4.

0 Pinnacle 27 Operator Instructions

12

5.0 Pinnacle 27 EZload/Non EZ load Troubleshooting

5.5 General Troubleshooting

5.6 Troubleshooting Chart

Malfunction corrections are based on visual observations made by the operator. The causes of the
malfunctions are isolated by the symptom of the
malfunction and noting at which point in the operating cycle the malfunction occurred. Malfunctions
may be pinpointed to a defective electrical component or mechanical part by referring to the
Principles of Operation, the troubleshooting guide
and the wiring diagram.

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 find the appropriate description for your symptom. Read the corresponding PROBABLE CAUSE, then perform the
recommended procedure in the CORRECTIVE
ACTION column. When replacing electrical components that have push on terminals, label the electrical leads that were removed, to facilitate reconnect
ing them. Refer to the wiring diagrams
to resolve any wiring difficulties that may occur.
WARNING!
Always unplug the laminator to avoid possible electrical shock hazard before attempting to perform
any 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 Ready Light is ON.

the display shows TEMPERATURE

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

Check tray or
upper heat shoe safety interlock

Off/Standby switch defective

Test and replace control panel

PCB Assy If necessary

Thermal fuse up /down

defective (Located in heat
shoe )

Test and replace If

necessary (refer to wiring
diagram)

Circuit breaker opened

Reset or replace If
necessary

F1 20A/125VAC fuse blown on

main board

Test fuse and if necessary

replace main board

Transformer defective

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.

Main board defective

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

CalibrationsA. Motor jammed

A. Resolve loading
issue.

B. Motor connection is loose .

B. Reseat connector, visually

inspect motor connector
termination.

.
C. Encoder sensor connector
is loose.

C. Reseat connector, visually

inspect encoder connector
termination.

D. Encoder wheel is loose.

D. Inspect encoder wheel

E. Encoder sensor is damaged

E. Test and or replace if necessary (refer to electrical schematics).

F. Left hand side cover is

removed. (GW)

Er.2 on control display

Er.3 on control display

A. Main NTC sensor loose.

A. Reseat connector, visually

inspect ntc connector termination.

B. Main NTC sensor damaged.

B. Replace main ntc sens

or.

A. Roller NTC connector is

loose.

B. Roller NTC Sensor damaged.

Air bubbles in film

F. Excess light difussing

emmiter with cover removed.
Install cover to resolve.

Insufficient film tension

A. Reseat connector, visually

inspect ntc connector termination.
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 Troubleshooting

120 VAC

TF
LINEAR X'FORMER
3
LINE SW

3
2
1

EN0

1
2
3

2
1

T-OUT2
2.5MM/2P

2
1

T1-OUT1
3.96MM/2P

5
2

T1-in3.96MM3PIN 3T

EZ 65 Main Board AC Block

June 12, 2006

TF1 192*C
UP TF2

UP TF1

TF3(Thermostat)

70*C OFF
LINE

RB
50OHM

CN3(NTC2)
2.5MM/3P

RA
50Ohm

TF2 192*C
UP TF2

Terminal 1(PA12)(right)

1
2

EN0

LINE SW
177+/-10

HEAT2
T250

177+/-10

VPO

177+/-10
177+/-10

PIN

177+/-10

RA12

UA3

QA10
1

H1
HEATER SHINK for BAT26-600B

Terminal 2(PA12)(left)

T250

1
RA15
4.7K

RA14

1
2

A2

ZC

HEAT1

PWM

RA16

470

RA13 470 1/2W

4

177+/-10
177+/-10

A1 G
3
BAT26-600B

HEAT UP

PIN

177+/-10

1K

QA6

10k
3

2SC18151
TLP3063

177+/-10
177+/-10
177+/-10
177+/-10
VPO
HEAT DOWN

1
2

US Version

RA33
10K

3G
ROLLER HEATER(3.96MM3PIN)
1
2
3

1
2
3

QA16

SAnRex / T16C6
1K RA31

LINE SW

PWM2

RA34
470

4
H2
HEATER SHINK for TMG16C60

Pre-Heater

RA32

A2
2

CN2(NTC1)
2.5MM/2P

UA4

RA30
1K

A1

ZC
TLP3063

10K

QA12 2
2SC18151

1
2

Pre-Heater Control

Friday, November 10, 2006

LED

CONTROL PANEL PCB

CN8
SW SLIDE 3PIN

Board June 6 2006

RC2
1K
COM1

3/8
10
9
1
2
4
6
7
5

330
330
330
330
330
330
330
330

7V ~ 11V

1
2
3
4
5
6
7
8
9
10
11
12

PROTECTION
+5V
PWM2
PWM
Motor On/Off
Motor Reverse
VR-1
VR-2
SPEED EYE
+5V

10
9

CC6
0.1U/50V

+
-

3/8
10
9
1
2
4
6
7
5

8
U2C
LM324

8.

RANGE
RC29
10K
Motor On/Off
+5V
Motor Reverse

COM4
COM5

PA4/TMR

26

PA5/INT

25

PA6/SDA

24

PA7/SCL

23

PB3/AN3

OSC2

22

PB2/AN2

OSC1

21

PB1/AN1

VDD

20

10

PB0/AN0

RES

19

RC24 100

PA3/AN3

PA2

PA1

PA0

COM1

NTC2

PB4/AN4

2
QC6

1
2SC1815

RC17
10K

AC BUZZER

RC18
10K

AC Buzzer 3 KHz
5

NTC2
2.5MM/2P

+5V

4MHZ

CYC1
+5V

RC6
100K

CC3 CC2
30P/50V

RC7
10K

0.1U/50V

VSS

PD1/PWM1
PD0/PWM0

17

RC26 100

13

PC1

PC4

16

RC25

14

PC2

PC3

15

CC7
0.01U/50V

1N4148 SWC5 HI TEMP

2

DC4
1

1N4148 SWC4 LO TEMP

2

DC2
1

1N4148 SWC3 Reset

2

DC3
1

1N4148 SWC2
2

Motor Run/STOP
COM5

RC22
10K

7V ~ 11V

CC8
0.1U/50V

RC27
100

PWM

100

13

14
U2D
LM324

CC5
0.1U/50V

NTC1

U2A
LM324

RC28
10K

RC31
1.39k
CC9
0.1U/50V

PROTECTION

AC BUZZER

NTC1
2.5MM/2P

2.0MM/2P 2.0MM/2P
CN2
CN2

Sleep Disable = LO

12

+5V

PWM2

2
1

SLEEP DISABLE

TO Main
Heater NTC
sensor

Slide SW Function
Sleep Disable

SLEEP DISABLE

DC5
1

test Value

1
2

PC0

RC34
10K

1N4148 SWC6 NC1(Power)

2

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

12

VR-1

DC6
1

SPEED EYE

CC1
30P/50V

18

+5V

1N4148 SWC7Motor Reverse

2

RC30
1.39k
CC4
0.1U/50V

RC23
100

11

VR
10K

DC7
1

+5V

PB7/AN7

PB5/AN5

BZC1
AC BUZZER
VR-2

HEATER Actual

LOW TEMP: 250*F (120*C)

MIRCO IC TEMP SETTING FOR
ROLLER HEATER
60*C

28

COM2

RDP

ICTEMP SETTING FOR MAIN

* MIRCO
HIGH TEMP: 300*F (150*C)

27

RC20
100
RC21
100

8.

1N4148
2

QC5 2SA1015
1
2

PB6/AN6

NTC1

com
G
F
E
D
C
B
A
RDP

U1
HT46R23-28

COM3

RANGE

3/8
10
9
1
2
4
6
7
5

com
G
F
E
D
C
B
A
RDP

LED

11HEADER2.0 11PIN

VR1
10K

com
G
F
E
D
C
B
A
RDP

LEDC1 LEDC2 LEDC4 LEDC3

POWER READY LO TEMP HI TEMP

LEDC3
LED 7 SEG

LEDC2
LED 7 SEG

8.

CN1

RC4
1K
COM3

DC8
1

1
2

SW
SW SLIDE 3PIN

AUTO OFF PCB

1
2

RC32
100

7
U2B
LM324

TO Pre-Heater NTC
sensor(503GT)

NTC2

RC33
10K

5.0 Pinnacle 27 EZload/Non EZ load Troubleshooting

115VAC

RC8
RC9
RC10
RC11
RC12
RC13
RC14
RC15

G
F
E
D
C
B
A
RDP

COM4

RC3
1K
COM2

LEDC1
LED 7 SEG

QC4
2SA1015 RC5
1K
3

+5V

1
2
3
4
5
6
7
8
9

+5V

QC3
2SA1015
3

+5V

RC16 10KX8

QC2
2SA1015
3

11

+5V
QC1
2SA1015
3

+5V

5.0 Pinnacle 27 EZload/Non EZ load Troubleshooting

115VAC

TF
LINEAR X'FORMER
3
LINE SW

3
2
1

EN0

1
2
3

2
1

T-OUT2
2.5MM/2P

2
1

T1-OUT1
3.96MM/2P

5
2

T1-in3.96MM3PIN 3T

EZ 65 Main Board AC Block

June 12, 2006

TF1 192*C
UP TF2

UP TF1

TF3(Thermostat)

70*C OFF
LINE

RB
50OHM

CN3(NTC2)
2.5MM/3P

RA
50Ohm

TF2 192*C
UP TF2

Terminal 1(PA12)(right)

1
2

EN0

LINE SW
177+/-10

HEAT2
T250

177+/-10

VPO

177+/-10
177+/-10

PIN

177+/-10

RA12

UA3

QA10

T250

A1 G
3
A2

H1
HEATER SHINK for BAT26-600B

Terminal 2(PA12)(left)

HEAT UP

PIN

177+/-10

1K
1
RA15
4.7K

RA14
BAT26-600B

1
2

2
3

ZC

HEAT1

PWM

RA16

470

RA13 470 1/2W

4

177+/-10
177+/-10

QA6

10k
3

2SC18151
TLP3063

177+/-10
177+/-10
177+/-10
177+/-10
VPO
HEAT DOWN

1
2

US Version

RA33
10K

3G
ROLLER HEATER(3.96MM3PIN)
1
2
3

1
2
3

QA16

SAnRex / T16C6
1K RA31

LINE SW

RA34
470

4
H2
HEATER SHINK for TMG16C60

Pre-Heater

RA32

A2
2

CN2(NTC1)
2.5MM/2P

UA4

RA30
1K

A1

ZC
TLP3063

10K

QA12 2
2SC18151

1
2

Pre-Heater Control

Friday, November 10, 2006

PWM2

SW 2

S1
1

SW 3
2

SAFTETY SW2 15A/250VAC

SW4
2

SAFETY SW4 15A/250VAC

SW5
2

SAFTETY SW3 15A/250VAC

UP TF1

SAFTETY SW5 15A/250VAC

circuit breaker 10A 250VAC

EL1 JUMPER #1.3*22 X2PCS
Power Cord

L L
POWER SW 16A/250V

LINE

T250
1

F1
10A/250VAC

T250

PIN

PIN

T250

1
CY1
103/AC400V

SW 1
JA1

EC1
2

N N
T250
1

NEUTRAL
T1-OUT2

0.68uf/275VAC

1M 1/2W

T250

PIN

PIN

PIN

LINE SW

EN0

EC2
1UF/250VAC

R1
V1
MOV

T250

PIN

CY2
103/AC400V

T250

T250

PIN

PIN

TF3 130*C

6 T1

1
2

T1-in 3.96mm 3PIN 3T

2
5

3.96MM/2P
T-OUT1

EN0

1
2
3

3
2
1

1
2

MAIN
BOARD

LINE SW

2.5MM/2P

EN0

LINEAR X'FORMER

VPO

TF1 192*C
UP TF2

RA30
1K

UP TF1

UA4

A1
1

UP TF2

ROLLER HEATER(3.96mm 3PIN)

1
2
3

Terminal 1(PA12)
70*C OFF

Pre-Heater
177+/-10
177+/-10
177+/-10

QA16

LINE SW

1
2
3

A2
2

LINE

3G

TF2 192*C

SAnRex / T16C6
4
1K RA31

TS1(Thermostat)

Heater Down
170Ohm

ZC
TLP3063

H2
HEATER SHINK for TMG16C60

Heater Up
170OHM

1
2

T250

177+/-10
177+/-10
177+/-10

10

HEAT UP

PIN

177+/-10
177+/-10

PIN

1
2

177+/-10
177+/-10
177+/-10
HEAT DOWN

Terminal 2(PA12)

PIN

PIN

HEAT1
T250

1K

LINE SW

H1
HEATER SHINK for BAT26-600B

177+/-10

UA3

T250
QA10

VPO
RA12

HEAT2

A1 G
3

Main-Heater

5.0 Pinnacle 27 Non EZ load Troubleshooting EU Version

LINE

A2

BAT26-600B
RA13 470 1/2W
4

ZC
TLP3063

S1

SW 2
1

SW 3
2

SAFTETY SW2 15A/250VAC

UP TF1

SAFETY SW4 15A/250VAC

circuit breaker 10A 250VAC

EL1 JUMPER #1.3*22 X2PCS
Power Cord

L L
LINE

POWER SW 16A/250V

T250
1

F1
10A/250VAC

T250

PIN

PIN

T250

LINE

CY1
103/AC400V
SW 1

JA1

EC1
2

N N
T250
1

NEUTRAL
T1-OUT2

0.68uf/275VAC

1M 1/2W

T250

PIN

PIN

PIN

LINE SW

EN0

EC2
1UF/250VAC

R1
V1
MOV

T250

PIN

CY2
103/AC400V

T250

T250

PIN

PIN

TF3 130*C

6 T1

1
2

T1-in 3.96mm 3PIN 3T

2
5

3.96MM/2P
T-OUT1

3
2
1

4
1

1
2

EN0

1
2
3

MAIN
BOARD

LINE SW

2.5MM/2P

LINEAR X'FORMER

EN0
VPO

TF1 192*C
UP TF2

RA30
1K

UP TF1

UA4

A1
1

UP TF2

ROLLER HEATER(3.96mm 3PIN)

1
2
3

Terminal 1(PA12)
70*C OFF

Pre-Heater
177+/-10
177+/-10
177+/-10

QA16

LINE SW

1
2
3

A2
2

LINE

3G

TF2 192*C

SAnRex / T16C6
4
1K RA31

TS1(Thermostat)

Heater Down
170Ohm

ZC
TLP3063

H2
HEATER SHINK for TMG16C60

Heater Up
170OHM

1
2

T250

177+/-10
177+/-10
177+/-10

10

HEAT UP

PIN

177+/-10
177+/-10

PIN

1
2

177+/-10
177+/-10
177+/-10
HEAT DOWN

Terminal 2(PA12)

PIN

PIN

HEAT1
T250

1K

LINE SW

H1
HEATER SHINK for BAT26-600B

177+/-10

UA3

T250
QA10

VPO
RA12

HEAT2

A1 G
3

Main-Heater

5.0 Pinnacle 27 EZ load Troubleshooting EU Version

A2

BAT26-600B
RA13 470 1/2W
4

ZC
TLP3063

2.5MM/2P
1N4004 7V ~ 11V
DB2

UA5

CN1(2.0 11PIN)
7V ~ 11V

20V ~ 26V
31DQ06
DB7
+
31DQ06
+
DB5

+5V
PWM2
PWM
Motor Reverse
Motor On/Off
VR1
VR-2
SPEED EYE

C3
2200U/50V

2
Ib

Ia

DA11
DA10
31DQ06 31DQ06 CA3
1000U/25V

RA1
2K

1
CA8
0.1/50V

FR104
RA41
0

RA21
22K

7V ~ 11V

7
U3B
LM358

CA13
0.1U/50V

DC FAN
DA13
1N4004

RA22
1K

To Cool Fan

RA23
1K

forword:

DC 8.5V ~ DC22V

reverse:

DC

7.2V
7V ~ 11V

M
MO1
DC24V

DC FAN1
2.5MM/2P
DA7
1N4004

QA5
2SC1815
1

RA10
1K

Motor Reverse

DA2
1N4148
UA1
RA4

0.011/2W(

+
DA9
FR104

CA16

33063AVP

Driver C

Switch C

Isensor

Switch E

Timing Cap

VCC

Comp-IN

GND

28V~38V

VR-1

28V ~ 38V
3
2

VR-2

2
1

680

10U/50V
RA6
910

RA38
10K

RA37
10K

RA36

CA11
470P/50V

RA11
10K

QA13 2SA1015
1

3
QA14
2SC1815
RA5
4.7k

RA35
4K7

RA42
1K

RA43
10K

20V ~ 26V

RA39 10K
RA40
10K

Motor On/Off

QA3 2
2SC1815
3

RA7
4K7
1
2
QA4
3
2SC1815

1
2
2

DA4
2
1N4004
13

1
2

DA5 1N4148
1
2

MOTOR
CONNECTOR/3.96MM 2PIN

QA7
2SD882
1

U2A
LM358

KA1

CA6
CA5
0.1/50V +
1000U/25V 5V

2.5MM/2P

RA20
22K

CA10
0.1/50V

CA4
0.1/50V
DA3

DA1
1N4148

1
2

2SC1815

QA2

7V ~ 11V

RA18
100

2
+

6
RA19
22K

CA12
0.1U/50V

SMI-SH-206D/DC6V

RA17
22K

CA9
0.1/50V

L2 100UH

+5V

TO Fan NTC sensor

CA7
0.1/50V

11

+5V

1
2

VOL

2
1

DA8 MOT
QA1
L1
FR104
ZD1 20V(OPEN) IRF5305(IRF9Z34N) Choke 80~100uH 2
1

RA25
4.7K

NTC1
2.0MM/2P

H4
HEAT SHINK FOR IRF5305

RA2
4.7K

FOR motor speed

HI=Motor On
LO=Motor Off
RA8
10K
1
RA9
10K

Friday, November 10, 2006

PCB Cool
Fan

3QA15
2SD882

5.0 Pinnacle 27 EZload/Non EZ load Troubleshooting

115VAC

1
2
3
4
5
6
7
8
9
10
11
12

PROTECTION

RA29
1K

220U/16V

T-OUT1 3.96MM/2P

CA14
4.7UF/25V

CA2

CA1

31DQ06
DB6

1N4004
+
DB4

1
2
3

SPEED EYE

3
+

31DQ06 DB8

1000U/16V

1
2

CA15
10UF/25V

CN6
2.5MM/3Pin

78L05/TO220

1N4004
DB3

2
RA28
47K

10K

+5V

DA6
1N4148

RA27
1.5K

1N4004
DB1
-

RA24

90*C = Lo Ohm Value

70*C = Hi Ohm Value

1
2

QA9
2 2SC1815
1
3

RA26
10K

T1-OUT2

+5V

PROTECTION

7V ~ 11V
QA8
2SA1015
2
3

VPO

EZ 65 Main Board DC Block

June 9, 2006

5.0 Pinnacle 27 EZload/Non EZ load Troubleshooting

5V

5V

RB1
560

5V

RB2
100K

5V

3
2
1

RB5
22K
RB3 22K

2.5MM/3Pin

1
2
3

CN4
CN4
2.0MM/3Pin

2
QB1
3
2SC1815

CN6
2.5MM/3Pin
1
2
3

Low Active

RB4
47K

RA5
560
1

LED1

SPEED EYE PCB

LED2

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

11
10
9
16

8
18

14

15

7
RH Side

12

13
LH Side

------------671100008800

20

670400000700
670300013000
------------622000021200

2
19

911100000960
911100000970

911100000030

910000145300
------------910000139480
------------------------CONTROL PANEL ASSY

910000145240

910200036540
910200026250
660000002670
670800003400
910200037320
20 Counter PCB assy

910200026250