Formax 2200 User Manual

2200 Series
AutoSeal
®
Operator’s Manual 2200 Series
CONTENTS
1. GENERAL 5
2. SPECIFICATIONS 6
3. PROPER HANDLING OF THE MACHINE 7
4. SAFETY INSTRUCTIONS 8
5. SAFETY FEATURES 10
6. BASIC COMPONENTS OF THE MACHINE 11
7. ELECTRICAL CONNECTION 12
8. FD 2200 & 2200-EX AIR FEEDER 13
9. FD 2250 PILE FEEDER 19
10. REGISTER TABLE 29
11. BUCKLE FOLD UNIT 31
12. TRANSFER BRIDGE 33
13. SEALING UNIT 34
14. STACKER TABLE 35
15. AUTOMATIC SETTING 36 Operator Panel 36 Setting the Counter - Main Menu COUNTER 39 Clearing the Total Counter 39 Setting the Batch Counter 40 Paper Transport Control, Double Sheet Detection - Main Menu MONITORING 42 Paper Transport Control 42 Double Sheet Detection 43 Setting the Fold Length - Main Menu SET-UP 44 Standard Folds 44 Special Folds 51 Job Saved 59 Setting the Suction Length - Main Menu SET-UP 70 Saving of Job Data - Main Menu SAVING 73 Display of the Actual Job - Main Menu JOB 78 Correction of Fold Lengths - Menu FOLD LENGTH 79 Setting the Fold Rollers - Menu ROLLER GAP 80 Setting the Delivery Rollers - Menu DELIVERY 85 Choosing the Measuring System and the Language 87 Fold Plate Setting: Three Methods 88 Display of Malfunctions 91 Service Functions 92
18. OPERATION AND TRIAL FOLDS 95
19. FINE ADJUSTMENTS AND CORRECTIONS 97
20. TROUBLESHOOTING GUIDE 101
pressure seal mailer con gurations including, “C”, “Z”, “V” and
between suction- and  at pile feeders.
As soon as it comes up against the adjustable
the infeed rollers keep on moving.
by rollers (2) and (6); this is where the actual
plate and the infeed rollers and move it on.
Operator'sManual 2200 Series
General
5
FD 2200
FD 2200
FD 2250
FD 2200
FD 2200-EX
FD 2250
Variable Speed:
Duty Cycle:
Dimensions:
Weight:
Delivery Requirements:
better suited for the FD2200 and FD2200-EX.
Maximum
Minimum
W x L
W x L
4 x 4.75 in
Up to 40,000 sheets per hour – based on 11” Z-Fold (279mm)
Unlimited
Approx. 1,200 lbs (45 kg)
UL applied for
Operator'sManual 2200 Series
General
6
unsuitable applications. Responsibility lies alone with the user.
Reading the Operator’s Manual and observing the conditions for inspection and
maintenance are part of the proper handling of the machine.
representatives. Additional instructions are provided for this purpose.
Repairs and service should be carried out only by skilled personnel authorized by the
manufacturer or his representatives.
machine usage.
For regular one-shift-operation, two inspections per year is recommended.
uneven  oor to a certain degree.
No harmful emissions are produced.
Read the Operator’s Manual before working with the machine.
We recommend to carry out all operations and settings in the sequence mentioned in
this manual.
Operator'sManual 2200 Series
General
7
Operator'sManual 2200 Series
4. SAFETY INSTRUCTIONS
4.1 Safety Instructions for Transport and Set-Up
The following instructions and warnings are applied to the packing to ensure appropriate and safe transport:
General
Top! - Transport in upright position only!
Theses instructions and warnings must also be observed for transport within the users premises.
For transport to other premises resp. for return shipment the machines must be packed and provided with the same markings.
4.2 Fundamental Safety Instructions
Warnings and Symbols
The following symbols and designations are used in the manual to identify instructions of particular importance:
General instructions and special information how to use the machine most efficiently.
Instructions designed to prevent injury or extensive equipment damage.
!
Protect from humidity!
Fragile! ­Handle with care!
Basic Operation
8
The machine has been built in accordance with state-of-the art standards and the recognized safety rules. Nevertheless, operators and third parties may get injured when working with the machine, or damage to the machine and to other material property may result. The machine must only be used in technically perfect condition in accordance with its designated use and the instructions set out in the operator's manual. Any malfunctions, especially those affecting the safety of the machine, should therefore be rectified immediately.
Regular and proper cleaning contributes to a long life of the machine and a consistent quality.
Use the Formax recommended cleaner only for cleaning the fold rollers.
Do not use any solvents such as Acetone or Toluol. They would damage the nonmetal parts
Remove paper- or print powder dust from all  xed and moveable parts of the machine.
Use compressed air to clean the fold plates when paper with a high degree of powder
has been folded. Carefully remove deposits in the control box with a vacuum cleaner.
up.
Operator'sManual 2200 Series
General
9
4 Safety handwheel
Operator'sManual 2200 Series
General
10
4. Register Table
4
11
Plugs and sockets allow variable connections.
Do not bend or twist the cables sharply or place heavy objects on them -
When making or breaking any electrical connection, always  rst turn
At the rear of the base of the fold unit you will  nd the sockets for connecting
the various componets of the machine.
operator panel
stacker table
Plug connections are easily pulled or inserted by holding the plug with one
hand and opening resp. closing the safety bracket with the other hand.
12
Operator'sManual 2200 Series Air Feeder
8.AIRFEEDER FD 2200 & FD 2200-EX
Principle of Operation
Description
Theairfeederconsistsofafeederandaregistertable. It is suitable for handling a wide variety of papers - uncoated papers as well as coated, freshly printed or thin papers. The sheets are separated by air and vacuum. Air is supplied from the bottom of the stack both on the left and right side, separating the paper in the stack which now floats in a cushion of air. A rotating suction drum can then separate the sheets from the bottom of the paper stack. This principle has the advantage that paper can be continuously reloaded with the machine running. There is no need to stop the machine.
On the register table, a transport belt, which runs at an angle, moves the sheets against a register rail.
Componentsandoperatingelementsoftheairfeeder:
1 Feed table 2 Air guides left and right 3 Knobs for adjusting the air guides 4 Rear paper stop 5 Air adjustment valves 6 Suction drum with suction segment 7 Front paper stop 8 Guide rollers 9 Lever for adjusting the suction
segment 10 Lock screw 11 Window for adjustment of suction
segment 12 Vacuum adjustment valve 13 Register table 14 Ball cage 15 Handwheel 16 Lock screw 17 Lever for adjustment of sheet gap 18 Hold-down bars 19 Alignment rail 20 Adjustment wheel for changing
the infeed angle
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Operator's Manual 2200 Series Air Feeder
Setting the Format
Setting the Sheet Separation
When setting the format, care should be taken that the sheets are fed approximately from the center.
Loosen the handles (1) by turning them counter-clockwise.
Set the left feed guide to half sheet width with the help of the scales (2).
Tighten the handles (1) again.
Place a stack of about 50 sheets on the feed table.
Slide the right feed guide (3) against the edge of the stack.
Make sure that the sheet does not actually touch the guide. There should be a gap of approx. 0.5 mm. The right and left feed guide should be parallel.
Tighten the handles (4) at the right feed guide.
If the width of the paper is less than 7 cm, only one paper guide can be used.
Sheet separation is achieved by the combined action of the rotating suction drum, the paper stop and the air. Paper weight and type of paper have an influence on the setting.
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Setting the Air
A suction drum (5) separates the sheets from the bottom of the stack. This is achieved by the suction segment (6) inside the suction drum. The angle of the suction segment with respect to the paper stop can be changed to suit different types of paper.
Basic setting
Loosen the lock screw (7).
Turn the knob (8) until the figure "6" on a red background appears in the window (9).
Tighten the lock screw (7).
Now the suction segment is in its zero position (10).
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Operator's Manual 2200 Series Air Feeder
Mosttypesofpaperwithaweightof20 to24 #canbeseparatedinthisposition. For different paper grades, other figures must be set in the window:
-Papergradesbelow20# :7-9
-Papergradesabove24# :1-5
Setting for light paper grades:
For running light-weight paper, first try the suction segment setting as described under "Basic Setting". A steeper inclination is only necessary for special types of paper.
Light paper grades easily cling to the curve of the suction drum. Therefore the suction segment must be tilted in direction of the paper stop.
The inclination of the suction segment in this direction has the effect that the paper is wrapped around the suction drum (1). The sheets are easily separated from the stack and double sheets occur very rarely.
1
In the batch counting mode it may happen occasionally that a single sheet is fed during the interval time. This is caused by the fact that the suction drum continues to turn during the interval time (although without vacuum). For light paper grades the friction between paper and suction drum may be sufficient for detaching a sheet. To prevent this, a special plate (2) can be placed over the suction drum. This plate, which is pulled out of the feed table, can cover the suction drum to its highest point (3). Sheets are no longer affected by the friction of the suction drum.
Proceed as follows to pull out the plate:
Loosen the screw (4).
Insert a screwdriver in the hole (5).
Pull out the plate.
Tighten the screw (4).
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Operator's Manual 2200 Series Air Feeder
Setting for heavy paper grades
Heavy paper grades do not easily cling to the curve of the suction drum. For this reason the suction segment must be tilted in direction of the paper stack. The inclination of the suction segment in this direction has the effect that the paper is barely wrapped around the suction drum (1). This is sufficient because heavier paper grades are more easily separated from the stack.
Vacuum:
Vacuum can be modified by means of a regulating valve (2). This is necessary because heavy paper grades require more vacuum than light paper grades.
The vacuum can be modified by turning knob (2).
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2
Setting the vacuum:
For setting the vacuum, the machine must be turned on.
Exercise caution in the vicinity of rotating shafts and rollers! Hair,loosegarmentsandjewel
!
SERIOUS INJURY MAY RESULT!
Do not get close to rotating shafts and rollers while the machine is running and the noise-absorbing cover is open!
!
SERIOUS INJURY MAY RESULT!
Exercise caution in the vicinity of the perforating- and slitting knives! They have sharp edges for proper function!
!
SERIOUS INJURY MAY RESULT!
Close the valve (2) for setting the minimum effect.
Start the machine.
Slowly open the valve (2) by turning the knob clockwise. Observe the sheet separation while doing this.
At first no sheets are pulled off the stack or they are pulled off irregularily. The more the valve is opened, the smoother is the paper transport.
Make sure that much vacuum does not cause feeding of double sheets.
erymaygetcaught!
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Switch off the machine.
Operator's Manual 2200 Series Air Feeder
Air
•Openthevalves (1) at both air brackets.
In most cases it is sufficient to open the second and the last valve (with respect to the format length).
1
closed open
Front Paper Stop
The position of the front paper stop (2) can be adjusted in a horizontal and vertical direction.
Adjusting the horizontal position:
The horizontal position of the front paper stop determines the suction point on the paper and in turn depends on the position of the suction segment in the suction drum.
The inclination of the suction segment must be set correctly before making the horizontal adjustment.
When the suction segment is adjusted, the horizontal position must also be changed accordingly.
Turn the handwheel until the openings of the suction drum (3) are exactly above the openings of the suction segment (4).
Adjust the horizontal position of the front paper stop in such a way that it forms a vertical line (5) with the leading edge of the suction openings. To achieve this, turn the knurled screw (6) counter-clockwise or clockwise.
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Adjusting the vertical position:
The respective paper thickness is set by adjusting the vertical position of the front paper stop. Proceed as follows:
Place a stack of about 50 sheets on the feed table.
Start the machine.
Exercise caution in the vicinity of rotating shafts and rollers! Hair,loosegarmentsandjewel
!
SERIOUS INJURY MAY RESULT!
Do not get close to rotating shafts and rollers while the machine is running and the noise-absorbing cover is open!
!
SERIOUS INJURY MAY RESULT!
Exercise caution in the vicinity of the perforating- and slitting knives! They have sharp edges for proper function!
!
SERIOUS INJURY MAY RESULT!
By turning the knurled screw (7), adjust the vertical position of the paper stop in such a way that only one sheet is pulled off the stack.
erymaygetcaught!
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Operator's Manual 2200 Series Air Feeder
Positioning the Paper Stack
Sheet Gap
Fan the paper stack well to avoid double sheets.
Place the stack on the feed table.
Position the rear paper stop. It prevents the paper from sliding off the table.
For normal folds the sheet gap should be set only via the potentiometer (1) on the operator panel.
555
However, if small formats with a length below8" aretobefolded,thesheet gap can also be adjusted by means of a lever (2).
The adjustment changes the speed of the suction drum, i.e. different speeds of feeder and fold rollers result in different sheet gaps. A smaller sheet gap increases the speed of the folder, independent of the cycle frequency.
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1
Lever in right position:
Adjustmentofsmallformatsbelowalengthof8".
Lever in center position:
Setting for all "normal" folds.
The adjustment can be made with the machine running.
To increase the sheet gap, always use the potentiometer (1) on the operator panel, do not use the lever.
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Operator's Manual 2200 Series Flat Pile Feeder
9.FLATPILEFEEDERFD 2250
Principle of Operation
Description
Theflatpilefeederwithrearedgeseparatorissuitableforseparatingdifferent kinds of paper, uncoated as well as coated, freshly printed or thin paper.
Sheet separation is done by vacuum and air from the top of the paper stack. Air blowers separate the top sheets at the rear edge of the stack. Sheetseparatorslifttheuppermostsheetbyapprox. 3/4". This opens the rear air nozzles and an uninterrupted stream of air is blown under the separated sheet. The suction drum at the front edge of the stack grips the sheet and leads it onto the register table.
3
Componentsandoperatingelements oftheflatpilefeeder:
1 Pile table 2 Stacking stops 3 Carrier arm for rear edge separator 4 Rear edge separator 5 Operator panel 6 Valves for regulating the air flow 7 Sheet separator height adjustment 8 Knurled knob for rear edge separator 9 Knurled knob for stripper springs 10 Rear separator nozzles 11 Front separator nozzles 12 Hold-down rods 13 2 sucker cups 14 Suction drum with suction segment 15 Lever for adjustment of suction segment 16 Rear edge separator lock lever
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Operator's Manual 2200 Series Flat Pile Feeder
Setting the Format
Loading the Pile Table
Tilt up the front stop (1).
Push down the rear stop (2) and slide it to half the sheet width with the help of the scale (3).
The second rear stop (4) can be pulled out. This is necessary, if, for instance, the rear edge separator is in this position when feeding smaller paper sizes.
Turn on the main switch at the folder.
Lower the pile table.
The operator panel of the flat pile feeder has three push-buttons for lowering and raising the pile table.
Button (5): Pile table up:
The pile table moves up automatically to the correct position.
Button (6): Pile table down:
The pile table moves down, but only as long as the push-button is pressed.
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Button (7): Auto mode:
The feeder is designed in such a way that the pile table moves down automatically for reloading. This ensures that the loading height is always in an ergonomically favorable position. The distance that the pile table moves down corresponds to the height of the paper stack that is being replenished. The height adjustment is controlled by a photodetector (8). The photodetector can be adjusted by loosening a knob (9), thus making it possible to adapt the stack height to suit the operator.
Tilt up the rear edge separator (10).
Load paper on the pile table.
Use the automatic stacking mechanism. Push button (7) after each reloading process. This will lower the table automatically.
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Operator's Manual 2200 Series Flat Pile Feeder
Moving the Paper Stack to Work Position
When the pile table is loaded, the paper stack must be brought to the work position.
Push button (1). The stack moves automatically to the correct position, controlled by the stack sensor switch (2).
The stack height switch is a capaciti­ve sensor that reacts to the density of the paper stack. For this reason the gap between stack and suction drum can vary when the paper stack has reached the work position depending on the type of paper used.
The gap between stack and suction drum should be 8 mm.
Set the gap to 8 mm by turning the setting screw (3). A scale (4) facilitates this setting.
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Lower the front stop (5) and slide it against the paper stack.
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Air and Vacuum
Turn on the pump at the operator panel before setting air and vacuum. The correct setting for air and vacuum can only be determined by running a few sample sheets after all adjustments have been completed.
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Operator's Manual 2200 Series Flat Pile Feeder
Exchanging the Suction Drum
Adjusting the Suction Segment
The suction drum (1) is equipped with two PUR-rings for reliable sheet detachment. If marks occur on sensitive or freshly printed paper, a different suction drum (accesso­ry) can be used. This suction drum has a PUR-coating over the entire surface and consequently a higher coefficient of friction.
For installation of this suction drum proceed as follows:
Pull off the cover (2).
Loosen the screw (3) and remove the suction drum.
Install the PUR suction drum.
Tighten the screw (3).
Replace the cover (2).
The suction drum (4) separates the leading edge of the sheets from the stack. For this purpose there is a suction segment inside the suction drum. The suction angle can be changed by adjusting the lever (5) to adapt suction point and suction area to different types of paper. A scale (6) facilitates the adjustment.
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In most cases an adjustment is only necessary for light paper stock resp. paper with a downward curl.
Fine adjustment is only possible with the machine running.
In connection with the adjustment of the suction segment, the height of the separator plate (7) can also be varied.
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Operator's Manual 2200 Series Flat Pile Feeder
Setting the Rear Edge Separator
Lower the rear edge separator (1).
Loosen the lock lever (2).
2
Displace the rear edge separator in such a way that the stop rods (3) touch the rear edge of the paper stack.
The edges of the sucker cups (4) should be placed approx. 3-4 mm from the rear edge of the paper stack.
For light paper stock it is re­commended to place the suckers even closer to the rear edge of the stack. This is achieved by moving the stop rods (3) to the next set of holes (5).
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Tighten the separating head by turning the lock lever (2) clockwise.
Slide the left and right hold-down rods (6) towards the outer edge of the paper stack (approx. 1 cm inside the edge).
Adjusting the pressure of the hold-down rods: Heavy paper grades: Slide the weight (7) up. Light paper grades: Slide the weight down.
7
Check whether the automatic height setting mechanism is switched on.
The automatic height setting mecha­nism can be switched on and off by pushing button (8). The illuminated button shows that it is active.
For smaller paper sizes or flat sheets the automatic height adjustment is often not needed and can therefore be switched off.
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Operator's Manual 2200 Series Flat Pile Feeder
Adjusting the Stripper Springs
Adjust the automatic height setting as follows:
The left hold-down bracket (1) also serves as a height sensor controlling the height adjust­ment of the rear edge separator. As a result, the gap between the suckers and paper stack remains always the same although sheets are pulled off continuously. The basic position can be changed by means of a knob (2). A scale (3) facilitates the adjustment.
Increasing the gap: Move indicator to the plus-range "+". Reducing the gap: Move indicator to the minus-range "-".
Basic setting: Sucker cups should be 1-2 mm above the paper stack
(with air turned off).
The stripper springs (4) should reach about 2 mm into the stack to prevent double sheets. The position of the springs can be adjusted by means of a thumb screw (5).
- Turn the thumb screw counter-clockwise: Springs move away from the stack.
- Turn the thumb screw clockwise: Springs move into the stack.
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Making the Sucker Cups Inoperative
If double sheets occur, the stripper fingers must be adjusted in such a way that they reach further into the stack.
For short formats it is often advantageous to work without rear edge separators. In this case the sucker cups can be made inoperative.
Move the sucker cups to the top position (6).
Push the lock lever (7) backwards. This will
lock the sucker cups in the top position.
Switch off the automatic height setting
mechanism.
Now the air continuously separates the sheets from the rear edge.
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Operator's Manual 2200 Series Flat Pile Feeder
Air
The air separates the rear edge of the paper stack by means of two rear separator nozzles (1). The volume of the air can be adjusted by means of a valve (2). The effect of the air can be influenced by changing the angle of the rear separator nozzles. They can be pointed up- or downwards by turning a thumb screw (3).
- Air directed upwards: Turn the screw counter-clockwise. Too high: Double sheets may occur.
- Air directed downwards: Turn the screw clockwise. Too low: Sheets on top are not fanned properly.
Air volume and angle are set correctly when the top 10 - 15 sheets separate easily.
Use as little air as possible for proper function.
Another separator nozzle (4) is positioned between the rear separator nozzles. It creates an air cushion under the separated sheet so that it attaches itself to the suction drum. The air volume can be adjusted by means of the valve (5).
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Most setting elements are equipped with scales. For repetitive feeding jobs it is recommended to mark the settings at the scales. The machine can thus be set-up more quickly. Please note that the same result can only be reached if all conditions are the same.
To support the air cushion, front blowers (6) can be used. They blow air under the leading edge of the sheets so that the sheets cling more easily to the suction drum.
The air volume can be controlled by means of a valve (7), which can be closed com­pletely by turning it clockwise.
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Operator's Manual 2200 Series Flat Pile Feeder
AdditionalBlower
Side Blowers
Anadditionalsingleblower(1) stabilizes the air cushion near the leading edge of the floating sheet. This is especial­ly useful for long and narrow sheets.
The single blower (1) is positioned next to the front stop (2), while the stop plate (3) which comes with each single blower is pushed onto the rear paper stops.
When the single blower is used, the front blowers must be made inoperative. For this purpose detach the hose (4) for the front blowers from the valve (5) and connect the air hose (6) of the individual blower in its place.
The feeder can also be equipped with side blowers in the place of the rear edge separator (see separate mounting instructions). By supplying air to the side and rear edge of the stack, the topmost sheets are detached so that separation through the suction drum is possible. Contrary to operation with the rear edge separator, the topmost sheet is not lifted.
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The air nozzles (7) are attached to cross-bars at the side (8) and the rear (9) of the paper stack. For replenishing paper, the two cross-bars can be raised to provide access to the pile table.
After the replenishing process the bars are returned to the working position.
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Operator's Manual 2200 Series Flat Pile Feeder
Format setting:
Move the rear cross-bar (1) (secured with a clamp lever) in such a way that the
sheet stop rods (2) are placed against the left- and right-hand side edge as well as against the rear edge of the stack.
The weight rods (3) on the left- and right­hand side must touch the corners of the stack.
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Move the lateral cross-bar until the side stop
(4) touches the stack.
Adjust the air nozzles in such a way that they
are approx. 1 to 2 cm away from the side ­resp. rear edge.
Adjust the angle of the air flow by turning the
air nozzles so that about 10 sheets are separated.
The amount of air can be fine-adjusted by means of valves (5).
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1-2 cm
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The air cushion must not be so strong that the sheets under the suction drum are compressed.
Place the stop plate on the rear stops (6) so that an air cushion is created.
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Operator's Manual 2200 Series Flat Pile Feeder
Aspecialsidestopattheright-hand side is part of the "side blower" kit. This stop should beusedwhenthepapertendstodriftsideways.
The side stop is attached to the arm of the suction wheel and can be moved sideways so that it can be set to the format width.
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Operator's Manual 2200 Series Register Table
10.REGISTERTABLE
Setting the Format ­Flat Pile Feeder
Setting the Format ­AirFeeder
Register rail, ball cage and transport belt form one single unit and are adjusted together.
Make sure that the feeder is set to the correct format. Proceed as follows:
Loosen the lock screw (1) of the register rail by
turning it counter-clockwise.
Turn the handwheel (2) until the paper stop pin (3)
just touches the edge of the paper stack.
Retighten the lock screw (1) by turning it clockwise.
Set the rear paper support (11) to paper width,
using the scale and pointer.
Distribute the hold-down bars (5) across the sheet
width. Place one hold-down bar in front of the suction drum (6).
If the paper is less than 15 - 16 cm wide, the paper guide plate (4) must be removed.
Loosen the lock screw (1) by turning it counter-clockwise.
Set the alignment rail to the paper size by turning the handwheel (2).
The scale at the fold roller infeed section (7) must show the same number as the scale on the feeder (8).
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Tighten the lock screw (1) by turning it clockwise.
Distribute the hold-down bars (9) across the width of the sheet.
The infeed angle can be changed by means of the knurled screw (10) and the appropriate scale.
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Operator's Manual 2200 Series Register Table
Type of Balls
The number and type of balls in the ball cage (1) depend on format and type of paper.
Always try to use as few balls as possible. Balls not needed for a particular job should be removed to avoid wear of the transport belt.
1
It is recommended to use the following balls:
Papergradesbelow13 #:Plasticballs Papergradesfrom13 - 33 #:Plasticballs,every6thshouldbeasteelball Papergradesabove33 #:Mainlysteelballs
In the infeed section (the first 4 to 6 balls) it is recommended to always use one or two steel balls.
For very light paper grades every second ball opening should be left free.
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