Baumfolder BAUM 26 Folder 1st Station Contfeed
BA U
M
BAUM 26/BAUM 30
1ST STATION FOLDER
W/CONTINUOUS FEED
INSTRUCTION MANUAL
©Baumfolder Corp., 2004 Printed in U.S.A. TP10476-1
PAGE 1 TP10476-1
© 2004 BAUMFOLDER CORPORATION
All Rights Reserved
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.
FOLDER IDENTIFICATION
MODEL NO: _______________________________ SERIAL NO: _____________________________
SALES AGENCY: ____________________________________________________________________
INSTALLED BY: _____________________________________________ DATE: ________________
PHONE NO: _______________________________
TP10476-1 PAGE 2
CONTENTS
DESCRIPTION PAGE
I.) Safety .................................................................................................................................................................. 6
II.) Warning Labels ................................................................................................................................................. 9
III.) Introduction Overview ..................................................................................................................................... 10
IV.) Transportation/Installation .............................................................................................................................. 10
V.) Electrical Connections .................................................................................................................................... 11
1.0 .Wiring the Unit ................................................................................................................................... 11
1.1 . Pump & Blower Connections .............................................................................................................. 11
VI.) Feeder Operation .............................................................................................................................................. 12
1.1 . Air and Vacuum Setting....................................................................................................................... 13
1.2 . Sheet Separation and Suction Force .................................................................................................... 14
1.3 . Register Table and Double Sheet Detector ......................................................................................... 15
VII.) Baumset Adjustment ........................................................................................................................................ 16
1.0 .Adjusting Folding Rollers ................................................................................................................... 16
VIII.) Installing Fold Plates ....................................................................................................................................... 17
IX.) Operator Controls ............................................................................................................................................ 17
1.0 . Setting Folding Speed ......................................................................................................................... 17
1.1 .Setting Stacker Belt Speed ................................................................................................................... 17
1.2 .Emergency Stop Button ....................................................................................................................... 17
1.0 Control Panel BAN-5 ................................................................................................................................ 18
1.1 . Displays............................................................................................................................................... 18
1.2 .Machine Status Indicators .................................................................................................................. 18
1.3 .Machine Control Pushbuttons ............................................................................................................ 19
1.4 . Keypad Buttons with Selection Indicators .......................................................................................... 19
1.5 . Keypad Buttons for Selection Adjustments ........................................................................................ 19
2.0 RUN M ODE F UNCTIONS ................................................................................................................................20
2.1 . Machine Setup and Diagnostic Mode ................................................................................................. 20
2.2 . Counter Setup Mode ........................................................................................................................... 26
2.3 .Learn Mode ......................................................................................................................................... 27
2.4 . Make Ready Mode .............................................................................................................................. 28
2.5 .Network Job Mode .............................................................................................................................. 28
2.6 .Production Mode ................................................................................................................................ 29
3.0 CONTROLLER I NPUT D ESCRIPTIONS .............................................................................................................. 30
4.0 Process Variables ..................................................................................................................................... 32
4.1 . Total Input Count ................................................................................................................................ 32
4.2 . Total Output Count ............................................................................................................................. 32
4.3 .Batch Down Count .............................................................................................................................. 32
4.4 .Number of Batches .............................................................................................................................. 32
4.5 . Current Rate ......................................................................................................................................... 32
4.6 . Main Drive Run Time .......................................................................................................................... 32
4.7 . Main Drive Velocity ............................................................................................................................. 32
4.8 .Waste Count ....................................................................................................................................... 33
5.0 COUNTER SETUP VARIABLES ....................................................................................................................... 33
5.1 . Batch Preset......................................................................................................................................... 33
5.2 . Batch Output Type .............................................................................................................................. 33
5.3 .Batch Output Time .............................................................................................................................. 33
5.4 . Sheet Length ....................................................................................................................................... 33
5.5 . Gap Length .......................................................................................................................................... 33
5.6 . Suction Length .................................................................................................................................... 33
6.0 SYSTEM M ESSAGES AND R UN M ESSAGES ....................................................................................................... 34
6.1 . Power-Up Fault Messages .................................................................................................................. 34
6.2 . Run Time Fault Messages ................................................................................................................... 35
6.3 . Machine Run Error Messages ............................................................................................................. 36
PAGE 3 TP10476-1
CONTENTS
DESCRIPTION PAGE
X.) Setting Fold Plates ........................................................................................................................................... 38
XI.) Scoring/Slitting/Perforating ........................................................................................................................... 39
1.0 . Slitter Shaft Removal ........................................................................................................................... 39
1.1 . Scoring ................................................................................................................................................ 39
1.2 . Perforating ........................................................................................................................................... 39
1.3 . Slitting ................................................................................................................................................. 39
1.4 . Trimming Edges of Booklets ................................................................................................................ 40
1.5 . Trimming a Strip from Center of Sheet ................................................................................................. 40
1.6 . Blade Installation ................................................................................................................................. 40
XII.) Lubrication/Maintenance ................................................................................................................................. 42
XIII.) Technical Specifications & Accessories ......................................................................................................... 43
XIV.) Troubleshooting ............................................................................................................................................... 44
XV.) Service ............................................................................................................................................................ 46
TP10476-1 PAGE 4
List of Tables
DESCRIPTION PAGE
Table 1. Machine Setup Parameter List ................................................................................................................................ 20
Table 2. Statistics ................................................................................................................................................................. 21
Table 3. Machine Settings .................................................................................................................................................... 22
Table 4. Machine Diagnostic Parameter List ......................................................................................................................... 23
Table 5. Safety Settings ........................................................................................................................................................ 24
Table 6. Machine Statistics .................................................................................................................................................. 24
Table 7. Machine Operating Statistics ................................................................................................................................. 25
Table 8. Output Type Animations ....................................................................................................................................... 26
Table 9. Count Source Selection ........................................................................................................................................... 26
Table 10. Learn Mode Status ................................................................................................................................................ 27
Table 11.Suction Mode Symbols .......................................................................................................................................... 27
Table 12. Suction Length Function ....................................................................................................................................... 28
Table 13. Determining the Large Display Contents ............................................................................................................... 29
Table 14. Reset Mode Selection ............................................................................................................................................ 29
Table 15. Inputs .................................................................................................................................................................... 30
Table 16. LED Status Indicators ............................................................................................................................................ 32
Table 17. Output Delay and Duration ................................................................................................................................... 33
Table 18. Power Up Fault Messages ..................................................................................................................................... 34
Table 19. Run Time Fault Messages ..................................................................................................................................... 35
Table 20. Machine Run Error Messages ............................................................................................................................... 36
PAGE 5 TP10476-1
FUNDAMENTAL SAFETY
INSTRUCTIONS!
The diagrams and descriptions used in these instructions are not necessarily
applicable to the specification of the machine supplied. Modifications, made
for reasons of technical or operational improvement, are embodied without
notice.
TP10476-1 PAGE 6
FUNDAMENTAL SAFETY
INSTRUCTIONS!
These operating instructions are designed to familiarize
the user with the machine and its designated use.
The instruction manual contains important information on
how to operate the machine safely, properly and
most efficiently. Observing these instructions helps to
avoid danger, to reduce repair costs and downtimes and
to increase the reliability and life of the machine.
In addition to the operating instructions and to the mandatory rules
and regulations for accident prevention and environmental protection
in the country and place of use of the machine, the generally
recognized technical rules for safe and proper working must also be
observed.
The following signs and designations are used in the
manual to designate instructions of particular importance.
1.0.3
The machine/installation is designed exclusively for paper finishing
of minimum and maximum sheet sizes (see corresponding operating
instructions). Using the machine/ installation for purposes other than
those mentioned above is considered contrary to its designated use.
The manufacturer/supplier cannot be held liable for any damage or
injury arising from such misuse. The risk of such misuse lies entirely
with the user.
Operating the machine within the limits of its designated
use also involves observing the instructions set out in the
operating manual and complying with the inspection and
maintenance directives. The working temperature of the
machine should range between 0° and 55° C.
1.1 Organizational measures
1.1.1
The operating instructions must always be at hand at the
place of use of the machine/plant, e.g. by stowing them in the tool
compartment or tool box provided for such purpose.
Important
(refers to special information on how to use the
machine/plant most efficiently)
Attention
(refers to special information and/or orders and
prohibitions directed towards preventing
damage)
Danger
(refers to orders and prohibitions designed prevent injury or extensive damage)
1.0 Basic operation and designated use
of the machine/plant
1.0.1
The machine /plant has been built in accordance with
state-of-the art standards and the recognized safety rules.
Nevertheless, its use may constitute a risk to life and limb
of the user or of third parties, or cause damage to the
machine and to other material property.
1.1.2
Personnel entrusted with work on the machine must have
read the operating instructions and in particular the chapter on
safety before beginning work. Reading the instructions after work
has begun is too late. This applies especially to persons working
only occasionally on the machine, e.g. during setting up or
maintenance.
1.1.3
For reasons of security, long hair must be tied back or
otherwise secured, garments must be close fitting and no
jewelry, such as rings, may be worn. Injury may result
from being caught up in the machinery or from rings
catching on moving parts.
1.1.4
Observe all safety instructions and warnings attached to
the machine/plant.
1.1.5
See to it that safety instructions and warnings attached to
the machine are always complete and perfectly legible.
1.1.6
In the event of safety relevant modifications or changes in
the behavior of the machine/plant during operation, stop
the machine/plant immediately and report the malfunction
to the competent authority/person.
1.0.2
The machine/plant must only be used in technically perfect
condition in accordance with its designated use and the
instructions set out in the operating manual, and only by
safety-conscious persons who are fully aware of the risks
involved in operating the machine/plant. Any functional
disorders, especially those affecting the safety of the
machine/plant, should therefore be rectified immediately.
1.1.7
Never make any modifications, additions or conversions
which might affect safety without the supplier’s approval.
This also applies to the installation and adjustment of
safety devices and valves as well as to welding work on
load-bearing elements.
PAGE 7 TP10476-1
1.1.8
Spare parts must comply with the technical requirements specified by
the manufacturer. Spare parts from original equipment manufacturers
can be relied to do so.
1.1.9
Report any accident that occurs due to a malfunction of the machine
though all prescribed safety precautions were observed directly to
our agency or to the Heidelberg service department (VFKD).
1.2 Selection and qualification of personnel
- Basic responsibilities
1.3.1.4
Before starting up or setting the machine/plant in motion, make sure
that nobody is at risk.
1.3.2
Special work in conjunction with utilization of the machine/plant and
maintenance and repairs during operation; disposal of parts and
consumables.
1.3.2.1
Always press the emergency (Not-Stop) button first, if you stop the
machine for adjustments or maintenance work which must not be
done while the machine is in operation.
1.2.1
Employ only trained or instructed staff and set out clearly the
individual responsibilities of the personnel for operation, set-up,
maintenance and repair.
1.2.2
Make sure that only authorized personnel work on or with the
machine.
1.2.3
Work on the electrical system and equipment of the machine/plant
must be carried out only by a skilled electrician or by instructed
persons under the supervision and guidance of a skilled electrician and
in accordance with electrical engineering rules and regulations.
1.2.4
Work on gas fueled equipment (gas consumers) may be carried out by
specially trained personnel only.
1.3 Safety instructions governing specific
operational phases
1.3.1 Standard operation
1.3.1.1
Avoid any operational mode that might be prejudicial to safety.
1.3.2.2
For extensive maintenance or repair work, turn off the main power
supply.
1.3.2.3
After making adjustments or after doing maintenance or repair work,
always make sure that all tools or other objects are removed from the
machine. Otherwise they might fall into the machine, causing severe
damage or injuries.
1.3.2.4
Keep the floor around the entire machine clean. Immediately clean
any oil, grease or paint spills up off the floor. Remove tools, cleaning
cloths or paper scraps from all work areas.
1.3.2.5
Never operate a folding machine without buckle plates or deflectors
since these are protective as well.
1.3.2.6
Never clean moving parts of the machine (rollers, shafts) or remove
any test sheets, spoiled sheets or bits of paper in such areas.
1.3.2.7
Observe the adjusting, maintenance and inspection activities and
intervals set out in the operating instructions, including information
on the replacement of parts and equipment. These activities may be
executed by skilled personnel only.
1.3.1.2
Take the necessary precautions to ensure that the machine is used
only when in a safe and reliable state. Operate the machine only if all
protective and safety oriented devices, such as removable safety
devices, emergency shut-off equipment, sound proofing elements
and exhausters, are in place and fully functional.
1.3.1.3
Check the machine/plant at least once per working shift for
obvious damage and defects. Report any changes (incl. changes in the
machine’s working behavior) to the competent organization/person
immediately. If necessary, stop the machine immediately and lock it.
TP10476-1 PAGE 8
1.3.2.8
Brief operating personnel before beginning special operations and
maintenance work, and appoint a person to supervise the
activities
..
.
..
1.3.2.9
If the machine/plant is completely shut down for maintenance and
repair work, it must be secured against inadvertent starting by:
– locking the principal control elements and
removing the ignition key and/or
– attaching a warning sign to the main switch.
1.4.1 Electric energy
1.4.1.1
Use only original fuses with the specified current rating. Switch off
the machine/plant immediately if trouble occurs in the electrical
system.
1.5 Description and definition of the safety
labels and pictographs on the machine
Replace damaged pictographs with new ones. The corresponding
reference numbers are indicated.
1.4.1.2
If provided for in the regulations, the power supply to parts of
machines and plants, on which inspection, maintenance and repair
work is to be carried out, must be cut off. Before starting any
work, check the de-energized parts for the presence of power
and ground or short-circuit them in addition to insulating adjacent
live parts and elements.
1.4.1.3
The electrical equipment of machines/plants is to be inspected and
checked at regular intervals. Defects such as loose connections or
scorched cables must be rectified immediately.
1.4.1.4
Necessary work on live parts and elements must be carried out only
in the presence of a second person who can cut off the power
supply in case of danger by actuating the emergency shut-off or
main power switch. Secure the working area with a red and white
safety chain and a warning sign. Use insulated tools only.
1.4.1.5
Only unplug or plug in electrical connectors if the main switch
has been disconnected.
Warning!
Folding rollers rotate in opposite directions.
Keep hands away from rollers while the machine
is running!
Warning!
To avoid bruising, keep hands away when
operating moving machine parts!
Warning!
Do not reach into moving belts!
Warning!
Be careful! Height adjustment devices
might cause bruising!
Warning!
Only operate machine when covers are
closed.
1.4.1.6
Only connect the folding units and no machines of other brands to
the existing connectors. Any electrical connection of STAHL
folding machines with other brands needs our express consent.
1.4.1.7
For electrical connection, observe the prescribed admissible voltage
and frequency.
1.4.1.8
Keep switch cabinets closed.
1.4.2
Oil, grease and other chemical substances
1.4.2.1
When handling oil, grease and other chemical substances,
observe the product related safety regulations.
1.6 Explanation of the pictographs used
in the operating instructions
Warning!
You might risk bruising when
moving the machine.
PAGE 9 TP10476-1
INTRODUCTION OVERVIEW
The 1st station (parallel) folder with continuous
feeder contains the following main components (Figure 1):
1. Continuous Feeder
2. Register
3. 1st Station Folder (Parallel)
4. Fold Roller Baumset settings
5. Fold Plates
6. Slitter Shafts (not shown)
7. Delivery (Stacker, not shown)
8. Operator Controls
9. Double Sheet Detector (not shown)
10. Vacuum Pump (not shown)
11. Handwheel
11
5
3
2
4
8
1
(3.03m)
119"
54.5"
(1.38m)
(1.97m)
77.5"
(1.17m)
(1.73m)
(3.78m)
46"
68"
149"
(6.73m)
265"
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 crossmembers 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.
Remove the connecting bolts from the side frame at the
front of the register. Move the feeder next to the properly
aligned fold head and adjust it so that the holes in the
register and in the side of the folder are at the same height.
Remove the transport supports after you
align the feeder.
Install the drive belts on the folding unit and check
their tension.(Figure 3)
BAUM 26
Figure 2
TP10476-1 PAGE 10
BAUM 30
Figure 3
ELECTRICAL CONNECTIONS
1.0 Wiring the Unit (3 phase)
All repair or disassembly work must be performed
by qualified personnel. Before inspecting the
electrical system, always turn the main power
switch OFF before opening the door of the circuit
cabinet.
Check that your power supply meets the requirements
given in the machine specifications. Use an allen wrench to
unlock the circuit cabinet door and open it.
Feed the power supply cable from your distribution
panel through the side of the circuit cabinet. Connect the
customer's supply conductors to the main disconnect at L1,
L2 & L3. Connect the earth ground conductor to the adjacent
ground terminal block.
Before operating the folder for the first time, measure
the line to line voltage to determine where to set the transformer tap. Turn off the main disconnect and move the 7L3
tap of the transformer to the appropriate voltage tap of the
transformer.
Turn the main power switch to the "ON" position.
Switch the pumps on momentarily and check for proper
pump rotation as indicated by the rotation arrow on the
respective pumps. Immediately turn off the pumps if the
rotation is wrong. If both motors are turning in the wrong
direction, switch any two wires at the main disconnect
switch. If only one rotation is incorrect, interchange any two
of the three wires #1, #2, or #3 at their appropriate terminal
block connection point.
1.1 Pump & Blower Connections
Once the pump and blower rotational directions have
been checked and verified, connect the vacuum hose and the
blower hose to their appropriate tubes and secure them with
hose clamps.
PAGE 11 TP10476-1
CONTINUOUS FEEDER OPERATION
1.0 Loading the Continuous Feeder
Before loading the sheets, use the knobs (Figure 4-1) of
the side guide to set the side for the correct folding format
according to the scale on the feeder. Make certain that you
always maintain the required 8-12 mm gap between the
incoming sheets and the alignment ruler.
The bottom table is equipped with a conveyor belt that is
wide enough to stretch across all usable formats. When you
change sheet formats, you must also adjust the lower side
rails.
1
Figure 4
The deflector belts (5-1) that are wrapped around the
reversing drum operate independently of the loading and
outfeed tables. It will rarely be necessary to change the belt
position. Make certain that the belts are not placed on the
sheet edge (5-2). With the feeder running, use the lever to
move the deflector belts to their proper position.
2
1
Figure 5
When loading the feeder, make certain that the paper
stack does not exceed the maximum height of 3.00" or 8cm.
When feeding a new sheet stack, e.g. when
changing to a new sheet size, help the first
sheet along until it is taken up between the
reversing drum and the deflection belts.
This is done by pressing the stack down on
the middle conveyor belt while pushing the
stack forward at the same time until it is
securely held by the reversing drum and
the deflection belts.
The suction plate blower can be moved or
unscrewed for more convenient sheet
removal.
A movable feeder sensor switch (6-1) is located under the
sucker wheel (6-2). This tab is activated by the leading edge
of the sheet stream, thus providing fully automated control of
the sheet stack feed.
The position of the leading sheet edge at the switch tab
determines the speed at which the stack is advanced; therefore, the stack speed is automatically adjusted to any production speed.
TP10476-1 PAGE 12
Stack feeding is stopped automatically if the tab of the
switch is pushed beyond a preset point by the leading sheet
edge (6-3).
Make certain that the switch tab remains
in a verticle position during the sheet
feed operation and that it does not
vibrate (flutter) with each passing sheet.
The position of the switch tab is set at the factory. If
necessary, it can be adjusted both horizontally and vertically
by knobs located on the feeder side frame.
Place the lateral blower (7-1) along the edge of the sheet
stack and the holddown wheels (7-2) on the trailing edge of
the top feeding sheet.
2
Figure 6
1
3
Figure 7
1.1 Air and Vacuum Settings
Use knob (8-1) to adjust the height of the front blowers
and set the angle of the air flow with the lever (8-2) above
the knob. The pointer on the operator side shows airflow
direction.
Use knob (8-3) to adjust the position of the transfer plate.
The distance between the top of the stack and the bottom
of the sucker wheel should be about 1 cm. Lift the
transport plate for large sheets or drooping sheet edges.
Lower the transport plate for small sheets.
1 2
Use knob (8-4) to adjust the air volume that the suction
plate blowers produce.
Use knobs (8-5 thru 8-8) to adjust the air volume produced by the front blowers separately for each section.
Symbols by the knobs indicate the zone which each
knob regulates.
PAGE 13 TP10476-1
2
1
Figure 8
3
4
5
6
7
8
1.2 Sheet Separation and Suction Force
The holddowns (9-1) on the two sides of the sucker wheel
(9-2) should always be positioned slightly lower than the
sucker wheel. This causes the sheet which is sucked against
the wheel to arch up slightly allowing the top sheet to be
peeled away from a second sheet which may be clinging to it.
With stiff and heavy paper, the holddowns must be set so that
the suction wheel can still pick up the sheet.
The suction wheel is controlled by a solenoid valve (9-3).
The normal setting is indicated with a red mark.
The point at which the suction is applied can be adjusted
by swinging the suction point forward or backward with the
knob (9-4).
It may be necessary to move the suction point back if the
leading edge is curled down, or forward if the leading edge is
curled up. This adjustment can be further assisted by raising
or lowering the bridge with the knob.
The solenoid valve can be quickly and easily removed by
releasing the clamps (9-5) to allow dry cleaning of the inner
piston. To clean the piston cavity, unscrew and remove the
back cover (9-6) on the solenoid block and pull a soft cloth
through from the threaded side of the hole. Do not use any
solvent, lubricating agents or air blasts.
Be careful not to damage the piston or it's
bushing.
1
5
Figure 9
6
3
4
1
2
TP10476-1 PAGE 14
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