing the circle clip.
4. Disconnect the lid sensor connector, see fig. 3.
Fig. 3 - Disconnecting the lid sensor connector.
5. Remove the screw holding the lid sensor, and remove the sensor, see
fig. 4.

tighten the lid sensor screw.
Fig. 4 - Removing the lid sensor mounting screw.

5. 1 1 R ep lac i n g op erator pa ne l ( K -205188)
TOOLS REQUIRED:
5/32” ball Hex driver, screwdriver type
2. Using the 5/32” Hex driver, remove the two cap screws underneath
the operator panel, see fig. 1.
WARNING - The screws are difficult to reach, but DO NOT slide the
PhotoPress over the edge of the table.
Fig. 1 - Unscrewing two cap screws.
3. Being careful not to tug the cable, remove the operator panel and
unplug the connector, see fig. 2, and...
4. Remove remove the panel.
Fig. 2 - Lift out the panel and disconnect the

cable.
6. Installing the replacement panel is the reverse of the above procedure.
Fig. 3 - Removing the panel.

5. 1 2 R emov i n g fro n t an d right cove r

TOOLS REQUIRED:
NOTE: The front and right side cover are one peace and must be re-
moved together.
1. Remove the rear cover and operator panel as described in parts 5.2
and 5.11.
2. Remove 8 screws holding the front and right cover.

Fig. 1 - Remove 8 screws holding the front and

right cover.
3. Carefully bend the right side of the cover to clear the latch mecha-
nism, see fig. 2, then...
Fig. 2 - Bending the right cover away from the

latch mechanism.
4. Tilt out the cover. Be careful not to scratch the paint on the foot plate.
Fig. 3 - Tilting out the cover.
5. Reinstallation is the reverse of the above procedure. When reinstall-

ing the front and right cover, place the bottom edge of the cover on
the foot plate and check that the lip on the left side clears the bearing
plate. Then bend the right cover and, being careful not to scratch the
paint on the foot plate, tilt into place.

5. 1 3 R ep lac i n g l atc h s en sor swit ch (K -205993)

TOOLS REQUIRED:
1. Remove the rear cover, operator panel and front and right cover as
described in parts 5.2, 5.11 and 5.13.
2. Remove the two switch connectors. Use care as the connectors are
a tight fit.
Fig. 1 - Disconnecting connectors.
3. Remove the two switch mounting screws, and...
Fig. 2 - Removing the two screws.
4. Remove the switch.
Fig. 3 - Removing the switch.
5. Before mounting the new switch, close the lid so that the latch en-
gages. Install the new switch and screws but leave them loose. Now,
tighten the lower screw very lightly. Tilt the switch so that the plunger
is fully depressed and the switch housing just makes contact with the
latch. Now, tilt the switch away from the latch slightly. There should
be a 0.010” to 0.015” gap between the latch and switch housing.
Fig. 4 - Installing and adjusting the new switch.

5. 1 4 R ep lac i n g l atc h motor (K -205318)

TOOLS REQUIRED:
1. Remove the rear cover, operator panel and front and right cover as
described in parts 5.2, 5.11 and 5.13
2. Disconnect the latch motor connector.
Fig. 1 - Disconnecting the latch motor

connector.
3. Remove two screws on the latch motor mounting bracket and lift out
the motor.
Fig. 2 - Removing the latch motor mounting

screws.
Fig. 3 - Lifting out the latch motor.
4. Installation of the replacement motor is the reverse of the above pro-

cedure. When installing the new motor be sure that the wires are not
pinched between the motor mounting bracket and the frame. Install
both mounting screws, but leave them loose. Place the belt around
the idler and motor pulleys. Using a screwdriver, press the mount-
ing bracket to tension the belt. Apply about 5 pounds (2Kg) of force.
Now, with your other hand tighten the mounting screws. Reconnect
the connector and verify that the wires are not pinched.
Fig. 4 - Setting tension on the belt.

5. 1 5 R ep lac i n g en c o d er (K -205366)
TOOLS REQUIRED:
Ratchet 90 degree #2 Phillips Screwdriver
2. Remove the rear cover and front and right side cover as described in
parts 5.2 and 5.12. Open the latch by manually by turning the screw,
at the rear of the PhotoPress, counter-clock wise until the latch opens.
Then disconnect the latch return spring.
Fig. 1 - Disconnecting the latch return spring.
3. Disconnect the connector going to the encoder.

NOTE: This is a latching connector, so you must depress the latch at
the end of the connector while removing it. Use a 90 degree ratchet-
ing screwdriver to remove the two screws.
CAUTION: Do not let screws fall into the PhotoPress. If a screw does
fall in - it MUST be retrieved otherwise it may become jammed in mov-
ing parts.
Fig. 2 - Using a ratchet 90 degree screwdriver is

needed in the confined space.
4. Carefully remove the encoder assembly. The encoder meshes with

the encoder cup, mounted at the end of the platen motor shaft, so it
may require some manipulation to remove the encoder assembly.
Fig. 3 - Carefully lifting out the encoder assembly.

5. Reassembly is the reverse of the above procedure. As described
above, the encoder assembly and encoder cup (mounted at the end of
the platen motor shaft) mesh together. So you must take care when
installing the encoder. If the encoder seems to not fit properly, it is
most likely that it is not meshing with the encoder cup. Keep working
the encoder until it fits properly and with the mounting holes lining up.
There is no alignment procedure, other then what is described in this
step.

5. 1 6 R ep lac i n g l i d (K- 2 0 5132)
TOOLS REQUIRED:
2. Open the latch manually by turning the screw at the rear of the Photo-
Press counter-clock wise until the latch opens. Then open the lid.
Fig. 1 - Opening the latch manually.
3. Identify four screws to remove. From the front of the lid these are the
2nd, 5th, 8th and 10th screws, see fig. 2.
NOTE: A magnetic screwdriver is helpful.
Fig. 2 - Identifying the four screws to remove.
4. Remove the four screws.
Fig. 3 - A magnetic screwdriver is helpful.
5. Remove four screws from the hinge side of the lid, and lift out the lid.
6. Reassembly is the reverse of the above procedure.
Fig. 4 - Removing the four screws from the hinge

side of the lid.

5. 1 7 R ep lac i n g p l aten mot or brushe s (K -207466)
NOTE: PhotoPress units with serial numbers 10001 through 10040 where built with early design platen motors. Motor
brushes are not supported for these earlier motors. We recommend that the platen motor for those PhotoPress units
be upgraded to the currently manufactured platen motors--instead of replacing those motor brushes. Upgrading these
motors will also require reprogramming the PhotoPress unit to the latest “MARK13” firmware; which is available from
the Powis web site, (www.powis.com)
NOTE: Changing Platen motor brushes may be accomplished in one of two ways. You can change the brushes with
the motor in the PhotoPress or remove the motor and then change the brushes. Both methods have advantages and
disadvantages. Removing and installing the brushes with the motor in the PhotoPress is cumbersome because there
is a confined space in the area of the motor brushes. Changing the brushes after removing the motor is easy; how-
ever removing the motor is an extra time consuming step. Experience has shown that the best choice is to change the
brushes with the motor still in the PhotoPress. With experience, by doing this job several times and using special tools,
this job can be accomplished in a reasonable time.
TOOLS REQUIRED:
Ratcheting offset screwdriver with medium size flat driver.
Large flat blade screwdriver.
Flashlight.
Dental mirror.
Fig. 1 - Required tools.

2. Remove the rear cover and electronics tray as described in parts

5.1 and 5.2.
3. The Platen motor is a DC motor with positive and negative brushes.

A red dot marks the positive brush, which faces to the rear of the
PhotoPress.
4. Use an offset ratchet screwdriver with a medium size flat blade to

loosen the cap for the negative motor brush. Then use a short (or
“stubby”) screwdriver (or the bit from the offset ratchet screwdriver) Fig. 2 - removing the negative motor brush.
to unscrew the negative motor brush cap. See figure 2.
5. Carefully remove the brush from the motor. Caution: The brushes
are fragile and can be damaged easily. See figure 3.
Fig. 3- Motor brushes are fragile, remove them

carefully.
6. Use a medium size flat blade screwdriver to unscrew the motor cap
for the positive motor brush and remove the brush. See figure 4.
Fig. 4 - Removing the positive motor brush.
7. Installing new platen motor brushes is the reverse procedure of

removal. Note the imprinting of text characters on one side of the
brushes. Brushes should be installed in the motor such that these
characters face the rear of the PhotoPress.
8. Reinstall the electronics tray and back cover as described in sec-

tions 5.1 and 5.2.
9. Power on the PhotoPress and verify proper operation.
Fig. 5 - Insert brushes in motor such that text

faces rear or PhotoPress.

5. 1 8 R ep lac i n g p l aten mot or (K -205191)

NOTE: Early PhotoPress units with serial numbers 10001 to 10040 where built with different platen motors then
later ones. Replacing platen motors on these PhotoPress units will also require reprogramming the PhotoPress unit to
the latest “MARK13” firmware; which is available from the Powis web site. See Appendix A - “Early platen motor con-
version” at the back of this document.
TOOLS REQUIRED:
#2 Phillips screwdriver
5/32” ball Hex driver, screwdriver type (MSC pn# 05050109
recommended)
5/32” ball Hex “L” driver key modifies as described below.
Large flat blade screwdriver
Flashlight
Dental mirror
Paper towels
Fig. 1 - Required tools.
Modify a 5/32” ball ended, Hex “L” driver key by cutting off the “L” part.
Use an appropriate grinding tool. This modified Hex driver is helpful to
start the motor mounting screws. See figure 2
Fig. 2 - Modified 5/32” ball Hex “L” driver.

and 5.2
3. Visually locate four motor mounting screws, see figure 3 - a dental

mirror may be helpful. The screws are partly hidden by one of the
sprockets and the motor itself. Experience has shown that removing
the least accessible crews first is the best way.
Fig. 3 - One of four Platen Motor mounting

screws.
4. Use a ball Hex 5/32” driver to remove each screw completely before
going on to the next. Remove the screw shown in figure 3 last, as it
is the easiest to access, while holding the motor against the bearing
plate with your other hand, see figure 4.
Fig. 4 - Loosening a motor mounting screw with

a 5/32” Hex driver.
5. Once all mounting screws are removed, carefully remove the motor
straight out from the bearing plate. As you pull the motor out it will
contact bottom plate of the PhotoPress. At that point, carefully angle
the motor towards you and continue removing the motor until it is free
of the bearing plate, see figure 5.
Fig. 5 - Removing platen motor from bearing

plate.

6. Before installing the motor you should carefully move the platen up,
until the platen is level with the tamping plates. This will allow better
visibility when verifying proper motor instillation later. Use the 5/32”
ball Hex driver by inserting it the into the chain and using the driver to
pull the chain, see Fig. 7.
Warning: Do not grasp the chain to move the platen. The platen drive
system is heavy had has a considerable mass. Injury can be caused
if your fingers are pinched between the chain and a sprocket.
The recommended way to manually move the platen is as follows: Use

the same 5/32” Hex driver that you used to loosen the motor screws. Fig. 6 - Using the 5/32” Hex driver to manual
Carefully insert the Hex driver into the chain and pull to your left, see move platen.
figure 6. The chain should move with a moderate amount of force.
This will move the chain, the four screws and the platen. The platen
will move up. Continue moving the platen in this way until the upper
surface of the platen is level with the tamping plates. Do not allow the
platen to move higher than the tamping plates, see figure 7.
.
Fig. 7 - Do not allow platen to move higher then

the tamping plates.
7. Inspect the motor before installing it in the bearing plate. Verify that
there are no visible signs of damage to the motor, gear or encoder
cup. Verify that the encoder cup (located at the end of the motor
shaft) is clean and free of grease. If a new motor is being installed;
log the motor model number and serial number then notify Powis
Parker Inc. of this information along with the serial number of the Pho-
toPress (located on the label on the rear panel). See figures 8 and 9.
Fig. 8 - Inspect motor and log serial number.
Fig. 8 - Inspect encoder cup. It must be free of

grease.

8. It is imperative that no grease gets on the encoder cup (located at

the end of the motor shaft) or the encoder circuit card (located above
the installed motor). The encoder circuit card may fail if grease is
transferred from the encoder cup to the components of the encoder
circuit card, so care must be taken when installing the motor such that
grease is not transferred from the big gear to the encoder cup and
then to the components of the encoder circuit card.
Before mounting the motor, carefully wipe grease, using a paper

towel, from the big gear by reaching through the motor mounting hole,
see figures 9 and 10.
Fig. 9 - Paper towels used to clean gear.
Fig. 10 - Cleaning big gear.

9. Carefully insert the motor into the mounting hole in the bearing plate.
This process is basically the reverse of when you removed the motor
from the PhotoPress. Be careful to not allow the encoder cup to bump
into the large gear, as this may cause grease to come in contact with
the encoder cup. Verify that the positive motor terminal faces to the
rear of the PhotoPress and to your right. Verify that the motor regis-
ters in the hole in the bearing plate. Place a screw on the modified
5/32” Hex driver, see figure 11, then while holding the motor, start the
screw into the bearing plate. Once you have a few threads of the
screw started, you can turn the Hex driver around and use the ball end
to drive the screw until it becomes snug. Repeat with the remaining
screws. Start with the most easily accessible screw. Fig. 11 - Place platen motor screw onto the
modified 5/32” Hex key, and...
10. Once all four screws are installed, tighten them firmly with the 5/32”
Hex driver.
Fig. 11 - ...start the screw.
11. Before installing the back cover you must verify that no grease was
transferred to the encoder cup from the big gear. This could have
happened if the encoder cup was bumped into the big gear during mo-
tor instillation.
Using a flashlight, look between the Rear Frame Plate and the Platen
and locate the encoder cup and see if you can find any grease on the
encoder cup. Now, using the 5/32” driver, carefully insert it through
the chain and contact the end of the driver with a tooth of the sprocket,
see figure 12. Caution: do not allow the upper surface of the platen to
move above the tamping plates. Now, while slowly and carefully mov-
ing the handle of the diver to your left to slowly move the chain, and Fig. 12 - Using the 5/32” Hex driver to manually
observe the encoder cup as it also turns. Rotate the encoder cup one move chain while inspecting encoder cup.
complete rotation while verifying that no grease in on the encoder cup.
If you notice grease on the encoder cup; you may remove the grease
with a long cotton swab dampened in alcohol.
12. See part 5.1 and 5.2 for reinstalling the electronics tray and back
cover.
13. Power on the PhotoPress and verify proper operation.

6. 1 U p g ra di n g fi rmware
1. Location of SAM-BA program –

The software can be found and downloaded from ATMEL's website at
http://www.atmel.com/dyn/products/tools_card_v2.asp?tool_id=3883
2. Save the Powis PhotoPress Firmware on your computer and note the location
3. Turn on the PhotoPress and wait until the lid opens. Then close the lid.
4. Remove the plastic plug from the left side of the PhotoPress. This is the USB port.
5. Plug a USB cable into your PC computer.
6. While holding down the OPEN button, plug the other end of the USB cable into the USB port of the PhotoPress.
7. Turn off the PhotoPress, and unplug the USB cable from the PhotoPress.
8. Now plug the USB cable back into the USB port of the PhotoPress.
Note: It is not necessary to turn on the PhotoPress.

Note: The Firmware on the PhotoPress PCA is now erased
9. The computer will detect the PCA in the PhotoPress – Follow the steps below
a. Select “Yes, this time only” and click “Next”
Select “Install from a list…..” then click “Next”

Select “Don’t Search”…. then click “Next”
Select “atm6124…” then click “Next.”
Click “Continue Anyway”

Click “Finish”
10. On your computer, open SAM-BA. It should respond with the following dialog:
11. Verify that the “Select the connection:” and “Select your board:” fields match the ones above, and then click on the
“Connect” button.
The following dialog box should appear:

12. Click the “Flash” tab and enter the path of the file to be loaded to the PhotoPress in the “Send File Name” field
13. Click the “Send File” button. The following dialog box should appear:
Click the “No” button

WARNING: Clicking on the “Yes” button will prevent this PhotoPress PCA from being reprogrammed later.
14. Click the Execute button
15. Now close SAM-BA and unplug the USB cable from the PhotoPress.
16. Turn on the PhotoPress and verity proper operation.

7 SERVICE KITS
7. 1 Ser v i c e k i t p ar t n u mbe rs
K-205129 Service Kit, PHP, Power Supply

K-205132 Service Kit, PHP, Cover, Top Wave
K-205139 Service Kit, PHP, PCB, Kit
K-205160 Service Kit, PHP, Switch, level w/roller
K-205188 Service Kit, PHP, Operator Interface
K-205191 Service Kit, PHP, DC Gear Motor and Cable
K-205318 Service Kit, PHP, Motor, Latch Actuating
K-205366 Service Kit, PHP, Assy, Encoder
K-205485 Service Kit, PHP, Line Fuse, 2.5A, 250V
K-207466 Service Kit, PHP, Platen Motor Brush
K-205857 Service Kit, PHP, Power Entry Module
K-206993 Service Kit, PHP, Latch Switch and Bracket
K-205905 Service Kit, PHP, Pressure Pad
K-205872 Service Kit, PHP, Counter
K-205015 Service Kit, PHP, Lid Flag and Sensor
K-205017 Service Kit, PHP, Platen Flag
K-205000 Service Kit, PHP, PCB Fuses
K-200384 Service Kit, PHP, Sensor

7 SERVICE KIT PICTURES
7. 2 Ser v i c e k i t p h otographs
K-205129 - PHP, power supply K-205132 - Cover, Top Wave
Item Qty. Item Qty.

Power Supply 1 Cover, top wave 1
Screw 1 Screws 8
K-205139 - PCB kit K-205160 - Platen interlock switch

Item Qty. Item Qty.
Controller PCB assy. 1 Switch, level w/roller 1
Screws 4 Screws 2

K-205188 - Operator interface K-205191 - DC gear motor and cable

Item Qty. Item Qty.
Operator interface panel 1 Platen motor assembly with cable 1
Screws 2 Screws 4
Split washers 4
K-205318 - Motor, latch actuating K-205366 - Assy. encoder

Item Qty. Item Qty.
Motor with mounting bracket 1 Encoder assy. 1
Screws 2 Screws 2

K-205485 - Line fuse, 2.5A, 250V K-207466 - Platen motor brush

Item Qty. Item Qty.
2.5A 250V Fuses 2 Platen motor brush 1
K-205857 - Power entry module K-206993 - Latch switch and bracket

Item Qty. Item Qty.
Power entry module 1 Switch 1
Screw 2 Screw 2

K-205905 - Pressure pad K-205872 - Counter

Item Qty. Item Qty.
Pressuer Pad 1 Counter 1
Screw 1
K-205015 - Lid flag and sensor K-205017 - Platen flag

Item Qty. Item Qty.
Lid flag 1 Lid flag 1
Sensors 1 Screws 2
Circle clip 1
Screw 1

K-205000 - PCB Fuses K-200384 -Sensor
Item Qty. Item Qty.

Fuse, 3.0A 10 Sensor 1
Fuse, 0.75A 10 Screw 1
Fuse, 0.062A 10

8 APPENDIXES
Appendix A - Early platen motor conversion
PhotoPress units with serial numbers 10001 to 10040 were built with different platen motors then later ones. The two
motor types run in opposite directions and have different gearing.
Motor brushes are not supported for the earlier motors. Instead of replacing motor brushes on earlier platen motors,
we recommend that the platen motor for those earlier PhotoPress units be upgraded to the currently supplied platen
motors. Upgrading these motors will also require reprogramming the PhotoPress unit to the latest “MARK13” firmware;
which is available from the Powis web site, (www.powis.com)
Use service kit K-205191 to replace platen motors.
Platen motor used with early PhotoPress units. Platen motor used with later PhotoPress units.

8 APPENDIXES
Appendix B - Coil spring conversion
PhotoPress units having serial numbers 100001 to 100048 where built with coil hinge springs. Later units
where built with a one piece machined hinge spring. If desired, the coil hinge springs may be changed to
the one piece spring. Request Technical Bulletin TB10-01 from Powis Technical Support.

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PHOTOPRESS

Copyright Powis Parker Incorporated 2010

PhotoPress Service Manual, Rev. B 8/26/11 i

3 THEORY OF OPERATION AND OVERVIEW

5 SERVICE AND CALIBRATION PROCEDURES

7 SERVICE KIT PART NUMBERS

ii PhotoPress Service Manual, Rev. B 8/26/11

PhotoPress Service Manual, Rev. B 8/26/11 Page 1

1. 2 N OTE S , CAU TI O NS , A ND WARNINGS

WARNING: Unplug the PhotoPress before cleaning, or performing maintenance on it.

WARNING: Connect all electrical equipment to properly grounded power outlets.

Page 2 PhotoPress Service Manual, Rev. B 8/26/11

PhotoPress Service Manual, Rev. B 8/26/11 Page 3

(Continued on next page)

Page 4 PhotoPress Service Manual, Rev. B 8/26/11

PhotoPress Service Manual, Rev. B 8/26/11 Page 5

Page 6 PhotoPress Service Manual, Rev. B 8/26/11

PhotoPress Service Manual, Rev. B 8/26/11 Page 7

ITEM # DESCRIPTION ITEM # DESCRIPTION

Page 8 PhotoPress Service Manual, Rev. B 8/26/11

PhotoPress Service Manual, Rev. B 8/26/11 Page 9

Page 10 PhotoPress Service Manual, Rev. B 8/26/11

PhotoPress Service Manual, Rev. B 8/26/11 Page 11

3. 8 C o n t rol l er c i rc u i t b o ard a sse m bly

ITEM # DESCRIPTION ITEM # DESCRIPTION

Page 12 PhotoPress Service Manual, Rev. B 8/26/11

Power Requirements: PHP: 115V (110-125VAC) 50-60 Hz, 3 Amps

Power Consumption: PHP: 300 Watts max

Recommended Operating 15 to 35 degrees (C), 59 to 95 degrees (F)

Dimensions: 23.5”W x 22.5”H x 19.6”D

Bind Speed: Small: 70 sec

Safety Certifications: UL, CE, CUL

PhotoPress Service Manual, Rev. B 8/26/11 Page 13

Page 14 PhotoPress Service Manual, Rev. B 8/26/11

4. 1 Gen e ra l tro u bl es h oo ting

• PHOTOPRESS IS POWERED ON BUT DOES NOT OPERATE

• PHOTOPRESS WILL NOT AUTO CYCLE

• PHOTOPRESS WILL NOT POWER UP OR WILL NOT OPERATE

PhotoPress Service Manual, Rev. B 8/26/11 Page 15

• PLATEN MOTOR RUNS INTERMITTENTLY OR NOT AT ALL

• PLATEN MOTOR MAKES EXCESSIVE NOISE WHILE RUNNING

• COUNTER NOT WORKING

Possible Cause Solution

Page 16 PhotoPress Service Manual, Rev. B 8/26/11

In the following chart, a blinking LED is represented in BOLD type.

Possible Cause Solution

Possible Cause Solution

PhotoPress Service Manual, Rev. B 8/26/11 Page 17

Possible Cause Solution

Page 18 PhotoPress Service Manual, Rev. B 8/26/11

Circuit card failure. Replace circuit card. Refer to section 5.5.

Possible Cause Solution

Encoder board faulty. Replace encoder board. Refer to section 5.15.

PhotoPress Service Manual, Rev. B 8/26/11 Page 19

• Error# 16 - OPEN SMALL MEDIUM LARGE BIND - Generic error.

• Error# 17 - OPEN SMALL MEDIUM LARGE BIND - Quadrature Encoder error.

• Error# 18 - OPEN SMALL MEDIUM LARGE BIND - FACTORY USE

• Error# 19 - OPEN SMALL MEDIUM LARGE BIND - FACTORY USE

Page 20 PhotoPress Service Manual, Rev. B 8/26/11

PhotoPress Service Manual, Rev. B 8/26/11 Page 21

When servicing a PhotoPress the following tools are required:

TOOLS FOR UPGRADING OF FIRMWARE

Modified 5/32” ball Hex “L” driver.