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37 

The GBC SmartPunch is a machine that punches various die set hole patterns into single sheets of 
paper.  The machine is placed between a multi-function printer / copier and a finisher.  There are two 
paper paths.  One is the bypass section, which does not punch paper.  The other is the punch path.  The 
punch path can be selected by pressing through the printer driver or the touch panel display on the  of the 
Sharp series of Multifunction printer/copier. 

The SmartPunch consists of several input / output devices to operate the machine functions.  The system 
intelligence is a Microchip micro-controller PIC17C752.  The present code is written in Microchip 
assembler.  The list of I/O devices is: 

Refer to the electrical wiring information, when reading the following material. 

Sensor 1 

Optical 

Sheet speed measurement, Jam detect 

Sensor 2 

Optical 

Stepper 1 control, Sheet speed measurement, Jam detect 

Sensor 3 

Optical 

Punch mechanism control, Backstop raiser, Jam detect 

Sensor 4 

Optical 

Jam detect at entrance of U-Channel 

Sensor 5 

Optical 

No longer used 

Sensor 6 

Optical 

Stepper 2 Control, Jam detect 

Sensor 7 

Optical 

Exit sensor, Jam detect 

Sensor 8 

Optical 

Bypass sensor, Sheet speed measurement, Jam detect 

Sensor 9 

Optical Vane 

Monitors rotation of punch mechanism, Controls clutch and brake 

Switch 1 

Keypad 

Selects punch mode  

Switch 2A 

Mechanical 

Interlock Voltage, no machine movement if door is open 

Switch 2B 

Mechanical 

Door open signal 

Switch 3 

Mechanical 

Chip tray switch 

Switch 4 

Mechanical 

Die Set switch 

 

Diverter 

DC Solenoid 

Diverts paper from bypass to punch sections 

Brake 

DC Brake 

Stops the punch mechanism, keeps it in correct position 

Clutch 

DC Clutch 

Clutches the punch mechanism to drive through paper 

Backstop 

DC Solenoid 

Provides stop for paper to rest against during punching 

Transport 

AC Motor 

Provides paper movement through machine 

Punch 

AC Motor 

Provides power to punch the paper 

Stepper 1 

PWM Signal 

Controls Stepper Motor 1 

 

Winding 

On / Off signal for stepper holding current 

Stepper 2 

PWM Signal 

Controls Stepper Motor 2 

 

Winding 

On / Off signal for stepper holding current 

LED 1 

Chip Tray 

ON: Chip Tray missing, FLASHING: Chip Tray may be full 

LED 2 

Die Set 

ON: Die Set not installed properly 

LED 3 

Door 

ON: Door is Open 

LED 4 

Jam  

ON: Paper Jammed in Machine 

LED 5 

Punch On 

ON: Punch Enabled 

 

MULTI-FUNCTIONPRINTER COMMUNICATION: 
Punch 

Input 

Multi-function printer turns on Punch enabled mode 

Motor 

Input 

Multi-function printer turns on SmartPunch Motor  

Jam 

Output 

Punch signals a jam or the door is open (no operation allowed) 

Tray / Die 

Output 

Punch indicates tray or die set missing (bypass only allowed) 

 

SERIAL EEPROM CONTROL: 
1 Input 

3 Outputs 

Counts number of punches for die set full, Saves value 

38 

 

For the SmartPunch to operate, all optical sensors must be clear.  Any blocked sensor or open door will 
prevent operation.  The machine may operate in bypass mode with or without a chip tray or die set.  Both 
of these must be present to punch. 

 

If punch is not enabled, the SmartPunch will run in bypass mode (no punching).  Either the multi-function 
printer or the first sheet entering the machine will turn on both stepper motors. The time is measured for 
the leading edge of the first sheet to pass sensor 8. Knowing the distance between sensors and the time 
it takes for the sheet to pass both sensors, we can determine the speed of the paper. The time is 
compared to a list and Stepper 1 and stepper 2 are adjusted to closely match the incoming speed. 

If the punch is enabled, the backstop is raised, the brake is engaged, and both the transport and punch 
motors are started.  Also, the divert solenoid is activated to direct the sheets into the punch path.  As 
above, the input speed is measured, this time using Sensor 1 and 2.  Stepper 1 is adjusted to meet the 
measured input speed; Stepper 2 is accelerated to the speed of the transport motor.  Sensor 2 now 
delays for a time period based on the input speed to ensure that the sheet has cleared the multi-function 
printer exit roller. After this delay, stepper 1 accelerates the sheet to match the transport speed. 19 msec 
after the sheet’s trailing edge passes sensor 2, Stepper 1 is decelerated to match the previously 
measured input speed.   

 

The punch cycle begins 40 msec after the leading edge of the sheet reaches Sensor 3. The brake is 
released, and the clutch is engaged. Sensor 9 now looks for the leading edge of its flag, and when seen, 
the clutch is disengaged, and the backstop is lowered.  When the trailing edge of the flag is seen, the 
brake is engaged.  When Sensor 3 sees the trailing edge of the sheet, the backstop is raised. 

 
Stepper #2 Control: 

72 msec after the leading edge of the sheet passes Sensor 6, Stepper 2 is decelerated to match the 
measured input speed from the multi-function printer. This delay ensures that the sheet exits from the 
transport rollers.  When the trailing edge of the sheet passes Sensor 6, Stepper 2 is accelerated to match 
the speed of the transport motor.         

 

39 

One of the first rules of troubleshooting is to first understand the normal operating sequence of the 
machine. Then carefully listen to the key operator’s description of the problem or complaint.  Follow this 
by your own visual observation. The cause of the problem can be determined by noting at which point in 
the operating cycle the problem occurred. To pinpoint the problem to a defective electrical component or 
mechanical part, use the Troubleshooting Guide and the Electrical Schematic Diagram. 

During any service call, it is a good practice to check the cable connections for fit and alignment.  

 
 

 

 

40 

 
 

The Troubleshooting Guide Chart that follows is arranged in order of the normal operational sequence. 
When a malfunction occurs, read down the SYMPTOM column until you reach the appropriate description 
for your symptom. Read the corresponding PROBABLE CAUSE and then perform the recommended 
procedure in the CORRECTIVE ACTION column. 

 

SYMPTOM 

PROBABLE CAUSE 

CORRECTIVE ACTION 

No indication of power 
 

Not plugged in 
 

Check to ensure that power cord is 
properly connected to the machine 
as well as the supply voltage.  
 
Check the power supplied from the 
outlet 
 

No indication of power, 
Unit is plugged in 
 
 
 
 
 
 

Main Control Board, a minimum of 2 of 
the 3 LED’s on this board should be lit, 
if not, board is bad 
 
Display Panel or Cable 
 
 

Replace Main Control Board 
 
 
 
Inspect or replace 
 
Inspect or replace 
 
Inspect or replace 
 
Change the jumper to the proper line 
voltage 

Machine will not start, READY 
LED is ON 
 
 
 
 
 
 
 

Check Power Supply Board LED, if not 
lit, board is bad 
 
Check Main Control Board LED’s, if a 
minimum of two of the three are not lit, 
board is bad 
 
Door is not closed or properly making 
the interlock 
 

Power down Punch and then Multi-
function printer 
 
Power up Punch then Multi-function 
printer 
 
Inspect cable connections, replace 
board as needed 
 
Inspect cable connections, replace 
board as needed 
 
Inspect and correct 

Paper Jam LED is lit, customer / 
operator has been unable to 
locate the jam 
 
Paper Jam, not able to find any 
large sheets, removed sheets 
are torn 
 

A Sensor is blocked 
 
 
Suspect a small piece of paper is 
hidden somewhere in the paper path 

Separate the SmartPunch from the 
Multi-function printer and the 
Finisher, clean out the entire paper 
path 
 
Unplug sensor one at a time to see 
which one is active.