Baumfolder BAUM 2018 Instruction Manual

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BAUMFOLDER

1ST STATION FOLDER W/PILE FEED

INSTRUCTION MANUAL

©Baumfolder Corp., 1999 Printed in U.S.A. TP10313

BAUM 2018

PAGE 1 TP10313

WARNING

 Do not operate this machine without all guarding in place.  Do not make adjustments or perform maintenance on this machine with power on.  Keep the machine and the work area clean and free of spills to prevent accidents.  Be sure to replace any safety decals that may have been detached for any reason.

Baumfolder Corporation reserves the right to make changes in design or to make additions or improvements in its products without imposing any obligation upon itself to install them on its previously manufactured products. It is recommended that modifications to this equipment not be made without the advice and express written consent of Baumfolder Corporation.

MODEL NO: _______________________________ SERIAL NO: _____________________________

SALES AGENCY:____________________________________________________________________

INSTALLED BY: _____________________________________________ DATE: ________________

PHONE NO: _______________________________

TP10313 PAGE 2

FOLDER IDENTIFICATION

CONTENTS

DESCRIPTION PAGE

I.) Safety ................................................................................................................................................................. 6

II.) Warning Labels ................................................................................................................................................ 7

III.) Introduction Overview .................................................................................................................................... 8

IV.) Transportation/Installation ............................................................................................................................. 8

V.) Squaring the Machine ..................................................................................................................................... 8

VI.) Electrical Connections .................................................................................................................................... 9

1.0 .Wiring the Pump................................................................................................................................. 9

1.1 .Other Connections .............................................................................................................................. 9

1.2 .Tapping the Transformer .................................................................................................................... 9

1.3 .Pump Connections ............................................................................................................................... 9

VII.) Installing Fold Plates & Stacker Delivery ................................................................................................... 10

VIII.) Operator Controls .......................................................................................................................................... 10

1.0 . Setting Folding Speed........................................................................................................................ 10

1.1 . Setting Stacker Belt Speed ................................................................................................................ 10

1.2 . Emergency Stop Button..................................................................................................................... 10

1.0 Control Panel BAN-5.............................................................................................................................. 11

1.1 .Displays.............................................................................................................................................. 11

1.2 .Machine Status Indicators ................................................................................................................. 11

1.3 .Machine Control Pushbuttons ........................................................................................................... 11

1.4 .Keypad Buttons with Selection Indicators ........................................................................................ 12

1.5 .Keypad Buttons for Selection Adjustments....................................................................................... 12

2.0 RUN MODE FUNCTIONS ............................................................................................................................... 12

2.1 .Machine Setup and Diagnostic Mode ............................................................................................... 12

2.2 .Counter Setup Mode .......................................................................................................................... 16

2.3 .Easy Mode and Continuous Cycle Mode........................................................................................... 17

2.4 .Learn Mode ........................................................................................................................................ 17

2.5 .Make Ready Mode ............................................................................................................................. 18

2.6 .Network Job Mode ............................................................................................................................. 19

2.7 .Production Mode................................................................................................................................19

3.0 LOGIC B OARD S TATUS I NDICATORS .............................................................................................................. 20

4.0 Process Variables Definitions ................................................................................................................. 21

4.1 .Total Input Count .............................................................................................................................. 21

4.2 .Total Output Count ............................................................................................................................ 21

4.3 .Batch Down Count ............................................................................................................................. 21

4.4 .Number of Batches............................................................................................................................. 21

4.5 .Current Rate ....................................................................................................................................... 21

4.6 .Main Drive Run Time ....................................................................................................................... 21

4.7 .Main Drive Velocity .......................................................................................................................... 21

4.8 .Waste Count (DCT500) ..................................................................................................................... 21

5.0 COUNTER S ETUP VARIABLES ........................................................................................................................ 21

5.1 .Batch Preset ....................................................................................................................................... 21

5.2 .Batch Output Type ............................................................................................................................. 21

5.3 .Batch Output Time ............................................................................................................................ 22

5.4 .Sheet Length ...................................................................................................................................... 22

5.5 .Gap Length ........................................................................................................................................ 22

5.6 .Suction Length ................................................................................................................................... 22

6.0 SYSTEM MESSAGES AND RUN MESSAGES ...................................................................................................... 23

6.1 .Power-Up Fault Messages.................................................................................................................. 23

6.2 .Run Time Fault Messages ................................................................................................................. 24

6.3 .Machine Run Error Messages ........................................................................................................... 25

PAGE 3 TP10313

CONTENTS

DESCRIPTION PAGE

IX.) Pile Feeder Operation .................................................................................................................................... 26

1.0 .Loading .............................................................................................................................................. 26

1.1 .Hold-down Locations ......................................................................................................................... 26

1.2 .Air and Vacuum Setting .................................................................................................................... 26

1.3 .Front Blow Tube Settings .................................................................................................................. 27

1.4 .Vacuum Wheel................................................................................................................................... 27

X.) Register Operation ......................................................................................................................................... 28

1.0 .Double Sheet Detector ....................................................................................................................... 28

XI.) Baumset Adjustment ...................................................................................................................................... 29

1.0 . Adjusting Folding Rollers ................................................................................................................. 29

XII.) Setting Fold Plates .......................................................................................................................................... 30

XIII.) Setting Deflectors ........................................................................................................................................... 30

XIV.) Stacker Operation .......................................................................................................................................... 31

XV.) Scoring/Slitting/Perforating .......................................................................................................................... 32

1.0 .Slitter Shaft Removal ......................................................................................................................... 32

1.1 .Scoring ............................................................................................................................................... 32

1.2 .Perforating ......................................................................................................................................... 33

1.3 .Slitting................................................................................................................................................ 34

1.4 .Trimming ........................................................................................................................................... 35

XVI.) Lubrication/Maintenance .............................................................................................................................. 36

XVII.) Technical Specifications ................................................................................................................................37

XVIII.) Accessories ...................................................................................................................................................... 37

XIX.) Troubleshooting .............................................................................................................................................. 38

XX.) Operating Tips ................................................................................................................................................ 40

XXI.) Principles of Mechanical Folding ................................................................................................................. 42

XXII.) Folding Chart .................................................................................................................................................. 43

XXIII.) Manual Usage ................................................................................................................................................. 45

XXIV.) Typical Layout & Sheet Orientation ............................................................................................................ 46

XXV.) Impositions ...................................................................................................................................................... 47

#1 4 - PAGE............................................................................................................................................. 47

#2 4 - PAGE, DOUBLE IMPOSITION .................................................................................................. 47

#3 6 - PAGE, STANDARD ..................................................................................................................... 47

#4 6 - PAGE, ACCORDION ................................................................................................................... 47

#5 8 - PAGE, PARALLEL IMPOSITION .............................................................................................. 47

#6 8 - PAGE, RIGHT ANGLE ................................................................................................................ 47

#7 8 - PAGE, RIGHT ANGLE OBLONG .............................................................................................. 48

#8 8 - PAGE, RIGHT ANGLE DOUBLE IMPOSITION ....................................................................... 48

#9 8 - PAGE, PARALLEL OVER & OVER ........................................................................................... 48

#10 12 - PAGE BOOK, SADDLE STITCH ............................................................................................. 48

#11 12 - PAGE BOOK, SADDLE STITCH ............................................................................................. 48

#12 12 - PAGE LETTER FOLD, HEADS OUT ...................................................................................... 48

#13 12 - PAGE LETTER FOLD, HEADS IN .......................................................................................... 49

#14 12 - PAGE LETTER FOLD, ACCORDION ..................................................................................... 49

#15 16 - PAGE, THREE RIGHT ANGLE BOOK IMPOSITION........................................................... 49

#16 12 - PAGE FOLDER, HEADS OUT ................................................................................................. 49

#17 24 - PAGE BOOKLET ....................................................................................................................... 49

#18 32 - PAGE BOOK .............................................................................................................................. 49

XXVI.) Service ............................................................................................................................................................ 50

TP10313 PAGE 4

List of Tables

DESCRIPTION PAGE

Table 1. Machine Setup Parameter List "A" ...................................................................................................................... 13

Table 2. Machine Monitor Parameter List ......................................................................................................................... 13

Table 3. Machine Setup Parameter List "B"....................................................................................................................... 14

Table 4. Machine Diagnostic Parameter List ...................................................................................................................... 15

Table 5. Future Features List ............................................................................................................................................... 15

Table 6. Machine Usage Status Parameter List ...................................................................................................................16

Table 7. Output Type Animations ....................................................................................................................................... 16

Table 8. Count Source Selection .......................................................................................................................................... 17

Table 9. Learn Mode Status ................................................................................................................................................ 17

Table 10. Suction Mode Symbols ....................................................................................................................................... 18

Table 11. Suction Length Function ..................................................................................................................................... 18

Table 12. Determining the Large Display Contents ............................................................................................................ 19

Table 13. Reset mode Selection ........................................................................................................................................... 19

Table 14. LED Status Indicators .......................................................................................................................................... 20

Table 15. Output Delay and Duration ................................................................................................................................. 20

Table 16. Power Up Fault Messages .................................................................................................................................... 23

Table 17. Run Time Fault Messages ...................................................................................................................................24

Table 18. Machine Run Error Messages ............................................................................................................................. 25

PAGE 5 TP10313

SAFETY FIRST

10. Make sure that all safety devices are in place before restarting the machine.

Your new Baum paper folding machine has been designed in accordance with the latest safety specifications. The warning and caution labels on the machine must remain in place. Make sure all guarding provided is in place before starting up and running the machine.

Due to the nature of the work process of paper folding machines, there are parts and areas on the machine which cannot be completely covered without interfering with the operation of the machine. Therefore, sound personal work habits and strict observance of all safety precautions is required for the protection of the operator, co-workers, and the machine.

Be sure to follow these

safety precautions:

1. Study the safety instructions at your plant and those provided in this manual.

2. Study the operating instructions carefully before operating the machine.

3. Make sure that your co-workers are familiar with the work process, potential danger areas, and all necessary safety measures.

11. Never clean moving parts of the machine (rollers, shafts, etc.) or remove any test sheets or paper jams while the machine is running.

12. Keep the floor around the entire machine clean. Immediately clean up any oil, grease, or paint spills from the floor. Remove tools, cleaning cloths, and paper scraps from all work areas.

13. Never allow unauthorized personnel to make adjustments on the machine, remove problem sheets, or start the machine.

14. Never climb over the machine or crawl into it while it is turned on.

15. Immediately repair or replace any safety devices which have become ineffective or are missing.

16. Report any exposed cables or exposed electrical connections.

17. Always have a certified qualified electrician perform all electrical maintenance.

18. Do not make adjustments or perform maintenance with the power on.

4. Make sure that the machine is in good working order before turning it on.

5. If the machine suddenly stops for whatever reason, do not restart it right away. Someone may have stopped the machine, but failed to press the emergency (Stop) button. If the machine is restarted unexpectedly, your co-worker could be seriously injured.

6. Always press the emergency (Stop) button first if you stop the machine for adjustments or maintenance work which must not be done while the machine is in operation.

7. For extensive maintenance or repair work, turn off the main power supply.

8. Never use improper or defective tools.

9. After making adjustments or after doing maintenance or repair work, always make sure that all tools and other objects are removed from the machine. Otherwise, they might fall into the machine, causing severe damage or injuries.

19. Become familiar with and follow the safety labels on the next page. Replace any of these labels that are damaged or lost.

Additional Notes:

20. Do not attempt to remove a paper jam, no matter how minor it may appear to be, while the machine is running.

21. When cleaning the fold rolls, use the handwheel for turning. Be sure the power to the machine is off.

22. Turn off the machine before making any adjustments to the scoring, perforating, or slitting attachments. Keep hands and clothing away from the slitter shafts when the machine is running.

TP10313 PAGE 6

WARNING LABELS

GUARD MISSING

WARNING

50944

CAUTION – HAZARDOUS MOVING PARTS – GUARDS MUST BE IN PLACE WHEN

OPERATING FOLDER – KEEP HANDS, HAIR & LOOSE ARTICLES AWAY FROM MOVING PARTS.

DO NOT OPERATE

50215

CAUTION - HAZARDOUS MOVING PARTS

DO NOT OPERATE MACHINE

WITHOUT GUARD IN PLACE

40686

WARNING

GUARD MISSING

DO NOT OPERATE

50945

C A U T I O N

HIGH VOLTAGE

EXISTS WHEN

DOOR IS OPEN

REMOVE VOLTAGE

AT POWER SOURCE

BEFORE SERVICING

42877

CHANGE SPEEDS " ONLY"

WHEN FOLDER IS RUNNING

39379

PAGE 7 TP10313

INTRODUCTION OVERVIEW

The 1st station [parallel] folder with pile feeder

contains the following main components (Figure 1):

1. Pile Feeder

2. Register

3. 1st Station Folder (Parallel)

4. Fold Roller Gapsets

5. Fold Plates

6. Slitter Shafts (not shown)

7. Delivery (Stacker)

8. Operator Controls

9. Double Sheet Detector (Caliper)

10. Vacuum Pump (not shown)

11. Handwheel

Level the machine on the floor. Place a spirit level on

the #2 fold roller (Figure 3) and on the feeder crossmembers.

SQUARING THE MACHINE

It is essential that this folding machine is square in

order for it to work properly. To square the machine, measure diagonally across corners from feeder frame to folder frame (Figure 4). Dimensions shown are approximate. Be sure that the measurements taken are identical within 1/16-inch. If the machine is out of square, shift the frames in the direction needed until the proper squareness is obtained.

Figure 3

Figure 1

TRANSPORTATION/INSTALLATION

As soon as you receive your new folder, and before removing the machine from the skid, check carefully for any damage to the shipments. If any damage is found, promptly contact your Baumfolder sales representative.

To lift the folder from the skid, place the fork lift rails under the lower rails as shown in Figure 2. Note that the fork lift must have at least a 1500 lb. capacity.

Remove all rust protection coating after unpacking the folder.

Figure 2

TP10313 PAGE 8

Figure 4

ELECTRICAL CONNECTIONS

1.0 Wiring the Pump (2018 / 1 phase)

Connect the pressure/vacuum pump at the pump junction box (Figure 5) using the attached cable. Follow the instructions below for the proper connections.

There are six wires from the control box to the pump. Wire #1 connects to the terminal marked 1 in the pump motor. Wire #2 connects to the terminal marked 4 in the pump motor. Wires #3 ,#4 ,#5 & #6 are not used and should be taped off separately. The green wire is the ground that is attached to the motor frame.

1.1 Other Connections

Refer to the serial number plate for electrical requirements. The serial number plate notes the voltage, phase and hertz, minimum time delay fuse, total machine amperage, and minimum wire conductor size for the main power connection.

The main power is connected directly to the line side of the main power switch. In a 2018 single phase use L1 and L2 only.

All electrical connections are to be made by a certified electrician. Refer to local building electrical codes for proper and safe connections.

For the following items, refer to Figure 6. Run a power cable from your distribution box to the main control box on the pile feeder. Turn the main power switch to zero. Using the appropriate tool, open the latches on the control box door and open the door.

NOTE: The door is connected to the main box by a ground wire that should not be removed.

1.2 Tapping the Transformer

Pass the power cable through the strain relief and the hole provided in the control box. Connect the power cable to the open terminals on the main disconnect in the control box. The incoming ground wire should be attached to the ground stud located in the lower right-hand corner of the control box.

To tap the transformer, read the incoming voltage at the main disconnect. Then move the wire numbered 11L1 on the transformer to the corresponding tap on the transformer.

Tighten all screw connections and close the door before switching the machine on.

A connector is provided for power connection to the stacker. The stacker must be plugged into the socket for the machine to operate, if not, install the blind plug attached to the box.

A connector is provided for power connection to the second station (8-page) fold unit. If no additional folding station is to be connected, the connector must be closed off with a blind plug.

1.3 Pump Connections

Connect the air hoses to the pump. The small diameter hose is connected to the vacuum side of the pump. Connect it to the barbed fitting above the ball valve on one end and the other end to the vacuum solenoid valve on the pile feeder.

Connect the larger diameter hose to the remaining outlet port on the pump and to the barbed fitting on the pile feeder at the end of the blow bar.

Troubleshooting tips and actions required for the display messages that may appear on the control readout may be found the "Diagnostic Messages" section of the manual.

Figure 5

Figure 6

PAGE 9 TP10313

INSTALLING FOLD PLATES & STACKER DELIVERY

Install the fold plates into the folder. When installing the fold plates, take note of the symbol on the fold plate stop (Figure 7-1). The swing deflector may only be brought forward when the deflector symbol is also in the forward position. Lock the fold plates in position with the clamp levers (7-2). See "Fold Pan" section for fold plate setting procedure.

Attach the delivery stacker (3-2) by hooking the hanger brackets onto the round rods at the exit end of the folder. Plug the stacker power cable into the corresponding outlet on the main control enclosure on the pile feeder (Figure 6-

1).

Pull the handwheel (Figure 1-11) to manually turn the fold rollers to be sure that they are operating smoothly. Check for any foreign material, and be sure that the deflectors do not touch the fold rollers.

OPERATOR CONTROLS

The main operator control panel (Figure 8) is located at the pile feeder. See the "Control Panel" section for a detailed description of all the buttons.

1.0 Setting Folding Speed

The speed of the fold rollers may be set while the folder is running! This is done by adjusting the speed control potentiometer located on the top left side of the main control panel. Clockwise rotation speeds the folder up; counterclockwise rotation slows the folder down.

1.1 Setting Stacker Belt Speed

An infinite speed range between high and low is set by turning the control knob (Figure 9-1).

1.2 Emergency Stop Button

When an emergency stop button (8-1 & 9-2) is pressed, the result is:

Sheet feed - stop Folder drive - stop

Pile lift - stop The pressure/vacuum pump continues to operate. The emergency stop button must be pulled to release before the machine can be restarted. An error message "StoP" will appear on the readout. The emergency stop buttons are found at the main operator control panel (8-1) and the delivery control (9-2).

Figure 7

BAUMFOLDER

CORPORATION

Figure 8

TP10313 PAGE 10

Figure 9

1.0 Control Panel BAN-5

3 2

BAUMFOLDER

CORPORATION

8 9

9 13 11 16 26 27 22 23 4 5 7 615 3

Figure 1. Control Panel.

25 2824 28 12 10 1417

1 29 30 31 32 33

18 19 20 21 34 35

1.1 Displays

01) Large Display Eight digit multi use display composed of 7segment LEDs.

02) Small Display Three digit multi use display composed of 7segment LEDs.

03) Ten segment bar graph display The suction length display is used to display the Suction Length as a percentage of Sheet Length. This allows a range from 5% to 50%.

1.2 Machine Status Indicators

04) Suction Indicator The suction indicator will track the suction output. The LED will turn on when the suction output turns on.

05) Pile indicator The indicator is lit when the feeder is in automatic feed mode. The indicator will flash if the feeder is in reverse mode (Continuous Feeder) or moving down (Pile feeder)

06) Input Indicator The input indicator shows the status of the suction photo-eye.

07) Output Indicator The output indicator lights when the Batch Preset is reached and the user has selected a batching option. The output indicator is lit during the time the batching option is active. Batching options are Feed interruption, Speed up table, Marking table or Kicker.

1.3 Machine Control Pushbuttons

08) Main Drive Start

09) Main Drive Stop

10) Pump Start

11) Pump Stop

12) Feeder Start

13) Feeder Stop

14) Pile Feeder Up, Continuous Feeder Start

15) Pile Feeder Stop, Continuous Feeder Stop

16) Pile Feeder Down, Continuous Feeder Reverse

17) Emergency Stop

PAGE 11 TP10313

1.4 Keypad Buttons with Selection Indicators

18) Show Output Count

19) Show Batch Count and Number of Batches

20) Show Current Rate

21) Show Input Count

22) Learn Mode

23) Make Ready Mode

1.5 Keypad Buttons for Selection Adjustment

24) Gap Minus

25) Gap Plus

26) Suction Length Minus

27) Suction Length Plus

28) Batch Preset Minus

29) Batch Preset Plus

30) Counter Setup Mode

31) Machine Setup Mode

32) Batching Time Minus

33) Batching Time Plus

34) Network Job Mode

35) Reset

36) Potentiometer Speed adjustment

2.1 Machine Setup/Diagnostic Mode

Pushing this key puts the controller in machine setup mode.

Machine setup mode provides a method to view and optionally change operating parameters for the controller. The decimal points in the large display (1) will move from side to side to indicate that various parameters may be changed. In this mode, the small display gives the selected parameter number, while the large display (1) shows a parameter value. The suction length display (3) is disabled.

Parameter Group Selection

The plus and minus keys are used to select the various parameter groups: machine setup parameters, machine monitor parameters, machine diagnostic parameters, knife status parameters, and machine usage parameters.

Parameter Selection within a Group

2.0 Run Mode Functions

After turning on the main switch, thecontrol automatically runs a self test. During this self test all displays and indicator lights come on for approxmately 4 seconds. After a successful self test, the display reverts to the previous count screen active before power shutdown. In this mode, various job parameters can be displayed on the large display (1) and the small display (2) shows the gap length. The suction length display (3) is active in this mode and shows the suction length as a percentage of sheet length.

The DCT500 mode select keys perform the same function in all modes, except Counter Setup. This allows a user to quickly switch between the operating modes on the counter. Select Make-Ready is not a mode unto itself, but rather is a modifier to all modes.

During the self test operation, do not press any button. Pressing of a button will cause an error message to appear in the main display.

If the large display (1) decimal points are moving, this set of minus and plus buttons will select the machine parameters within each group, see tables 1-6.

Select Parameter Adjustment

If the large display (1) decimal points are moving, this set of minus and plus buttons will move through the set of values for the selected parameter, see tables 16.

TP10313 PAGE 12

2.1.1 Machine Setup Parameters

Parameter Function Type Variable Displayed

P00 Input Factor Setup Variables Adjustable 1-24 P01 Output Factor Setup Variables Adjustable 1 to Input Factor P02 Tremat Setup Variables Adjustable 1 or 0 P03 Knife Setup Variables Adjustable 1 or 0

Table 1. Machine Setup Parameter List

P00: Input Factor

Each sheet sensed by the Sheet count sensor is multiplied by the Factor number and added to theTotal Input Count, but does not effect the Batch Down Count, Number of Batches or the Rate. The Factor can range from 1 to 24. If the Input Factor is changed, it also changes the value of the Output Factor to the same setting.

P01: Output Factor

This number is added to the Total Output Count but does not effect the Batch Down Count, Number of Batches and the Rate. The Factor can range from 1 to Input Factor setting.

2.1.2 Machine Monitor Parameters

# Function Type Variable Displayed

P10 Machine Speed Process Variable Based on input Meters/Minute P11 Job Run Time Process Variable Based on input Hours P12 Job Stop Time Process Variable Based on input Hours P13 Job Make Ready Time Process Variable Based on input Hours P14 Pause Time Process Variable Based on input Hours P15 Job Number Process Variable Based on Input Number 1 - 9999 P16 Employees Number Process Variable Based on input 1 - 255

P02: Tremat

This is an unavailable option.

P03: Knife

This is an unavailable option.

Table 2. Machine Monitor Parameter List

P10: Machine Speed (Velocity)

This selection shows the machine speed in meters/ minute.

P11: Job Run Time

Displays the time duration this job has ran. Time displayed in .01 Hours. This information becomes part of the job record.

P12: Job Stop Time

Display the time duration this job has been interrupted. Time displayed in .01 Hours. This information becomes part of the job record.

P13: Job Make Ready Time

Displays the length of time that the Make Ready feature was enabled. Time displayed in .01 Hours. This information becomes part of the job record.

P14: Pause Time

Display the length of time that the Job was Paused. Time displayed in .01 Hours. This information becomes part of the job record.

P15: Job Number

A Job Number may be entered so that production data may be recorded against it. This is an operator entry. This information becomes part of the job record.

P16: Employees Number

An Employee may be assigned a number. When the employee operates the machine, his number may be entered. This information becomes part of the job record.

PAGE 13 TP10313

2.1.3 Machine Setup Parameters

# Function Type Variable Displayed

P20 Units of Measure Setup Variables Adjustable Inches, Meters P21 Language Setup Variables Adjustable English, German, Codes P22 Network Address Setup Variables Adjustable 0-255 P23 Pause Setup Variables Adjustable 1 or 0 P24 Network Setup Variables Adjustable 1 or 0 P25 Easy Setup Variables Adjustable 1 or 0 P26 Software Version Machine Configuration Fixed V X.X.X P27 Machine Type Machine Configuration Fixed Set at Factory P28 Serial Output Type Machine Configuration Fixed Off, Display, or Network

Table 3. Machine Setup Parameter List

P20: Units of Measurement

This selection specifies the unit of measurement used to display all lengths. Inches (SAE) is the default selection. Available choices are Meters (measurement displayed in cm) and Inches (measurement displayed in inches and tenths of inches).

P21: Language

This selection specifies the Language used to display fault messages. Available choices are ENGLISH, DEUTSCH, and CODES, see Tables 1618, Error Message

Translation. English is the default selection.

P22: Network Address

This selection specifies the unit address used for Network communication. Available choices are 0 through

255. Address 0 is the default selection. Network functions are not available in software version 2.6.0

P23: Pause

P25: Easy Mode

Enable Easy Mode by selecting 1. Disable Easy Mode

by selecting 0.

Easy Mode has two sheet control methods, Easy setup or Continuous cycle. Easy setup will run any job with a 1 inch sheet gap. The sheet gap display contains 3 dashes and the Suction Length bar graph is turned off.

In Continuous cycle setup, the suction cycle is determined by the sheet gap setting, sheet length setting and the suction length setting. Sheet error detection methods are turned off.

P26: Hardware and Firmware Version

This selection shows the hardware and firmware versions of the unit. The left side of the display shows logic board type. The right side of the display shows the firmware version (2.X.X).

P27: Machine Type

This selection, in maintenance mode, shows the selected machine configuration.

P24: Network Enable

Network components must be installed and enabled in Maintenance Mode. Enable Network by selecting 1. Disable network by selecting 0.

TP10313 PAGE 14

P28: Serial Output Type

This selection, in maintenance mode, shows selected

serial output type.

P28: Serial Output Type

This selection, in maintenance mode, shows selected

serial output type.

2.1.4 Diagnostic Parameters

P30 Status Input Port 1

P30.1 P30.2 P30.3 P30.4 P30.5 P30.6 P30.7 P30.8 Pile Motor Function Pile Down Pile Stop Pile Up Compress. Compress. Drive Start Energized Control K1 Button Button Button Stop Button Start Button Relay K3

P31 Status Input Port 2

P31.1 P31.2 P31.3 P31.4 P31.5 P31.6 P31.7 P31.8 Pile Sensor Double Pile Sheet Start Sheet Stop Thermal Wrong Sheet Emerg.Stop

Sheet Fault Bottom Button Button Fault Fault Drive Stop

P32 Status Input Port 3

P32.1 P32.2 P32.3 P32.4 P32.5 P32.6 P32.7 P32.8 Ergonomic Not used Not used Not used Not used Suction Delivery Photo eye Pile Load Controller Count Input Suction Eye Fail Wheel

P33 Status Input Port 4 (Extension Port)

P33.1 P33.2 P33.3 P33.4 P33.5 P33.6 P33.7 P33.8 Not used Not used Not used Not used Not used Not used Not used Not used

P34 Status Output Port 1

P34.1 N P34.2 P34.3 P34.4 P34.5 P34.6 P34.7 P34.8 Not used Not used Not used Not used Pile Down Pile up Release Compress

P35 Status Output Port 2 (Extension Port)

P35.1 P35.2 P35.3 P35.4 P35.5 P35.6 P35.7 P35.8 Not used Not used Not used Not used Not used Not used Not used Not used

Button

is active is active Drive Start Start (K4)

Table 4. Machine Diagnostic Parameter List

P30: Input Port 1 Status P31: Input Port 2 Status P32: Input Port 3 Status P33: Input Port 4 Status (Extension)

This selection shows the inputs status(see table4).

P34: Output Port 1 Status P35: Output Port 2 (Extension)

This selection shows the outputs status (see table 4).

2.1.5 Future Features

# Function Type Variable Displayed

P40 Last Knife Eye Time 1 Not used Not used Not used P41 Last Knife Eye Time 2 Not used Not used Not used P42 Last Knife Eye Time 3 Not used Not used Not used P43 Strokes knife 1 Not used Not used Not used P44 Strokes knife 2 Not used Not used Not used P45 Strokes knife 3 Not used Not used Not used

Table 5. Future Features List

PAGE 15 TP10313

2.1.6 Machine UsageStatus Parameters

# Function Type Variable Displayed P50 Power on time Machine Status Based on Inputs Time in 1/100 Hours P51 Machine run time Machine Status Based on Inputs Time in 1/100 Hours P52 Total Input Sheets Machine Status Based on Inputs Number in 1000 Sheets

Table 6. Machine Usage Status Parameter List

P50: Power On Time

This selection shows the time in 1/100 hour during the main switch of the machine is on.

P51: Machine Run Time

This selection shows the time in 1/100 hour during the main drive contactor of the machine is on.

P52: Total Input Sheets

This selection shows the total input counts in 1000 sheets

Exit Machine Setup and Diagnostic Mode

Pressing any of these keys will cause the controller to change to a new mode.

2.2 Counter Setup Mode

Pushing this key puts the counter in counter setup mode.

The speed up-table output activates the marking table output for the batching time duration.

The MKE mode is an unavailable option.

The kicker is a future feature.

The output types are represented by animated symbols.

The sequence of frames for the animations is shown in table 7.

Feed Interruption Speed Up Table MKE Table Kicker

Frame

Not

Available

Future

Feature

Table 7. Output Type Animations

Counter setup mode is used to prepare the controller to run a job. The large display (1) shows the batch preset on the left-hand side and the batching output time on the right hand side. The decimal points in the large display (1) will move from side to side to indicate that a parameter may be changed. The small display (2) shows the batching type. The suction length display (3) is active.

Change Batching Type

The minus and plus buttons move through a list of four output devices. The chosen Type is then activated when the batch down-count goes to zero. Feed interruption stops the feeding of sheets for the batching time setting.

TP10313 PAGE 16

Batch Preset Adjustment

These buttons cause the batch preset value to increment or decrement. The preset will be reloaded after the user leaves the setup mode only if the value has been changed.

Batching Time Adjustment

The batching time adjustments allow the user to select the time duration associated with the currently selected output type. Two output types and times are available.

1. Feed interrupt has a range of 0.0 to 9.9 seconds.

2. Speed-up Table has a range of 0.00 to 5.00 seconds.

Select Count Source

The Output Count and Input Count keys select between count at delivery and feeder, respectively. One key LED will always be lit in Counter Setup to show the current count source, see table 8. Chasing LEDs will activate in the small display signifying the start setup mode. The next sheet fed through will be timed from leading edge to trailing edge and the delay time will be set to one half the sheet time. Please note this must be redone if the delivery

speed is changed.

Pressing these buttons will toggle between the EASY

mode or cYcL mode. Set EASY in the large display and

press again.

Select Continuous Cycle Mode

Pressing this button enables the selection of either the

EASY mode or cYcL mode

Pressing these buttons will toggle between the EASY

mode or cYcL mode. Set cYcL in the large display and

.press again.

Exit Run Mode

The batching count source will be the feeder photoeye.

The batching count source will be whatever is connected as t he delivery photoeye.

Table 8. Count Source Selection

Exit Counter Setup Mode

Pressing any of these keys will cause the counter to change to a new mode.

2.3 Easy Mode and Continuous Cycle

Mode

2.3.1 Easy Mode and Continuous Cycle Mode

Pressing any of these keys will cause the counter to

change to a new mode.

2.4 Learn Mode

This key places the controller in learn mode. Learn mode can only be activated if the folder is idle.

The learn mode allows the user to setup the suction valve controller. Both manual and automatic setup is accomplished in this mode. The large display (1) shows two separate data items. The suction mode is shown on the left and the sheet length is shown on the right. The small display (2) shows the current gap length. The suction length display is active. During Learn Mode, the Learn Mode key LED indicates whether a valid sheet has been learned.

No valid sheet has been read yet, the system is in Single Sheet mode.

A valid sheet has been read and the DCT500 has been setup to run. Single Sheet mode is off.

Job

Enable EASY mode at parameter P25, see Table 3.

Select Easy Mode

Pressing this button enables the selection of either the

EASY mode or cYcL mode.

Table 9. Learn Mode Status

When the LED is on, pushing the sheet start button will feed a single sheet of paper. If the sheet is fed properly, the indicator LED will go off. The suction mode will be set to automatic. The length of the sheet will be set as the current sheet length. The suction length will be set based on table 11 and the gap length will be set to 4 cm /1.50 inches.

PAGE 17 TP10313

If P06 is set to 0 (no knife is active) and 10 cm /4.0 inches. If P06 is setting to 1, knifes are active.

Gap Length Adjustment

The minus and plus keys adjust the gap length. The gap length range is 0.2 to 98.0 (0.5cm to 250cm).

Suction Length Adjustment

This is the same as in run mode

Select Suction Mode

These keys toggle between automatic control and cycle mode. In the cycle mode, the suction valve will be on for the suction length and off for the remainder of the sheet length plus the gap length. No adjustments are made for slipped sheets or process changes. The automatic mode corrects for process changes and controls the timing of the suction valve to maintain the user-selected gap. If the gap is less than 1.5 (4.0 cm), the right hand decimal point of the small display (2) will flash and the Leading edge control will be active. If the gap is greater than or equal to

1.5 (4.0 cm), full Leading and Trailing edge control is maintained. Refer to table 10 for suction mode symbol definitions.

The suction length adjustment keys allow the user to change the amount of suction applied to the current sheet length. The display shows the percentage in 5% steps. All of the bars must be totaled to get the value. The range of adjustment is 5% to 50% of the current sheet length. If the suction length is manually adjusted while the Learn Mode LED is on, the suction length will no longer be the Single Sheet suction length of 6.0. The new suction length will be based on the current sheet length and suction setting.

TWT-180 Mode Leading Edge Co ntrol Leading and Trailing Edge Control

Table 10. Suction Mode Symbols

Sheet Length Setting Resultant Suction Length Percentage

Greater than or equal to 30 cm. 30% of Sheet Length Less than 30 cm., and greater than or equal to 27 cm. 25% of Sheet Length Less than 27 cm., and greater than or equal to 24 cm. 20% of Sheet Length Less than 24 cm., and greater than or equal to 21 cm. 15% of Sheet Length Less than 21 cm. 10% of Sheet Length.

Table 11. Suction Length Function

Sheet Length Adjustment

The sheet length adjustment keys allow the user to override the automatic Learn Mode setting. When the user changes the sheet length, the suction length will be adjusted according to table 11. If a different suction length is desired, the value may be overridden with the suction length adjustment keys. The sheet length range is 10 cm /4 inches to 250 cm / 98.5 inches.

Exit Learn Mode

Pressing any of these keys will cause the controller to

change to a new mode.

TP10313 PAGE 18

2.5 Make Ready Mode

This key places the controller in the make ready mode. The key LED goes on. In this mode the folder will only feed single sheets and a batching output is issued for every two sheets fed. This allows the operator to easily set up the batching time.

Exit Make Ready Mode

2.7 Production Mode

Enter Run Mode and Select Large Display Content

Pressing any of these keys will cause the controller to

change to a new mode.

2.6 Network Job Mode

Pushing this key puts the counter in network job mode

This mode is only available if a STA-NET adapter is installed and activated through maintenance mode. In this mode the small display (2) always shows the word Job. The large display (1) shows either PAuSE or a job number which can be read from the network. The suction length display is disabled.

Select Job Number

This set of plus and minus keys step the large display (1) through pause mode and a list of available job numbers. While in network job mode, the folder is considered to be paused.

Load Job and Return to Run Mode

When this button is pushed the selected job will be loaded into the counter and the counter will return to run mode. If the large display (1) was showing the message PauSE, the network job mode will end, but no job will be loaded.

Exit Network Job Mode

These keys do not operate as mode select keys in counter setup. In all other modes, the keys both select the large display (1) contents and place the counter into run mode. Pushing one of the buttons will light the buttons associated LED and cause the parameter to be displayed. If both the input and output count keys are pressed simultaneously, then both LEDs go on and the waste count is displayed. See Process Variable Definitions.

Large Display Cont ents

Table 12. Determining the Large Display Contents

When the folder is started the counter will start up in the run mode, the normal operating mode of the counter. In this mode, various job parameters can be displayed on the large display (1) and the small display (2) shows the gap length. The suction length display (3) is active in this mode and shows the suction length as a percentage of sheet length.

Output Count Batch Count Down

Number of Batches Current Rate

Input Count

Waste Count

Gap Length Adjustment

Pressing any of these keys will cause the counter to

change to a new mode.

The gap length adjustment keys allow the user to change the current gap length. The range of adjustment is

0.2 to 98.0 (0.5 cm to 250 cm).

Suction Length Adjustment

PAGE 19 TP10313

Reset Function

Pressing and holding this key will result in a reset function being activated after a 5-second countdown. The function is based on the current large display selection, see table 12. The large display (1) will show countdown to reset in this manner. When the button is pressed the message CLr In 5 will show on the large display (1). At one second intervals the display will progress through CLr In 4, CLr In 3, CLr In 2, CLr In 1, and finally will show CLEArEd when the reset action is complete.

3.0 Logic Board Status Indicators

Several of the controller functions are monitored with LED indicators located on the Logic Board (see Table 14). The status of all other inputs are shown on the 8 Digit display in Machine Setup mode (see Tables 1 - 6).

Reference Name Description Designator

LED1 Tachometer Indicator Tracks the Tachometer input. LED2 Not Used Turns on when MKE output is activated. LED3 Suction Indicator Tracks the Suction output. LED4 K1 Status of Relay K1 LED5 Pile Down Tracks the Pile down output. LED6 Pile Up Tracks the Pile up output. LED7 Pile Indicator Tracks the Pile outputs. If one of the Pile

LED8 Logic +5VDC Supply Shows status of Logic +5VDC Supply LED9 Isolated +5VDC Supply Shows status of Isolated +5VDC Supply LED10 Isolated +24VDC Supply Shows status of Isolated +24VDC Supply LED11 Kicker Turns on when kicker output is activated.

Table 14. LED Status Indicators

Reset while showing Output Count will reset all job variables.

Reset while showing batch data will reset Number of Batches and reload the Batch Down Count.

Table 13. Reset mode Selection

outputs is on, this LED will be on.

TP10313 PAGE 20

4.0 Process Variables Definitions

4.1 Total Input Count

The Current Rate is rounded to the nearest hundreds. Current Rate can range from 0 to 99,999,900. This process variable is not stored in memory.

Total Input Count increments by the factor setting each time an input is received at the Input Count input. Total Input Count can range from 0 to 99,999,999. This process variable is stored in memory in case of a power outage. Reset job will clear this process variable to zero.

4.2 Total Output Count

Total Output Count increments by the factor setting each time an input is received at the Output Count input. Total Output Count can range from 0 to 99,999,999. This process variable is stored in memory in case of a power outage. Reset job will clear this process variable to zero.

4.3 Batch Down Count

The Batch Down Count is the number of remaining inputs necessary to trigger a batch output. As input counts are received, this value counts down to zero. Each input decrements the Batch Count Down by one. When zero is reached, the Batch Down Count resets to the Batch Preset. The Count input that is used by the Batch Down Count is determined by the Batching Selection in Machine Setup. If Feeder is the Batching Selection, the Batch Down Count will be affected by the Input Count Input. If Delivery is the Batching Selection, the Batch Down Count will be affected by the Output Count Input. Batch Down Count can range from 1 to 999. This process variable is stored in memory in case of a power outage. Reset job will clear this process variable to zero. Reset batch will load this process variable with the batch preset.

4.4 Number of Batches

The Number of Batches is the number of times the Batch Down Count has reached zero. Number of Batches can range from 0 to 9999. This process variable is stored in memory in case of a power outage. Reset job will clear this process variable to zero. Reset batch will clear this process variable to zero.

4.5 Current Rate

The Current Rate is based on the number of Input Count inputs received during the sample period. The Current Rate is calculated every second. The Current Rate is shown as rate per hour

4.6 Main Drive Run Time

The Main Drive Run Time is the amount of time the Drive output has been on since the last Clear All Memory Reset in Maintenance Mode. This value is displayed in the format HHHHHH.HH. Main Drive Run Time can range from 0.00 to 999,999.99. This process variable is stored in memory in case of a power outage. Reset ALL in maintenance mode will clear this process variable to zero.

4.7 Main Drive Velocity

The Main Drive Velocity is the speed of the Tachometer input. This value is displayed in meters per minute. This value is calculated every 300 milliseconds. This process variable is not stored in memory.

4.8 Waste Count (Option)

The Waste Count is the difference between the Total Input Count and the Total Output Count. Waste Count is accessible by pressing and holding the Total Count button followed by pressing the Total Output Count button. Waste Count can range from 0 to 99,999,999. This process variable is not stored in memory. Reset job will clear this process variable to zero.

5.0 Counter Setup Variables

5.1 Batch Preset

This parameter, accessible in the Batch Setup mode, specifies the batch count that will be used by the Batch Count Down. Zero is the default setting. This value can range from 0 to 999.

5.2 Batch Output Type

This parameter, accessible in the Batch Setup mode, specifies the batch output type that will be used when the Batch Count Down reaches zero. Available choices are Feed (FED), Delivery (DEL), Speed (SPD), and Table (TBL).

PAGE 21 TP10313

5.3 Batch Output Time

This parameter, accessible in the Batch Setup mode, specifies the output duration or delay that will be used when the Batch Count Down reaches zero. Available ranges are determined by the Batch Output Type selected. The Table below shows the ranges for each output type.

Output Delay Duration

Type Min. Time Max. Time Min. Time Max. Time

Feed Not applicable 0.0 Sec. 9.9 Sec. Table 0.000 Sec. 1.000 Sec. 100 ms Delivery 0.000 Sec. 1.000 Sec. 25 ms Speed Not applicable 0.00 Sec. 5.55 Sec.

Table 15. Output Delay and Duration

5.4 Sheet Length

This parameter, accessible in the Batch Setup mode, specifies the length of the paper that will be fed into the machine. Available range is 6.0 to 59.0. 6.0 is the default selection.

5.5 Gap Length

This parameter is accessible in Run mode and Learn mode and specifies the length of gap to use between sheets of paper that are fed into the machine. Available range is 0.2 to 98.0. 2.0 is the default selection.

5.6 Suction Length

This parameter is accessible in Run mode and Learn mode andspecifies the suction length used on a sheet of paper that is fed into the machine. Available range is 5% to 50% in 5% increments. 30% is the default.

TP10313 PAGE 22

6.0 System Messages and Run Messages

6.1 Power-Up Fault Messages

Messages that are displayed during power on self-test. If PLC System Errors are shown in the display, call service.

ENGLISH GERMAN CODES TYPE DESCRIPTION

88888 88888 88888 Information The controller is performing its lamp test. MEM TEST MEM TEST MEM TEST Information The controller is performing its RAM test. All Blank All Blank All Blank PLC System The display board is not functioning.

Error Cycle Power. If error persists, call service.

ID Fail ID Fail ID Fail PLC System System cannot recognize the controller board.

Error Action: Cycle Power, if error persists call service.

Error 1 Error 1 Error 1 PLC System The RAM test has found a bad memory location.

Error Action: Cycle Power, if error persists call service.

Error 2 Error 2 Error 2 PLC System The Pile Safety Relay is stuck on or there is no power supply to the

Error pile circuits. Action: Check the condition of Relay 1 (K1), Fuses

F1 and F2, and X18. Cycle Power. If error persists, call service.

Error 3 Error 3 Error 3 PLC System There is power in the Pile Drive when it is off. Action: Check the

Error condition of Relay 1 (K1), Fuses F1 and F2, and X18. Cycle

Power. If error persists, call service.

Error 4 Error 4 Error 4 PLC System The 24VAC inputs have current before the Watchdog relay has

Error been activated. Action: Check for stuck push buttons, faulty

sensors, or loose connectors. Cycle Power. If error persists, call service.

Error 5 Error 5 Error 5 PLC System The membrane switch panel has a key pressed during the power

Error on self-test. Action: Cycle Power, if error persists call service.

Error 6 Error 6 Error 6 PLC System The Watchdog sense circuit indicates Watchdog-timer operational

Error before it has been started. Action: Cycle Power, if error persists

call service.

Table 16. Power Up Fault Messages

PAGE 23 TP10313

6.2 Run Time Fault Messages

Run time fault messages are only displayed when the unit is in Run mode. Fault errors can still occur, but the corresponding fault message will not be displayed until the unit is switched to Run mode. Run time fault messages are PLC System Errors or errors in the whole Electric System. It is necessary to call a technician or service.

ENGLISH GERMAN CODES TYPE DESCRIPTION

DCT X.X.X DCT X.X.X DCT X.X.X Information This is the Software-Version(X.X.X)

Note: do not push any buttons until this message has been cleared from the display

K5 Relay K5 Relay Error 7 PLC System The drive stop relay, K5, is not responding to the controller.

Error Action: Call service.

Button Taste Error 8 Electrical A push button is in the wrong state during the version message

System display. Action: Check Buttons & Cycle Power. If error Error persists call service.

Watchdog Watchdog Error 9 PLC System The Watchdog Timer has elapsed without being serviced.

Error Action: Cycle Power. If error persists call service.

No Tach Impuls Error10 Electrical The Machine Tachometer is reading a velocity outside of the

System range 10  230 meters per minute, while the main drive should Error be running. Action: Check the electric. If error persists call

service.

Overload Uberlast Error11 Electrical A Thermal Overload has been tripped.

System Action: Check the electric. If error persists call service. Error

Pile Err Spg.Uber Error12 Electrical The Pile Safety Relay is stuck on or there is no power supply to

System the pile circuits. Action: Check the condition of Relay 1 (K1), Error Fuses F1 and F2, and X18, then cycle Power. If error persists

call service.

Overrun Uberlauf Error13 Electrical The Pile Table has moved past its safety stops. Action: Check

System the limit switches, pile table, and wiring. If error persists call Error service.

2nd Stat 2Station Error14 Electrical The Emergency Stop, Wrong Sheet, and Thermal Overload

System sense circuits are all indicating failure. Likely cause is Second Error Station connector problems. Action: Check the Second Station

Connector, connector X22, and each individual circuit. If error persists call service.

Suction Saugtakt Error15 Electrical Short circuit on Suction controller. Action: Check the electrics.

System If error persists call service. Error

Table 17. Run Time Fault Messages

TP10313 PAGE 24

6.3 Machine Run Error Messages

Machine Run Error Messages help the operator to indicate a production problem.

ENGLISH GERMAN CODES TYPE DESCRIPTION

Stop Stop1 Stop1 Information One of the stop buttons is depressed. ACTION: Make sure all

stop buttons are cleared and connectors X21, and X22 are seated.

Wrng Sht Fehlerbg Stop2 Machine The Wrong Sheet Detector has been tripped. ACTION: Clear

Run Error the fault. NOTE: If the main drive was running, the error

condition will remain latched until the Drive START is pressed.

2 Sheet Doppelbg Stop3 Machine The Double Sheet Detector has been tripped. ACTION: Clear

Run Error the fault and check X22. NOTE: If sheet feed was active, the

error condition will remain latched until the Sheet Start is pressed.

No Feed Bog.Fehl Stop4 Machine No paper detected within 40 cm of suction valve actuation,

Run Error while running in an automatic feed mode. ACTION: Check

misfeed, connector X14, and the condition of the count photoeye.

Feeder Sensor Stop5 Machine Photo-eye at suction valve is covered before Sheet Start is active.

Run Error

Long Sht Bg.Lang Stop6 Machine The count photo-eye has been covered for more than 150% of

Run Error the user set sheet length distance. ACTION: Check misfeed,

connector X14, and the condition of the count eye.

Knife 1 Schwert1 Stop7 Machine The knife input 1 has been active for more than 1.5 times the

Run Error last measured time. ACTION: Clear the fault.

Knife 2 Schwert2 Stop 8 Machine The knife input 2 has been active for more than 1.5 times the

Run Error last measured time. ACTION: Clear the fault.

Knife 3 Schwert3 Stop 9 Machine The knife input 3 has been active for more than 1.5 times the

Run Error last measured time. ACTION: Clear the fault.

Snsor DN Stpl Ab Stop 10 Machine The Pile has been moving down for more than 2.5 seconds

Run Error while the unit is feeding paper. ACTION: Check Pile Sensor.

Snsor Up Stpl Auf Stop 11 Machine The Pile has been moving up for more than 1.5 seconds while

Run Error the unit is feeding paper. ACTION: Check Pile Sensor.

Table 18. Machine Run Error Messages

PAGE 25 TP10313

PILE FEEDER OPERATION

1.0 Loading the Pile Feeder

Set the right hand side guide (Figure 11-1) to half the sheet using the scale (11-2). The vacuum wheel is in the center of the sheet. Lock the guide in place using the lever (11-3).

Remove the left hand guide (Figure 12-4) from the feeder. Move the sheet drag guide block (12-5) on the righthand guide to the rear of the paper stock.

Press the table down button (for controls, see page 8). A lower limit switch will halt the pile table when it descends to the lowest position. Load the paper against the front and right hand guides (11-1).

Press the table up button. The pile height sensor (11-6) will stop the upward travel of the table. During operation, the top sheet of the pile should be approximately 1/2" under the vacuum wheel and 5/8" under the sensor (11-6), with the pile up and the pump off. The pile height sensor is contact-free.

Reinstall the left hand guide (12-4). Slide the register guide (12-7) inward until the see-through left hand guide

(12-4) is approximately 1/16" away from the stack.

Figure 11

1.2 Hold-down Locations

Set the sheet hold-downs so the rubber bumpers rest on top of the sheet pile and prevent double sheets from being pulled in. Using the rubber bumpers is dependent upon the

stock being fed.

1.3Air and Vacuum Settings

Press the pile up button if it has not been pressed.

Press the pump "on" button.

Adjust the air flow into the top of the stack as shown in Figure 13, using the blow tube angle levers (Figure 14-1) and the air bleed off valve cover (14-2).

Figure 13 shows that the top four to five sheets are to be separated using the top blow tube (13-1). The bottom blow tube (13-2) separates approximately 1/2" of the stack under the top four or five sheets. The bottom blow tube (13-2) provides separation to send sheets up to the top to be fed.

Do not adjust the air angle flow too high into the sheets. The top sheets should be in a humped pattern as seen through the side guide for approximately 75% of the sheet length.

Figure 12

Figure 13

TP10313 PAGE 26

Figure 14

1.3 FRONT BLOW TUBE SETTINGS

The front blow consists of two tubes (Figure 13-1 & 2 and Figure 15-1 & 2) instead of the traditional one tube. The numbers on the left hand side of the tubes correspond to the chart (Figure 15-3) found on the side of the main control enclosure.

Setting Up

1.) Determine the width of the job to be run.

2.) Find the numbers on the right-hand side of chart

that correspond with the sheet width.

3.) Set the top (15-1) and bottom (15-2) blow tubes,

using the detent slots, to the respective numbers.

Vacuum adjustment is made at the pump (Figure 16) using the valve (16-1). Vacuum adjustment requirements should be minimal. Listen to the feeding at the vacuum wheel to determine if there is too much vacuum. The vacuum valve (16-1) should be set as shown for most applications.

1.4 Vacuum Wheel

The vacuum flow is controlled by a solenoid valve (Figure 11-4 & 17-1). This can be quickly and easily removed to clean the piston (17-2) by releasing the clamping springs. Be careful not to damage the piston and cylinder.

The vacuum wheel (Figure 18-1) is supplied with two O-rings (18-2) to assist feeding with a positive friction grip. These O-rings are replaced after removing the guard (18-3) by removing the two button head screws (18-4) holding it.

Figure 16

Figure 17

Figure 15

PAGE 27 TP10313

Figure 18

Use the fluted knob (Figure 19-1) to slide the side guide (19-2) with the marble holder (19-3) to the required location 1/16" away from the pile stack.

Move the sheet support (19-4) to the right hand side of the sheet.

Place the steel and/or plastic marbles into the marble holder (19-3). It is recommended to have at least two steel marbles in the first four to six positions closest to the pile feeder end.

The succeeding positions can be filled with steel or plastic marbles depending on the stiffness of the paper. For registering oblong sheets it is recommended to have at least 50% steel and 50% plastic marbles alternating in the marble holder.

Clip-on sheet hold-downs (19-5) placed across the register table prevent the sheets from rising. The hold-down with the angle-formed end is to be placed in front of the vacuum wheel.

The fluted knob (19-6) provides microadjust-ment of the side guide (19-2). Knurled knobs (19-7) provide bias adjustment for the side guide for adjusting sheets that are not square or for other unusual conditions.

The double sheet control (Figure 20) is adjusted to the thickness of the paper being fed by pulling up the lever (20-

1) and inserting two paper strips (20-2) of the sheets to be folded in the clip at the back of the lever.

The feeler segment remains inoperative when a single sheet is passing through. When double sheets are being fed through, the feeler segment is pulled against a microswitch and the double sheet is stopped. Sheet feeding is stopped and the message "2 sheet" appears on the counter readout. The message remains until the double sheet is removed. Raise the lever (20-1) to remove the double sheet.

Figure 19

TP10313 PAGE 28

Figure 20

1.0 DOUBLE SHEET DETECTOR

The double sheet detector consists of a scanner element, microswitch and a free-wheel roller.

If the setting for paper thickness is exceeded, the scanner element trips the microswitch, closing the magnetic valve for the suction cycle so that sheet transfer is stopped instantaneously. While the double sheet is stopped, the sheets that are in the machine continue to be folded.

The double sheet stop must be set so that the scanner probe remains untouched when a single sheet of paper passes through. When two or more sheets are detected, it must trigger the stop mechanism. (See Figure 21)

A double sheet strikes the scanner on the microswitch, interrupting the sheet flow-through.

Figure 21

BAUMSET ADJUSTMENT

1.0 Adjustment of Folding Rollers

Folding accuracy is determined largely by precise adjustment of the folding rollers.

Using the Baumset precision adjustment device, the correct setting of the rollers can be made simply by inserting the appropriate paper thickness between the adjustment plates. (See Figure 22) With multiple thicknesses, insert single strips of the paper being folded equal to the number of sheets passing through that roller combination..

Since the adjustment spindle acts directly on the folding rollers, clearance settings are exact.

Another method for setting the folding rollers is to insert paper strips between them by touch, the pressure adjustment being made by turning the knurled screw. The numbers on the Baumset adjustment knobs correspond to the buckle-plate numbers into which the sheet is fed. All upper buckle plates have odd numbers while the plates below are even.

The Baumset adjustment device is correctly zeroed at the factory. If any adjustment is necessary, strips of single paper thickness should be placed under every adjustment plate. The folding rollers are then reset by drawing strips of uniform thickness through the appropriate pair of rollers as far as possible to the other side. At the same time, the knurled screws are adjusted so that the strips can be withdrawn when medium drag is felt. When this operation is complete, the dial rings are reset to zero.

With single sheet thickness, the scanner remains untouched and sheets move freely.

Figure 22

PAGE 29 TP10313

SETTING OF FOLD PLATES

NOTE:

Check the symbols on the fold plate stop (Figure 23-1) for installation of the fold plate swing deflectors (Figure 24-1) to avoid damaging the fold rollers. The deflector must only be brought forward when the stop (23-1) with the deflector symbol is in the forward position.

Be sure that the adjustment screw (23-2) is in contact with the support rail on both sides.

Clamp the fold plates with the clamping screw (Figure

23-3).

The sheet-stop (23-4) should be moved to the desired fold length according to the scale (23-5) by loosening the clamping screw (23-6) and then turning the adjustment wheel (23-7).

The sheet stop can be set at an angle for sheets that are not cut square by loosening the clamping screw (23-6) and turning the front adjustment wheel. The clamping screw (23-3) must be tightened for this adjustment.

For the fitting of a fold plate, both sides of the stop (23-

1) must have the fold plate symbol turned to the front so that the adjustment screw contacts the support rail.

Equal adjustments at both ends are needed to prevent oblique folds or perforations.

CAUTION:

If the buckle space is reduced, be sure that the fold plate does not rub against the folding rollers. If this occurs, the rollers will be damaged. Check for rubbing by turning the handwheel on the folder before turning the power on.

Figure 23

SETTING OF SHEET DEFLECTORS

Fold plates that are not required for folding can be closed off with swing deflectors fitted in the infeed. The fold plate is slightly withdrawn and the deflector (Figure 25-1) is swung down and pushed in until it engages.

CAUTION:

Move stop (Figure 26-1) on both sides to avoid damage to the folding rollers. Loosen the knurled screw (26-2). Turn the stop and retighten the knurled screws. The deflector symbol (26-3) must be in forward position.

Figure 24

TP10313 PAGE 30

Figure 25

Check that the adjustment screws (26-4) are in contact with the support rail (26-5) on both sides. The basic position is marked by a notch (26-6) in the fold-plate frame.

Setting Stationary Deflector

(Separate sheet deflector) (Figure 27-1) The stationary sheet deflectors are installed and clamped in place in the same way as the fold plates.

NOTE:

The fold plates in an 8-page folder will work in the #4 fold plate position when four plates are desired. This applies to folders equipped with three fold plates and one stationery deflector.

STACKER (DELIVERY)

The motorized hang-on stacker has the following unique features.

Figure 26

 Independent speed adjustment by using the speed

selector (Figure 28-1).

 Telescoping delivery tray that is fixed in position using

thumbscrews (28-2) below the tray.

 Nosebar with brush (28-3) that prevents sheets from

becoming trapped and eliminating a pinch point.

 The stacker can be mounted level or at an angle to assist

stacking of sheets that tend to spring open.

The stacker electrical power source is provided by inserting the male receptacle on the stacker power cord into the mating connector found on the left hand side on the main electrical enclosure of the pile feeder.

Figure 27

Figure 28

PAGE 31 TP10313

SCORING/SLITTING/PERFORATING

Your new folder is capable of many different applications that compliment the folding performance and provide for greater productivity. The folder is equipped with slitter shafts that are quickly set up for the required operation. These shafts accommodate the mounting of the standard and optional accessories available that perform scoring, slitting and perforating functions. It is important to note that accessories from previous model Baumfolder machines with 7/8" diameter slitter shafts are still adaptable to your new folder.

1.0 Slitter Shaft Accessories Removal

To remove slitter shafts, remove knob (Figure 29-1). Insert knob into the center of the slitter housing (29-2) and remove the housing, using the knob. Add or remove the parts needed for the current job using the wrench (Figure

30) provided with the machine. See the following pages for more information on perfing, scoring, and slitting. Reinstall slitter housing and knob before starting the machine.

1.1 Scoring

The folder can be used to score a sheet and deliver it flat, or to score a sheet after a fold or folds have been made. To ensure accuracy in making right angle folds, always score the sheet where the fold or folds are to be made. This applies in all instances when a perforator cannot be used. Various weights of stock with few or numerous folds require a different type of score. Some jobs require a narrow, sharp score, usually when the folds are few, and a fuller, more rounded score when the job becomes bulky.

The new Baum Adjustable Score Assembly (Figure 31) makes it easier to adjust the depth of your score. This is adaptable for any Baum folder with 7/8-inch diameter slitter shafts. The Baum Adjustable Score Assembly consists of two special score collars which are connected by two adjusting screws. These screws provide precise control over the compression of the rubber score tire, which in turn determines the depth of the score.

For previous type scoring accessory setup, see Figure

32. Scoring blades can be mounted on either upper or lower shaft. They should be placed

Figure 29

Figure 30

TP10313 PAGE 32

Figure 31

Adjustable Score Assembly

Figure 32

so that the fold is made with, rather than against the scoring, or, in a continuing direction to the pressure or crease that has been applied by the scoring blade.

32-A) Score directly on the wide, soft rubber tire with a collar mounted at either side. By this method, depth of the scoring can be increased by compressing the collars to expand the tire.

32-B) For a wide, well-rounded score, the two steel collars alone are sometimes used. Sharpness and depth of the score can be controlled by regulating the distance the collars are placed away from the scoring blade.

1.2 Perforating

The folder may be used for perforating either the heads of booklets (to allow the air to escape in making right-angle folds) or to slot perforate sheets delivered flat, using blades and strippers best adapted for a particular job. All perforating blades are mounted on the upper shaft and run in a grooved steel collar on the lower shaft with the flat side of the blade just touching a side of the groove. When doing book work, perforator blades should be mounted with the bevel side of the blade toward the following bank of fold rollers. (See Figure 34). When mounted in this manner there is slightly less tendency for the sections of the signature to come apart and less tendency for one section to pull out of line with another. This is particularly true when folding in an up fold plate. A stripper must be used with each perforation. The forked spring steel stripper requires a little more care in mounting and is most often used when perforating only, as there is less tendency for the perforated sheet to break apart.

Figure 33

Figure 34

Perforator Blades

Part # Description

07618 6 Tooth Perforator ________ ________ 06605 12 Tooth Perforator ______ ______ ___ 07895 15 Tooth Perforator _____ _____ _____ 07896 18 Tooth Perforator ____ ____ ____ _ 29629 20 Tooth Perforator ___ ___ ___ ___ __ 07619 24 Tooth Perforator __ __ __ __ __ __ 06798 31 Tooth Perforator _ _ _ _ _ _ _ _ _ 07791 41 Tooth Perforator _ _ _ _ _ _ _ _ _ _ _ _ 11962 64 Tooth Perforator - - - - - - - - - - - - - - - - - -

Figure 35

PAGE 33 TP10313

1.3 Slitting (Cutting) Sheets

Folders may be used to cut folded or flat sheets apart. The general set up for blades and collars is shown in the Figure 36. Two or more cuts may be made if duplicate sets of slitters are used. Be careful when mounting slitter blades to collars in order to avoid ragged edges which can be caused by two conditions:

1) Nicks or burrs on the collars or blades. Remove carefully by filing or using a fine piece of emery cloth.

2) Incorrect mounting of blades caused by tightening with the wrong type screw. Always use flat head screws on the side of blades and blade holders which are countersunk. Before tightening the blade to the collar, slide the blade with the collar loosely attached on the end of the shaft. Then tighten securely to align both blade and collar, and allowing free horizontal movement. Place the blade on the upper shaft in the position where the cut is to be made. Then move the blade on the lower shaft so that the two blades are pressed snugly together. Too much space between the blades will produce a ragged cut. Figure 36-1 shows a spacing washer mounted on the outside of the blade for reinforcement. This helps prevent bending or twisting when running very heavy work or any job containing a large number of folds. Space the pull out tires evenly to support the sheet.

Figure 37

Figure 36

Slitter Blades

Part # Description

06378 3/32" Thick Countersunk Flat Side 06804 3/32" Thick Countersunk Bevel Side 15240 .062 Thick Countersunk Flat Side 15241 .062 Countersunk Bevel Side 15573 Hollow Ground Countersunk Flat Side 15574 Hollow Ground Countersunk Bevel Side

TP10313 PAGE 34

1.4 Trimming Edges of Booklets

Figure 38 shows the setup of cutting blades and strippers for trimming edges of booklets or outer edges of circulars running two or more up. Cutting blades are attached to blade holder collars so that the bevel of blades on the upper shaft are directed toward the strip being trimmed and the bevel of blades on the lower shaft are directed away from the strip. Blades mounted in this manner tend to turn trimmed edges down which helps guide them to the floor. Blade holder collars are turned out to allow a set of pull-out tires to be placed close to the cutting blades, preventing the sheet from buckling or twisting at the point where the cut is being made. Use as many additional pull-out tires in the center of the sheet as necessary. Set the collar, with blade attached, in the proper position on the upper shaft. Then move the collar/blade on the lower shaft so that the flat sides of both blades press snugly together. Too much space between the blades will cause a ragged edge on the finished booklet.

Do not attempt to trim less than one-eighth of an inch. On bulky or heavy sheets a wider trim is necessary. Figure 38 shows the type strippers used for this work, mounted on the square bar directly above the shafts. Note that one is right, the other left, placed accordingly. It may be necessary to bend the strippers slightly to avoid rubbing on the cross carrier or stacker. Strippers are adjustable for up and down movement.

You will note that the holes in one side of the cutting blades and blade holder collars are countersunk, so that flat head screws can be used to mount blades on the lower shaft, allowing clearance for the stripper which is placed between them. This also allows the cut out strip to pass between the lower blades without encountering screw heads. Attaching blades to collars is very important and should be done with care. The bevel of the cutting blades on the top shaft should always be directed toward the strip to be trimmed. The bevel of the blades on the lower shaft should be directed away from the strip. Before the cutting blades are tightened to the blade holder collars, slide both the collar and attached blade on the end of the shaft so that they are accurately aligned. Place cutting blades on the upper shaft to the proper position where the cut is to be made. Then place collars on the lower shaft so that the flat sides of the blades are pressed snugly together. Too much space between the blades will give a ragged edge. Always examine blades for dullness and nicks which will cause the same condition. When blades are in the proper position, mount the stripper as shown. Be sure the stripper does not touch the sides of the cutting blades. With this setup, the trimmed out section automatically goes between the blades on the lower shaft, where it is carried down and around and guided to the floor by the stripper wire.

Trimming a Strip from Center of Sheet

Figure 39 shows the setup for taking a quarter inch trim out of the center of a sheet. Two or more trims may be made as long as duplicate sets of cutters and strippers are used and this setup adhered to. A strip three sixteenths of an inch wide is the minimum trim. This is the thickness of two of the cutting blades placed together and attached to a blade holder collar. Blades on the upper shaft, for all trims up to one-quarter inch, are attached to one collar. If a strip wider than one-quarter of an inch is to be cut, each blade is attached to an individual collar and any desired width may be cut. To remove the trim, place the appropriate center stripper between two of the cutting blades, attached to a collar, as shown in Figure 39A.

Figure 38

Figure 39

PAGE 35 TP10313

LUBRICATION/MAINTENANCE

Pile Feeder

Vacuum Solenoid Valve The vacuum at the suction wheel is controlled by a

solenoid valve (Figure 40). This can be quickly and easily removed to clean the piston by loosening the clamping

Figure 40

Gear Reducer Check fluid level annually. Check for wear. Refer

O-Rings (on vacuum wheel) See Figure 18.

Vacuum Pump Loss of vacuum and blow can be caused by clogged filters.

Flat Belt Drive Shaft (hex shape) Check for wear periodically. Lubricate with Baum

Support Bars Lubricate the three support bars on which the register

springs. Be careful not to damage the piston and cylinder. See Figure 17.

to parts manual for part number.

Check periodically. Check vanes for wear after 15,000 hours of service. Refer to parts manual for ordering parts.

Lubricant "W". Lithium base grease or equivalent periodically.

guide slides periodically using Lithius base grease.

Folder

Handwheel Lubricate bi-annually with commercial grade

lubricating oil.

Fold Rolls WARNING: Never clean fold rolls while the machine is

running.

With the folder turned off, rub down the fold rolls with a cloth dampened with "Surewash". Never immerse fold rolls into the washing solvent. After cleaning, they should be rubbed down with a clean dry cloth.

Gear Drive The helical gear drive is lubricated by an automatic

grease dispenser located inside the LH guard. Use the label on the LH guard to record lubrication change date [It should be changed every 9 months]. To activate the dispenser, screw the eye bolt (Figure 41-1) into the lid (41-2) of the dispenser until ring (41-3) comes off. Shake the cannister when installing to insure that it rattles, signifying that it has been activated. See parts manual for replacement dispensers.

WARNING: Never open grease dispenser. Even when

Figure 41

empty, container remains under pressure. If damaged, caustic liquid may leak out. If contact is made with skin, flush repeatedly with water.

Pullout Tires Check periodically for wear, uneven tires can cause the

TP10313 PAGE 36

sheet to twist.

TECHNICAL SPECIFICATIONS

BAUM 2018

Maximum sheet size 20.5" x 25" [45.7 x 63.5cm]

Minimum sheet size 4" x 6" [10.1 x 15.2cm]

Maximum folder speed 8200 ipm [208m/min]

Maximum pile height 25" [63.5cm]

Minimum fold length 1.57" [40mm]

Maximum fold length 20.5" [45.7cm] (parallel folder)

Slitter shaft diameter 7/8" [22mm]

Electrical 220 Volt, 1 phase, 60 Hz, 23 Amperes

See serial plate on folder

ACCESSORIES

In addition to the various folding, slitting, perforating and scoring functions the Baum 2018 can perform even more productive functions using the following accessories.

 Jam Detectors  Remote Control  Static Eliminator  Sound Guards  Gluing Fold Plates

Contact your local Baumfolder Corporation sales representative for further information.

PAGE 37 TP10313

TROUBLESHOOTING

PROBLEM CAUSE REMEDY

Sheets stick together Inadequate ink drying, cut Fan out thoroughly when particularly along sides. with blunt guillotine blade. piling, increase blower air.

Suction wheels picks Excessive suction. Reduce vacuum setting. up double sheets. Air blow improperly set Increase air blow Sheets stick together

Double sheet stop Set only to single paper Correct to double paper reacts to single sheets. thickness. thickness. Tighten lock nut.

Sheet twists after suction Side Guide on register Bring guide plate forward. wheel finishes feed-in. set too far back.

Too few marbles at start of Increase number of marbles side gage. if necessary.

Suction gap too short. Increase gap setting.

Sheet leading edge If the leading edge of the sheet Adjust holder tongue buckles on register or is being buckled, the holder accordingly. lower sheets are being tongue below the suction wheel pushed forward. is too high; if too low, sheets

are pushed forward.

Dirty valve piston sticking. Clean.

Sheets fails to run into the Only at 1st buckle plate: Fit sheet deflector to 1st buckle plate. A curl in the sheet buckle and fold in 3rd

can cause the leading- buckle plate. edge to bend up or down thus missing the upper or lower buckle throat.

On all buckle plates: sheet Advance lower buckle plate missing the buckle plate lips accordingly. underlips.

Sheets fails to re-emerge Sheet unable to buckle as Set lower buckle plate from buckle plate. buckle space too small. lip further back.

Folding rollers blunt or Wash off rollers with the clogged with ink. type of rubberised-cloth

cleaning agent used in offset work.

Inadequate inside clearance Increase clearance as in buckle plate. necessary.

TP10313 PAGE 38

TROUBLESHOOTING - continued

PROBLEM CAUSE REMEDY

Sheets fails to re-emerge Product too thick for folding. Consult Baum technical rep. from buckle plate.

Not enough roll pressures. Check Baumset settings.

Sheet remains lying on Electrostatic charge in Fit discharge unit at the the roller table of the 2nd product caused by friction exit to the 1st station station or fails to run into with rollers and deflectors or arrange for appropriate the 1st buckle plate of the and also relatively low humidity on the premises. 2nd folding station. humidity.

Damping rods and sheet holder Raise as necessary. set too low.

Wrinkling after the 1st Register guide not at right- Set angle correctly. fold, either across or angles to the folding rollers. parallel.

Sheet drawn too sharply against Insert fewer balls or use the register guide causing a wave lighter ones. to form.

Buckle plate feed stop not Correct buckle plate stop parallel to the incoming sheet setting. edge.

Folding rollers set too tight. Slacken roller setting.

Crooked perforation after Register guide and buckle Reset. 1st fold. plate stop not at right angles

to each other.

Faulty setting of folding Check and reset as rollers and slitter shaft. necessary.

Lower buckle plate lip Set to zero position. crooked.

Sheet corners buckled Sheet deflector set too low. If the corners are buckled up or down after the upwards, set the upper 1st fold. sheet deflectors back

evenly; if the corners are buckled downwards, the lower deflectors must similarly be set back evenly by underlaying pieces of card. In no circumstances alter the basic setting of the deflectors.

PAGE 39 TP10313

OPERATING TIPS

Setup

When setting up a job on your folder, watch so the sheet doesn't end up with either the RH or LH edge along the edge of a fold pan or register plate. This could kick it over causing inaccurate folding.

Brass Tipped Screws

When replacing screws in collars and various other assemblies, be sure to note if they are brass tipped screws. Using non-brass screws as replacements will cause scarring of the shaft, making collars difficult to move.

Static Electricity

If you do not have an electrical static eliminator, here are some ideas to help reduce static electricity:  Make sure the machine frame is grounded.  Try using static tinsel across the register table and feeder.  Locate the folder out of direct drafts such as doorways and air vents.  Cover jobs with plastic between the press and the folder if much time will elapse before the job is to be run.

Cutting Blade Wear

To help extend the life of all cutting blades, check for possible burrs on the mounting collar. Lay a sheet of emery cloth on a flat surface and rub the collar around a few times to remove any burrs. The blade will now rest flat against the collar, giving a more even rotation.

Measuring Odd Thirds

When measuring odd thirds as needed for a Z-fold for example, on an 11 inch sheet, lay your ruler on a diagonal of 12 inches instead. Mark at four and eight inches, and you will now be able to easily measure 1/3 of the sheet.

Pull-out Bands

Periodically check for wear on the rubber pull-out bands on each slitter shaft. When each sheet passes through the last rolls, there is another 1 3/4 inches left on the sheet before it is completely out of the folder. At this point, the only thing controlling the sheet is the pull out bands. If they are worn or uneven, the sheet can twist after dropping out of the rolls when travelling that last 1 3/4 inches.Be sure when replacing these worn pull-out bands that you replace the complete set, so you will always have an even pull on both sides.

Slitter Shaft Setup

Here is an easy way to set up your slitter shaft accessories. Mark up a dummy sheet with the scores, perforations, etc. locations. Roll through by hand and position your slitter shaft accessories accordingly. Also, keep all set

screws for the slitter shaft accessories facing out, so you don't have to turn the shafts to get to the screws.

TIPS FOR FOLDING

The following section contains a number of hints drawn from practical experience for the setting up and adjustment of folding machines.

Roller Setting for Accordian and Letter Folding

The rollers used for these types of folds must be set only to single paper thickness. The folding rollers following the final fold must, however, be set once more to the total thickness of the paper passing through.

Processing Thin Printing Stock

It is essential that the folding rollers be adjusted with maximum precision. Lightweight printed stock is more easily folded when the paper is slightly moist as this imparts a greater degree of stiffness. For sheet transportation on the register table and at the right-angle folds, as few marbles as possible should be used and these should be of light weight. When lightweight printed stock is being folded, the folding machine should be started up as slowly as possible. Only after the necessary precision adjustments have been made should the machine speed be increased in accordance with the paper. It is essential to ensure that the speed is increased only to a point where quality is maintained.

Folding Roller Adjustment

Contrary to popular opinion, paper strips trimmed for this purpose should not be inserted between the clamp blocks of the Baumset. The strips should be folded according to the required pattern and inserted with the folds.

Paper Grain in Letter Folds

With paper of up to 90 g/m, the three-directional letter fold can be produced even if the grain is at right angles to the fold. From 90 g/m upwards, better folds are produced if the paper grain runs parallel to the fold.

Using Guide Marbles

The basic rule is that as few marbles should be used as possible. Steel marbles should be used only when necessary for the type of paper and the required fold. Conveyor tapes last longer if unnecessary marbles are removed. If stream delivery on parallel folding work is not uniform, try using more marbles after the parallel folding station. A simple rule of thumb is that the thicker the folded sheet becomes from station to station, the greater the load exerted by the balls should be to facilitate sheet movement.

TP10313 PAGE 40

Fixing Crooked Perforations

If misaligned perforations appear after the parallel folding station, first check for correct squareness setting of the register guide relative to the buckle plate stop. If square, the sheet deflector following the last buckle plate must be set back slightly on the side on which the sheet is tending to advance. Adjustment can be made by inserting a card underlay of suitable thickness. The affected sheet side then has to travel a greater distance, so a perfect perforation can be made without changing the fold position .

Bottom Plate Lip Adjustment

Since paper qualities and thicknesses vary greatly, it is essential that buckle plates are properly adjusted. With thin papers, the lower buckle lip is brought slightly forward. With thicker paper it must be set further back. The buckle plate configuration is directly related to the thickness and stiffness of the paper being folded. This relationship must be taken into account if a high quality fold is to be achieved. The adjustments can be made by setting the nuts on the top edge of the buckle plate to give the necessary reading against a scale on the side buckle plate post. A pointer marks the normal setting of the buckle plate. The inside width between the buckle plate section rods can also be varied without altering the setting of the buckle throat.

Figure 43

Figure 44

Figure 42

Figure 45

Figure 46

PAGE 41 TP10313

Principles of Mechanical Folding

The buckle folding principle

In buckle folding, each station consists of three rollers and a buckle plate. The first two rollers are arranged one vertically above the other and they carry the incoming sheet into the buckle plate until it reaches a feed guide stop that can be adjusted as required. The sheet is delivered into the buckle plate at a determined speed. The leading edge strikes the paper stop. Once against the stop the sheet continues to be driven. A buckle forms in the space between the three rollers. As this sags downward, it is picked up by the rotating rollers and the fold is formed as the sheet passes through them. It can be seen that in this case the folding process is not restricted to any cyclical movement and is thus capable of a very high output. For each folding station it is possible to fit up to four buckle plates, arranged alternately above and below. Buckle plates that are not required for a particular folding operation can be replaced by sheet deflectors, allowing one or more buckle plates in a folding station to be by-passed. It is thus possible to execute a large number of fold variations. The gap between the rollers must be set to the thickness of the paper that is passing through. Certain deviations must be made for special types of parallel folding.

Figure 49

Figure 50

Figure 47

Figure 48

TP10313 PAGE 42

Figure 51

Figure 52

SHEET STOP

FOLD PAN #3

FOLD PAN #1

DEFLECTOR OPEN

DEFLECTOR CLOSED

MAIN DRIVE

DEFLECTOR OPEN

FOLD PAN #2

SHEET STOP

FOLD PAN #4

IMPOSITIONS

18 MOST

POPULAR FOLDS

PAGE 43 TP10313

On a buckle folder, the sheet is laid flat on a register table and then enters the fold pan assembly where it comes to a stop against the stationary fold plate stop. A series of buckles then forms throughout the sheet. The buckles whithin the fold pan are kept very small by the narrow channel design. The buckles at the end of the fold pan, however, will be larger. The fold pans and fold rollers are configured such that the large buckle will always form downward, where it can be grabbed by the fold rollers and compressed into a fold.

Look at the figure below. You can see that fold pans #1 and #3 are angled upwards. Because of this and the configuration of the fold rollers, sheets fed into the #1 and #3 fold pans will always be folded up (i.e. so that the up surface of the sheet is folded into contact with itself).

Likewise, because foldpans #2 and #4 are angled down, sheets fed into them will be down-folds; the down surface of the sheet will be folded into contact with itself.

SHEET STOP

FOLD PAN #3

DEFLECTOR CLOSED

FOLD PAN #1

DEFLECTOR CLOSED

DEFLECTOR OPEN

MAIN DRIVE

DEFLECTOR OPEN

FOLD PAN #2

TP10313 PAGE 44

SHEET STOP

Fold Pan Fold

#1 UP #2 DOWN #3 UP #4 DOWN

FOLD PAN #4

MANUAL USAGE

LEADING EDGE

I D E

G U

I D E

Use this manual when you need to know how to set-up your folder to end up with a particular folded piece or, if possible, when planning the layout before printing the job. In most cases, the page numbers and their orientations after the fold are included. Below is an explanation of how to read the diagrams in this manual. On the next page is a quick explanation of the basic theory of buckle folding. Although reasonable care has been taken to assure accuracy, Baumfolder Corporation does not assume any responsibility for any errors that might inadvertently be contained in this manual. When trying a new fold, it is always advisible to set up a test run to check for potential problems.

1. Refer to the diagram below. Visualize the sheet to be folded lying flat on the register table. The edge toward the fold rolls is called the LEADING EDGE. The paper edge under the register guide will be referred to as the SIDE GUIDE.

In this manual, each folding diagram has been rotated clockwise 90 degrees from what is visualized below so that they appear as pictured to the right. The dotted lines represent the creases where the paper has been folded.

L E A D

E D

SIDE GUIDE

PAGE 45 TP10313

TYPICAL LAYOUT AND SHEET ORIENTATION

Each numbered Imposition Block in this manual contains: A. Imposition Title B. Fold Pans Used C. Sheet Layout D. Folded Sample

L E A

E D G

SIDE GUIDE

2. Dashed lines represent folds. Page numbers or letters without circles are face up. Page numbers or letters with circles are on the underside of the sheet. When letters are used, folds are to be made A to A, B to B, etc.

3. In order to use your Imposition Manual properly, note that the pans in each folding section are numbered conventionally as follows:

PARALLEL FOLDER 1st STATION (8 page)

#1 (UP) #1 (UP) #2 (DOWN) #2 (DOWN) #3 (UP) #3 (UP) #4 (DOWN) #4 (DOWN)

2nd STATION (16 page) 3rd STATION (32 page)

#1 (UP) #1 (UP) #2 (DOWN) #2 (DOWN) #3 (UP) #4 (DOWN)

NOTES

1. When planning an imposition, check your folded layout for proper page numbers and guide edges. Verify that your folder is large enough to do the job, that is, that the fold pan depths are sufficient for the folds desired.

2. If the desired imposition is unusual, try the stock on the folder before printing (make a trial folding run).

3. Use the most logical layout and avoid unnecessary problems such as air pockets and adverse paper grain.

4. For better results, use scores whenever possible.

5. There are alternate ways of making many of these impositions; those presented herein are in common use to achieve the results shown. An experienced operator will often develop alternate methods to achieve the same results.

TP10313 PAGE 46

4-PAGE

Parallel: 1 May be folded two or

more up and cut apart.

4-PAGE, DOUBLE IMPOSITION

Parallel: 1, 2, 3

May be folded two or more up and cut apart. Trim edge after folding.

6-PAGE, STANDARD

Parallel: 1, 3 May be folded two or

more up and cut apart.

6-PAGE, ACCORDION

Parallel: 1, 2 May be folded two or

more up and cut apart.

8-PAGE, PARALLEL IMPOSITION

Parallel: 1, 2

May be folded two or more up and cut apart.

8-PAGE, RIGHT ANGLE

Parallel: 1 8-Page: 1

PAGE 47 TP10313

2 1

5 6

7 8

8-PAGE, TWO RIGHT ANGLE OBLONG

Parallel: 1

8-Page: 1

8-PAGE, RIGHT ANGLE DOUBLE IMPOSITION

Parallel: 1 8-Page: 1, 2, 3

8-PAGE, PARALLEL OVER & OVER

Parallel: 1, 2, 4

May be run two or more up and cut apart.

4 3

12-PAGE BOOK, SADDLE STITCH

Parallel: 1, 2 8-Page: 2

5 6

7 8

4 3

12-PAGE BOOK, SADDLE STITCH

Parallel: 1, 2 8-Page: 1

7 8

12-PAGE LETTER FOLD, HEADS OUT

Parallel: 1 8-Page: 1, 2

12 11

TP10313 PAGE 48

5 6

3 4

1 2

11 12

7 8

2 1

4 3

12-PAGE LETTER FOLD, HEADS IN

Parallel: 1 8-Page: 1, 3

12-PAGE LETTER FOLD, ACCORDION

Parallel: 1 8-Page: 1, 2

16-PAGE, THREE RIGHT ANGLE BOOK IMPOSITION

Parallel: 1 8-Page: 1 16-Page: 1 May be run two or more up and cut apart.

12-PAGE FOLDER, HEADS OUT

Parallel: 1 8-Page: 1, 2

4 3

2 1

13 14

12 11

24-PAGE BOOKLET

Parallel: 1, 2

5 6

7 8

8-Page: 1, 2

2 1

4 3

6 5

23 24

14 13

18 17

16 15

11 12

6 5

7 8

2 1

32-PAGE BOOK

Parallel: 1, 2, 3 8-Page: 1, 2

8 7

4 3

25 26

27 28

29 30

31 32

18 17

24 23

11 12

15 16

PAGE 49 TP10313

Baumfolder has authorized dealers located throughout the United States.

Call toll free, 1-800/543-6107 for parts or the number of your nearest authorized dealer.

BAUMFOLDER

C O R P O R A T I O N

Producing Bindery Equipment Since 1917

1660 Campbell Road Sidney, Ohio 45365-0728 Phone; 937/492-1281 or 800/543-6107 Fax; 800/452-0947 Internet: www.baumfolder.com E-mail: baum@brightnet.com

TP10313 PAGE 50

Baumfolder BAUM 2018 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual