Formax 2200 User Manual

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2200 Series

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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

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

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

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

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

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

4 Safety handwheel

Operator'sManual 2200 Series

General

4. Register Table

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.

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

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.

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).

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.

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).

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).

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!

• 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).

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.

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!

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.

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.

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.

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

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.

567

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.

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.

• Lower the front stop (5) and slide it against the paper stack.

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.

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.

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.

Operator's Manual 2200 Series Flat Pile Feeder

Setting the Rear Edge Separator

• Lower the rear edge separator (1).

• Loosen the lock lever (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).

• 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.

• 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.

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.

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.

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).

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.

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.

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.

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.

• 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).

1-2 cm

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.

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.

Operator's Manual 2200 Series Register Table

10.REGISTERTABLE

Setting the Format Flat Pile Feeder

Setting the Format AirFeeder

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).

• 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.

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.

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.

Operator's Manual 2200 Series Buckle Fold Units

11.BUCKLEFOLDUNITS

Thebucklefoldunitshaveaninfeedwidthof15" (when inline with the sealer paper width is liminted to 11.5") and equippedwith4automaticfoldplates.

The automation of these fold plates comprises the automatic positioning of the foldplatestopsandtheautomaticclosingofthedeflectors. Itisnotnecessarytoremovethefoldplatesandtoinsertthedeflectorswhen changing the fold.

Description

1 Noise covers 2 Fold roller adjustment knobs 3 Handwheel 4 Main switch 5 Operator panel 6 Transfer bridge

Fold Plate Positions

Inthefoldunitthere are four positions forthefoldplates:

The fold plates are marked with a number. Care has to be taken that the fold plates are inserted in the correct positions, e.g. fold plate 1 in position 1, fold plate 2 in position 2, etc.

Operator's Manual 2200 Series Buckle Fold Units

Installing the Fold Plates

Connecting the Fold Plates

Setting Elements of the Fold Plates

The fold plates have one lock screw (1) each at the left- and right-hand side.

Insert the fold plates in such a way that the lock screws (1) fit in the recesses (2) in the frame of the fold unit.

Secure the fold plates by tightening the lock screws.

The electrical connection is done by means of special 90° plugs (3). They are inserted at the front of the fold plates and secured by lightly tightening the threaded sleeve.

Make sure that the main switch is OFF before pulling or inserting the plug!

The number of the plug must agree with the number at the front side of the plate!

• Knurled knob for angle corrections (4):

By turning the knurled knobs it is possible to make angle corrections of the paper stop, for example, if the paper is out-of-square.

Setting the Fold Length

• Setting knob for adjusting the lower lip of the fold plates: The lower lip can be adjusted by means of a setting knob in order to increase or decrease the space for forming the buckle, depending on paper thickness and paper stiffness. A scale indicates the positioning of the lower lip.

Basic position: "0" is flush with the top of the knob (5). Lower lip advanced: Small buckle space (6), setting knob "-" Lower lip set back: Large buckle space (7), setting knob "+"

- Thin paper grades: Advance the lower lip, "-"

- Heavy paper grades: Set back the lower lip, "+"

• Allen screws for changing the gap between the fold plate and the fold rollers:

For difficult-to-handle paper it is possible to set back the complete fold plate by up to 4 mm. For this two Allen screws (8) have to be loosened at the left and right side of the fold plate. A scale (9) facilitates precise setting.

Setting the fold length and closing the deflectors is controlled by the computer. The respective commands are entered on the operator panel (see paragraph 16.)

Operator's Manual 2200 Series Transfer Bridge

12.Transfer Bridge

Transfer Bridge

Folders with two fold units are always equipped with a transfer bridge (1). This bridge ensures the accurate transfer of the sheet onto the roller table.

Two ball cages guide the sheets. Proceed as follows when changing the format:

• Loosen the clamp screws (2) by turning them counter-clockwise.

• Shift the ball cage in such a way that the balls run on a belt.

• Tighten the clamp screws by turning them clockwise.

• If necessary, the ball cages can also be moved in or out (loosen Allen screws (3) on both sides).

The angle of the bridge is adjustable and can therefore be adapted to the paper quality and the type of fold.

• Loosen the Allen screws (4) on both sides.

• Change the angle of the bridge.

• Tighten the Allen screws.

Ejector Rollers

Make sure that the belts do not drag on the roller table! Set the adjusting brackets (5) on both sides of the bridge accordingly.

The ejector rollers on the delivery shafts must be set so that they are running on top of each other (6).

An adjustment is only necessary when the sheets are no longer guided properly after a change of format. To adjust:

• Turn the handwheel until the set screws of the ejector rollers are visible (7).

•LoosentheAllenscrewswitha3-mmAllenkey.

• Shift the ejector rollers to the required position.

• Tighten the Allen screws.

Sealing Unit

Align the sealing unit with the transport

table and secure it in position with the

thumbscrews. The plexi saftey cover

must be closed or the machine won’t

nectors 2,3 and 9

Plexi saftey cover

Photo-eye

Fuse (located on the back side)

Operator's Manual 2200 Series Stacker

14.STACKER

Stacker

Setting the Transfer Height

Setting the Format

Thestacker is mobile.The heightisadjustable by means of a gas-filledshock-absorber.

An additional control box (1) allows stopping and starting the machine (2) and paper feed (3) to facilitate setting the hold-down rollers.

• Loosen the lock screw (4) by turning it counter-clockwise.

• Lift or lower the delivery table.

• Tighten the lock screw (4) by turning it clockwise.

The hold-down rollers (5) are needed for achieving a clean fanned delivery. They prevent the folded sheets from opening up on the delivery belt. The hold-down rollers are adjustable in two direction (6, 7).

When moving them sideways make sure that the rollers always run on a delivery belt.

The distance between delivery shafts (8) and hold-down roller (9) should correspond to the sheet length of the folded sheet (10). To adjust, proceed as follows:

Electrical Connection

• Turn the setting wheel (11) to the left or to the right and shift the hold-down rollers to their new position.

Pushing the button (12) will move the delivery belts for easy removal of sample sheets.

The pressure of the hold-down rollers can be changed by turning the knurled screws (13). Chooselesspressureforthinpaperbelow20 # andmorepressureforpaperabove39 #.

The electrical connection of the delivery section is made by plugging the connecting cable into the socket (14) in the last fold unit.

When making or breaking any electrical connection, always first turn off the main

switch or the safety switch of the folder. Non-compliance may cause damage to electronic components!

Operator's Manual 2200 Series Automatic Setting

15.AUTOMATICSETTING

OperatorPanel

Description

The 2200 Series machines areequippedwithacentraloperator panel. Itisherewherethecommunicationbetweenoperatorandmachinetakesplace and where all the important settings and monitoring functions are carried out.

The swing-around operator panel can be moved to the position which is most convenient for the operator.

Setting elements and keys with the following functions:

12 3 4 5 6 7

Computer Automated System

555

CAS

F11 F12

F9 F10

F1 F2 F3 F4 F5

9101112 13 14 15

1 Sheet gap in delivery section 2 Fold speed 3 Sheet gap on the register table 4 Display

5 Display of menu FOLD LENGTH 6 Display of menu ROLLER GAP

7 Measuring system / language 8 Keys for numerical input

9 Pump 10 Fold roller drive 11 Sheet gap

12 Return to BASIC menu

13 Function keys for displaying different menus 14 Confirmation of a value entered 15 Information for service technician

456

0123

Operator's Manual 2200 Series Automatic Setting

Description of the Display

The operator panel contains an LC-display. After switching on the machine, the following message appears:

TOTAL: JOB NO:

00000000

OUTPUT:

00000

REMAINDER:

0000

MONITORING: DOUBLES:

TRANSPORT:

OFF OFF

0000

MONITORING SAVING

COUNTER SET-UP JOB

F1 F5F2 F3 F4

This display gives an overall view of the most important data.

For this reason the BASIC menu should always be called up when running the folder.

The displays for TOTAL, OUTPUT, REMAINDER, DOUBLES, TRANS- PORT always refer to the actual folding job. The JOB NO may refer to the actual folding job, but this is not necessarily

the case. When calling up the menu, the job number which was saved last or which was recalled from the memory is automatically displayed. A job which was not saved cannot have an identification number and is therefore not displayed.

The following main menus can be chosen from the BASIC menu:

• COUNTER Setting of total and batch counting

• MONITORING Activation of double sheet detection and paper travel control

• SET-UP Automatic setting of fold lengths / Input of setting infor-

mations

• SAVING Saving of repetitive jobs

• JOB Actual folding job

A number of function keys (F1 to F7) with arrows pointing to the headlines of

the main menu are grouped around the display. By pressing one of these keys, the selected main menu is displayed.

Operator's Manual 2200 Series Automatic Setting

Each menu is divided into a light and a dark section. Actual data is shown in the light section (1). In the dark section (2), additional menus are displayed, which can also be called up by pressing the function keys. The last line in the light section is the "command line" (3) and serves as an operator guide. This "command line" is very important because it indicates which command must be carried out next.

JOB SAVED:

FORMAT(in): FOLD

IN FOLD UNIT:

3 2

The keys on the operator panel are secured against incorrect operation, which means that malfunctions caused by unacceptable inputs or accidental pressing of keys will be prevented. Keys that are not used are automatically made inactive.

To help you familiarize yourself with this new system, the commands of the most important settings are explained step by step on the following pages. The sequence of the commands is shown by numbered input lines (4) so you will quickly understand the logic of the procedure.

Examples:

AFTER ENTERING NUMBER:

--------- SELECT ---------------JOB CONTENTS

LENGTH:WIDTH:

5.5 5.5

1: 2:

9999

FOLD SET-UP

1. Press key C The BASIC menu is displayed.

2. Press key F3 The SET-UP menu is displayed.

By following the sequence shown and observing the instructions, you will soon master the operation of the machine and benefit from the advantages of the computer control.

If you get confused while entering commands, simply return to the BASIC menu by pressing key C and start again.

The following operating instructions are arranged in such a way that all main menus

are described, starting with COUNTER and finishing with JOB.

Operator's Manual 2200 Series Automatic Setting

Main Menu COUNTER

Setting the Counter - Main Menu COUNTER

1. Press key C The BASIC menu is displayed.

TOTAL: JOB NO:

00000000

0000

OUTPUT:

00000

REMAINDER:

MONITORING: DOUBLES:

TRANSPORT:

OFF OFF

0000

MONITORING SAVING

COUNTER SET-UP JOB

F1 F5F2 F3 F4

2. Press key F1 The COUNTER menu is displayed.

COUNTER

The figures in the display refer to a previous folding job.

BATCH: INTERVAL: TOTAL:

AFTER ENTERING NUMBER:

0111

00000111

Clearing the Total Counter

CLEAR

SELECT

F1 F2 F3 F4

3. Press key F4 The total counter is cleared.

COUNTER

BATCH: INTERVAL: TOTAL:

AFTER ENTERING NUMBER:

SELECT

F1 F2 F3 F4

00000000

TOTAL

0111

CLEAR TOTAL

Operator's Manual 2200 Series Automatic Setting

Main Menu COUNTER

Setting the Batch Counter

The dark background of the line BATCH means that the preselected number of

sheets per batch can be entered.

The batch counter is used to mark a pre-selected number of sheets (batch) in such a way that it can be separated from the next batch. This makes it easy to remove the individual batches from the delivery table. The following data must be entered for batch counting:

• the desired number of sheet per batch (preselection)

• the length of the gap (interval) between batches

Example: Batches of 50 sheets.

4. Enter the number of sheets (e.g 50) The new BATCH is displayed.

COUNTER

BATCH: INTERVAL: TOTAL:

AFTER ENTERING NUMBER:

0050

00000000

CLEAR

SELECT

F1 F2 F3 F4

5. Press key The new batch is saved.

COUNTER

BATCH: INTERVAL: TOTAL:

AFTER ENTERING NUMBER:

SELECT

F1 F4F2 F3

00000000

TOTAL

0050

CLEAR TOTAL

The dark background of the line INTERVAL means that the interval needed for

batch counting can be entered.

Operator's Manual 2200 Series Automatic Setting

Main Menu COUNTER

Example: The gap between batches (interval) in the delivery section should be as long as it takes to feed 4 sheets.

6. Enter the interval (e.g. 4) The new INTERVAL is displayed.

COUNTER

BATCH: INTERVAL: TOTAL:

AFTER ENTERING NUMBER:

SELECT

F1 F4F2 F3

7. Press key The new interval is saved.

COUNTER

BATCH: INTERVAL: TOTAL:

0050

00000000

CLEAR TOTAL

0050

00000000

AFTER ENTERING NUMBER:

CLEAR

SELECT

F1 F2 F3 F4

The dark background moves again back to the BATCH line. By pressing key F1 it is possible to alternate between BATCH and INTERVAL lines.

When batch counting is not used, enter "0" for BATCH or INTERVAL.

8. Press key C Back to BASIC menu.

TOTAL

Operator's Manual 2200 Series Automatic Setting

Main Menu MONITORING

Paper Transport Control, Double Sheet Detection - Main Menu MONITORING

1. Press key C The BASIC menu is displayed.

TOTAL: JOB NO:

00000000

0000

OUTPUT:

00000

REMAINDER:

MONITORING: DOUBLES:

TRANSPORT:

OFF OFF

0000

MONITORING SAVING

COUNTER SET-UP JOB

F1 F5F2 F3 F4

2. Press key F2 The MONITORING menu is displayed.

MONITORING

DOUBLES: OFF TRANSPORT: OFF

SWITCH ON /OFF

DOUBLES TRANSPORT

Paper Transport Control

ON OFF ON OFF

F1 F5F2 F4

3. Press key F4 The paper transport control is active.

MONITORING

DOUBLES: OFF TRANSPORT: ON

SWITCH ON /OFF

DOUBLES TRANSPORT

ON OFF ON OFF

F1 F5F2 F4

Operator's Manual 2200 Series Automatic Setting

Main Menu MONITORING

Double Sheet Detection

4. Press key F1

MEASURE PAPER THICKNESS

START TWO SHEETS

Prior to switching the machine on, it must be set-up and the feeder must be loaded with paper.

5. Switch on pump and main motor. Press the sheet transport key (1x).

6. Press the sheet transport key (1x). The paper thickness is displayed.

MEASURE PAPER THICKNESS

PAPERTHICKNESS(in):

DOUBLE SHEET DETECTIONON

7. Switch off the main motor and the pump.

8. Press key C Back to BASIC menu.

0.10

If the double sheet detection or the paper transport control is to be deactivated,

the CONTROL menu must be called up by pushing key F2 in the BASIC menu - then push key F2 or F5.

Operator's Manual 2200 Series Automatic Setting

Main Menu SET-UP

Setting the Fold Length - Main Menu SET-UP

Theautomaticsettingofthe2200 Series makesitpossiblethatallstopsdriven by timing belts and servo motors - are set automatically to the position calculated by the computer. The fold plates which are not used for a particular folding job are automatically closed by deflectors and always remain in the fold unit.

The fold plate stops can be set in three different ways:

1. Automatic setting of pre-programmed standard folds

2. Entering the fold lengths individually on the keyboard - Special folds

3. Calling up fold programs from the memory - Job saved

Standard Folds

For this type of setting, it is not necessary to make a sample fold by hand and to measure it. Just enter the required type of fold.

The following standard folds are permanently programmed in the software:

Single fold

Z-fold 2x

Z-fold 4x

Letter fold

Double parallel fold

Open gate fold

Operator's Manual 2200 Series Automatic Setting

Main Menu SET-UP

Standard Folds

1. Press key C The BASIC menu is displayed.

TOTAL: JOB NO:

00000000

0000

OUTPUT:

00000

REMAINDER:

MONITORING:

DOUBLES: TRANSPORT:

ON ON

0000

MONITORING SAVING

COUNTER SET-UP JOB

F1 F5F2 F3 F4

2. Press key F3 The SET-UP menu is displayed.

SET-UP

SELECT WITH FUNCTION KEYS

-------- FOLD ------------SPECIAL STANDARD

SUCTION LENGTH

JOB SAVED

ROLLER GAP

DELIVERY

F1 F5F2

3. Press key F2 The STANDARD FOLDS menu is displayed.

STANDARD FOLDS

FOLD UNIT:

AFTER SELECTING FOLD:

FOLD UNIT FOLD SET-UP

F1 F5F3

Pressing key F3 several times will shift the cursor (dark rectangle) from

one symbol to the other.

Operator's Manual 2200 Series Automatic Setting

Main Menu SET-UP

Standard Folds

Settingexample:ADIN 11" x 17" sheetistobefoldedasfollows:

First fold unit: Z-fold Second fold unit: Letter fold

4. Press key F3 until the respective fold symbol for the first fold unit (Z-fold) is marked by the cursor.

STANDARD FOLDS

FOLD UNIT:

AFTER SELECTING FOLD:

FOLD UNIT FOLD SET-UP

F1 F5F3

5. Press key The selected fold is confirmed.

FOLD UNIT:

The format length of a previous job is shown in the display.

FORMATLENGTH(in):

AFTER ENTERING NUMBER:

STANDARD FOLDS

FOLD UNIT FOLD SET-UP

F1 F5F3

6.Entertheformatlength(17)Thenewformatlengthisdisplayed.

STANDARD FOLDS

FOLD UNIT:

FORMATLENGTH(in):

AFTER ENTERING NUMBER:

FOLD UNIT FOLD SET-UP

F1 F5F3

If a format is entered that cannot be handled by the machine because it is too small or too large, this is recognized by the computer and shown in the display.

Operator's Manual 2200 Series Automatic Setting

Main Menu SET-UP

Standard Folds

7. Press key The new format length is saved.

STANDARD FOLDS

FOLD UNIT:

FORMATLENGTH(in):

SET-UP OR CHOOSE FOLDUNIT

FOLD UNIT FOLD SET-UP

F1 F5F3

8. Press key F1 The second fold unit is selected.

STANDARD FOLDS

FOLD UNIT:

Since, in our example, a letter fold is to be made in the second

AFTER SELECTING FOLD:

fold unit, the cursor must be shifted to the respective fold

FOLD UNIT FOLD SET-UP

symbol.

F1 F5F3

9. Press key F3 repeatedly until the respective fold symbol for the second fold unit (letter fold) is marked by the cursor.

STANDARD FOLDS

FOLD UNIT:

AFTER SELECTING FOLD:

FOLD UNIT FOLD SET-UP

F1 F5F3

Operator's Manual 2200 Series Automatic Setting

Main Menu SET-UP

Standard Folds

10. Press key The new format length is saved.

STANDARD FOLDS

FOLD UNIT:

FORMATWIDTH(in):

The format width of a previous job is shown in the display.

11.Enterformatwidth(11)Thenewformatwidthisdisplayed.

AFTER ENTERING NUMBER:

FOLD UNIT FOLD SET-UP

F1 F5F3

FOLD UNIT:

FORMATWIDTH(in):

AFTER ENTERING NUMBER:

8.5

STANDARD FOLDS

If a format is entered that cannot be handled by the machine because it is too small or too large, this is recognized by the computer and shown in the display.

12. Press key

FOLD UNIT FOLD SET-UP

F1 F5F3

STANDARD FOLDS

FOLD UNIT:

FORMATWIDTH(in):

SET-UP OR CHOOSE FOLDUNIT

FOLD UNIT FOLD SET-UP

F1 F5F3

Operator's Manual 2200 Series Automatic Setting

Main Menu SET-UP

Standard Folds

13. Press key F5 The stops are positioned automatically and the

fold plates not needed are closed by deflectors.

STANDARD FOLDS

FOLD UNIT:

FORMATWIDTH(in):

SETTING FOLD STYLE

FOLD UNIT FOLD SET-UP

F1 F5F3

The display SETTING FOLD STYLE is flashing until the setting process

is completed. Then the following message appears:

MEASURE PAPER THICKNESS

START TWO SHEETS

Prior to switching the machine on, it must be set up and the feeder must be loaded with paper.

14. Switch on pump and main motor, press the sheet transport key (1x).

Operator's Manual 2200 Series Automatic Setting

Main Menu SET-UP

Standard Folds

15. Press the sheet transport key (1x) The paper thickness is displayed.

MEASURE PAPER THICKNESS

PAPERTHICKNESS(in):

DOUBLE SHEET DETECTIONON

After a few seconds the display returns to the SET-UP menu.

SET-UP

SELECT WITH FUNCTION KEYS

SUCTION LENGTH

JOB SAVED

--------- FOLD ------------SPECIAL STANDARD

ROLLER GAP

0.10

DELIVERY

F1 F5F2

16. Switch off main motor and pump.

17. Press key C Back to BASIC menu.

Operator's Manual 2200 Series Automatic Setting

Main Menu SET-UP

Special Folds

This kind of set-up resembles most the principle used in conventional folding machines because the fold length of each stop must be calculated or measured before setting. The actual setting, however, is done at the operator panel.

1. Press key C The BASIC menu is displayed.

TOTAL: JOB NO:

00000000

OUTPUT:

00000

REMAINDER:

0000

MONITORING: DOUBLES:

TRANSPORT:

ON ON

0000

MONITORING SAVING

COUNTER SET-UP JOB

F1 F5F2 F3 F4

To enter the measurements for the fold lengths, e.g. to set the fold plate stops,

the menu SET-UP must be called up via key F3.

2. Press key F3 The SET-UP menu is displayed.

SET-UP

SELECT WITH FUNCTION KEYS

SUCTION LENGTH

--------- FOLD ------------

SPECIAL STANDARD

F1 F5F2

JOB SAVED

ROLLER GAP

DELIVERY

Operator's Manual 2200 Series Automatic Setting

Main Menu SET-UP

Special Folds

3. Press key F1 The SET-UP SPECIAL FOLD menu for fold unit 1 is displayed.

SET-UPSPECIALFOLD(in)

FOLD UNIT:

ACT: 3.3 NOM:

ENTER NOMINAL VALUES

FOLD UNIT

F1 F5F2 F3 F4

ThedisplayshowsACT(Actual)asthecurrentfoldlength(e.g.5.5)

and the matching fold symbol, e.g. , , ...

Example:AsheetinformatDIN8.5" x 14"

is to be folded.

Example: Eccentric Z-fold

Example Foldplate1: 5.25 in

(Z-fold)Foldplate2: 5.25 in

Foldplate 3: 0 in Foldplate 4: 0 in

PLATE - + SET-UP

-PLATE:

5.25

14"

198

11"

4.Enterthefoldlengthforthefirstfoldplate Example:3.3

SET-UPSPECIALFOLD(in)

FOLD UNIT:

ACT:NOM:

AFTER ENTERING NUMBER:

FOLD UNIT

3.3 5.25

F1 F5F2 F3 F4

PLATE - + SET-UP

-PLATE:

Operator's Manual 2200 Series Automatic Setting

Main Menu SET-UP

Special Folds

5. Press key The fold length is saved.

SET-UPSPECIALFOLD(in) FOLD UNIT:

ACT:NOM:

ENTER NOMINAL VALUES

FOLD UNIT

6.PresskeyF2Foldplate2iscalledup.

SET-UPSPECIALFOLD(in)

FOLD UNIT:

ENTER NOMINAL VALUES

FOLD UNIT

3.3 5.25

F1 F5F2 F3 F4

T: 3.4 NOM:

PLATE - + SET-UP

-PLATE:

PLATE - + SET-UP

F1 F5F2 F3 F4

7.Enterfoldlengthforthesecondfoldplate Example:3.4

SET-UPSPECIALFOLD(in)

FOLD UNIT:

ACT:NOM:

AFTER ENTERING NUMBER:

FOLD UNIT

3.4 5.25

F1 F5F2 F3 F4

PLATE - + SET-UP

-PLATE:

Operator's Manual 2200 Series Automatic Setting

Main Menu SET-UP

Special Folds

8. Press key The fold length is saved.

SET-UPSPECIALFOLD(in)

FOLD UNIT:

ACT:NOM:

ENTER NOMINAL VALUES

FOLD UNIT

9. Press key F2 Fold plate 3 is called up.

SET-UPSPECIALFOLD(in) FOLD UNIT:

ACT: NOM:

ENTER NOMINAL VALUES

FOLD UNIT

3.4 5.25

F1 F5F2 F3 F4

5.5

PLATE - + SET-UP

-PLATE:

PLATE - + SET-UP

F1 F5F2 F3 F4

10.Enterfoldlengthforthethirdfoldplate Example:0

SET-UPSPECIALFOLD(in)

FOLD UNIT:

ACT: NOM:

AFTER ENTERING NUMBER:

FOLD UNIT

5.5 00

F1 F5F2 F3 F4

PLATE - + SET-UP

PLATE:

Operator's Manual 2200 Series Automatic Setting

Main Menu SET-UP

Special Folds

11. Press key The fold length is saved.

SET-UPSPECIALFOLD(in)

FOLD UNIT:

ACT: NOM:

ENTER NOMINAL VALUES

FOLD UNIT

12. Press key F2 Fold plate 4 is called up.

SET-UPSPECIALFOLD(in) FOLD UNIT:

ACT: NOM:

ENTER NOMINAL VALUES

5.5

F1 F5F2 F3 F4

PLATE - + SET-UP

5.5

PLATE:

-PLATE:

FOLD UNIT

PLATE - + SET-UP

F1 F5F2 F3 F4

13.Enterfoldlengthforthefourthfoldplate Example:0

SET-UPSPECIALFOLD(in)

FOLD UNIT:

ACT: NOM:

AFTER ENTERING NUMBER:

FOLD UNIT

5.5

F1 F5F2 F3 F4

PLATE - + SET-UP

-PLATE:

Operator's Manual 2200 Series Automatic Setting

Main Menu SET-UP

Special Folds

14. Press key The fold length is saved.

SET-UPSPECIALFOLD(in)

FOLD UNIT:

ACT NOM:

ENTER NOMINAL VALUES

FOLD UNIT

Now the fold lengths for all 4 fold plates of the first fold unit are entered.

5.5 00

F1 F5F2 F3 F4

PLATE - + SET-UP

-PLATE:

Operator'sManual 2200 Series

26. Press key The fold length is saved.

SET-UPSPECIALFOLD(in)

AutomaticSetting

Main Menu SET-UP

Special Folds

When all fold lengths have been entered, the next step is the command for automatic setting of the stops.

27. Press key F5

FOLD UNIT:

ACT:NOM:

ENTER NOMINAL VALUES

FOLD UNIT

SET-UPSPECIALFOLD(in)

FOLD UNIT:

ACT: NOM:

SETTING FOLD STYLE

5.5 000

F1 F5F2 F3 F4

5.5 000

PLATE - + SET-UP

PLATE:

FOLD UNIT

PLATE - + SET-UP

The display SETTING FOLD STYLE is flashing until the setting is

completed. Then the following display appears:

MEASURE PAPER THICKNESS

START TWO SHEETS

Prior to switching the machine on, it must be set up and the feeder must be loaded with paper.

F5F2 F3 F4

Operator'sManual 2200 Series

28. Switch on pump and main motor. Press the sheet transport key (1x).

29. Press the sheet transport key (1x) The paper thickness is displayed.

Main Menu SET-UP

MEASURE PAPER THICKNESS

AutomaticSetting

Special Folds

PAPERTHICKNESS(in):

DOUBLE SHEET DETECTIONON

0.10

After a few seconds the display returns to the SET-UP menu.

SET-UP

SELECT WITH FUNCTION KEYS

SUCTION LENGTH

JOB SAVED

-------- FOLD -------------ROLLER

SPECIAL STANDARD

GAP

DELIVERY

F1 F5F2

30. Switch off the main motor and the pump.

31. Press key C Back to BASIC menu.

Operator'sManual 2200 Series

AutomaticSetting

Main Menu SET-UP

Job Saved

Entering the Memory/Job Number

A job can be recalled from memory only when the identification number (memory- or job number) is known.

If the number is unknown, it is possible to display the contents of the memory and thus find the number.

1. Press key C The BASIC menu is displayed.

TOTAL: JOB NO:

00000000

OUTPUT:

00000

REMAINDER:

0000

MONITORING: DOUBLES:

TRANSPORT:

ON ON

0000

MONITORING SAVING

COUNTER SET-UP JOB

F1 F5F2 F3 F4

In order to set up a job from the memory, the SET-UP menu must be called up by pressing key F3.

2. Press key F3 The SET-UP menu is displayed.

SET-UP

SELECT WITH FUNCTION KEYS

SUCTION LENGTH

JOB SAVED

--------- FOLD ------------

SPECIAL STANDARD

F1 F5F2

ROLLER GAP

DELIVERY

Operator'sManual 2200 Series

3. Press key F6 The JOB SAVED menu is displayed.

AutomaticSetting

Main Menu SET-UP

Job Saved

JOB SAVED:

FORMAT(

in):LENGTH:WIDTH:

5.5

FOLD IN FOLD UNIT

AFTERENTERING VALUE:

------------JOB------------------- FOLD

- + CONTENTS

F1F5F2 F3 F4

The display shows the number of the job which was last saved or recalled from the memory. Select the job by using the F1 or F2 with the number key pad.

4. Enter the job number Example: 9999

1: 2:

1111

5.5

SET-UP

JOB SAVED:

FORMAT(in):LENGTH:WIDTH:

5.5

FOLD IN FOLD UNIT

AFTERENTERING VALUE:

---------------JOB ---------------- FOLD

- + CONTENTS

F1F5F2 F3 F4

1: 2:

9999

5.5

SET-UP

Operator'sManual 2200 Series

5. Press key The format and fold are displayed.

AutomaticSetting

Main Menu SET-UP

Job Saved

JOB SAVED:

FORMAT(in):LENGTH:WIDTH:

FOLD IN FOLD UNIT

-------------JOB ------------------ FOLD

- + CONTENTS

F1F5F2 F3 F4

The next input depends on what values are to be taken over from memory:

•FoldlengthsonlycontinuewithkeyF5

This key is pressed if the new job uses the same paper size and fold, but a

different paper weight.

• Fold lengths, suction length as well as setting values for fanned delivery, fold

speed, fold roller gap and sheet gap continue with key F3

This key is pressed if the new job uses the same paper size, fold and the same paper weight.

1: 2:

9999

SET-UP

The following example assumes that the new job uses the same paper weight and that all values have to be called up for that reason.

6. Press key F3 The CONTENTS menu is displayed.

JOB SAVED:

SHINGLING SPEED GAP

9999

07 08 06

MANUAL SETTING

-----------------JOB --------------- FOLD SET-UP

- + CONTENTS

F1 F5F2 F3 F4

7. These figures must be entered manually by turning the knobs with the corresponding controls.

786

Delivery Speed Sheet gap

Operator'sManual 2200 Series

8. Press key F3 Display ROLLER GAP.

JOB SAVED:

ROLLERGAP(in)

AutomaticSetting

Main Menu SET-UP

Job Saved

FOLD UNIT: GAP:

NOM:

MANUAL SETTING

--------------- SELECT --------------+ - CONTENTS AUTO+

F1 F5F2 F3 F4

For correct setting of the fold rollers the ACT (Actual) value must be changed to the NOM

(Nominal) value. This is done by turning the setting knobs (1).

The displayed NOM corresponds to

the value that was set during the saving process (individual corrections are taken into account).

All setting knobs have numbers so that the display message can be related to a specific fold roller.

0.10

ACT:

0.00

1/1

The NOM and ACT values of the individual fold rollers can be displayed by pressing keys F1, F2 or F4.

Key F1 (+): Display of NOM and ACT value for the next roller

(for example, advance from roller 2 to 3)

Key F2 (-): Display of NOMand ACTvalue for the previous roller

(for example, return from roller 2 to 1)

Key F4 (AUTO+): Automatic advance of NOM and ACT to the fold roller,

for which NOM and ACT do not agree

Description of the display messages:

GAP 5/2

5 Roller 5

2 Setting knob

on far side

GAP 1/1

1 Roller 1

1 Setting knob on

operator side

Operator'sManual 2200 Series

9. Turn setting knob 1 (operator side) on the first fold unit until ACT

shows the same value as NOM.

JOB SAVED:

ROLLERGAP(in)

AutomaticSetting

Main Menu SET-UP

Job Saved

FOLD UNIT: GAP:

NOM:

MANUAL SETTING =

------------- SELECT ----------------+ - CONTENTS AUTO+

F1 F5F2 F3 F4

When the values agree, the symbol "=" appears in the command line. All rollers can be called up and set by pressing keys F1, F2 or F4.

When the rollers in the first and second fold unit are set, the fold plate stops can be moved to their positions.

10. Press key F3

JOB SAVED:

FORMAT(in):LENGTH:WIDTH:

0.10

ACT:

0.10

1/1

9999

17 11

FOLD IN FOLD UNIT

AFTERENTERING VALUE:

--------------JOB ----------------- FOLD

- + CONTENTS

F1F5F2 F3 F4

1: 2:

SET-UP

Operator'sManual 2200 Series

11. Press key F4 The fold plate stops and deflectors are positioned.

AutomaticSetting

Main Menu SET-UP

Job Saved

JOB SAVED:

9999

FORMAT(in):LENGTH:WIDTH:

17 11

FOLD IN FOLD UNIT

SETTING FOLD STYLE

--------------JOB---------------- FOLD

- + CONTENTS

F1 F5F2 F3 F4

The line SETTING FOLD STYLE is flashing during set-up.

When the set-up is completed, this is signalled by a change of display:

SELECT WITH FUNCTION KEYS

1: 2:

SET-UP

SUCTION LENGTH

---------- FOLD ------------SPECIAL STANDARD

F1 F5F2

JOB SAVED

ROLLER GAP

DELIVERY

12. Press key C Back to BASIC menu.

Operator'sManual 2200 Series

AutomaticSetting

Main Menu SET-UP

Job Saved

Displaying the Contents of Memory

1. Press key C The BASIC menu is displayed.

TOTAL: JOB NO:

00000000

OUTPUT:

00000

REMAINDER:

0000

MONITORING:

DOUBLES: TRANSPORT:

ON ON

0000

MONITORING SAVING

COUNTER SET-UP JOB

F1 F5F2 F3 F4

To recall a job from memory, the menu SET-UP must be called up by pressing key F3.

2. Press key F3 The SET-UP menu is displayed.

SELECT WITH FUNCTION KEYS

-------- FOLD --------------

SPECIAL STANDARD

F1 F5F2

SET-UP

SUCTION LENGTH

JOB SAVED

ROLLER GAP

DELIVERY

Operator'sManual 2200 Series

3. Press key F6 The JOB SAVED menu is displayed.

AutomaticSetting

Main Menu SET-UP

Job Saved

4. Press key F1

By pressing key F1 (JOB) severaltimes,

the memory number, the format and the fold type of each individual job are displayed, in the sequence in which the jobs were saved.

JOB SAVED:

FORMAT(in):LENGTH:WIDTH:

1111

5.5 5.5

FOLD IN FOLD UNIT

AFTERENTERINH VALUE:

-------------JOB----------------- FOLD

- + CONTENTS

F1 F2 F3F5

JOB SAVED:

FORMAT(in):LENGTH:WIDTH:

SET-UP

3333

14 14

FOLD IN FOLD UNIT

AFTERENTERING VALUE:

--------------JOB----------------- FOLD

- + CONTENTS

SET-UP

F1 F2F3F5

Once the job is found, it can be set up as follows:

5. Enter the identification number Example: 9999

JOB SAVED:

FORMAT(in):LENGTH:WIDTH:

9999

5.5 5.5

The length and width still refer to the previous job.

FOLD IN FOLD UNIT

AFTERENTERING VALUE:

--------------JOB---------------- FOLD

- + CONTENTS

F1 F5F2 F3 F4

SET-UP

Operator'sManual 2200 Series

6. Press key

AutomaticSetting

Main Menu SET-UP

Job Saved

JOB SAVED:

FORMAT(

in):LENGTH:WIDTH:

9999

17 11

FOLD IN FOLD UNIT

-------------

- + CONTENTS

F1 F5F2 F3 F4

7. Press key F3 The CONTENTS menu is displayed.

JOB SAVED:

SHINGLING SPEE

JOB------------------ FOLD

1: 2:

SET-UP

9999

D GAP

07 08 06

MANUAL SETTING

----------------

- + CONTENTS

F1 F5F2 F3 F4

8. These figures must be entered manually by turning the knobs with the corresponding controls.

JOB-------------- FOLD

SET-UP

786

Delivery Speed Sheet gap

Operator'sManual 2200 Series

9. Press key F3

JOB SAVED:

ROLLERGAP(in)

AutomaticSetting

Main Menu SET-UP

Job Saved

FOLD UNIT: GAP:

NOM:

MANUAL SETTING

------------ SELECT ---------------+ - CONTENTS AUTO+

F1 F5F2 F3 F4

The fold rollers are be set by matching the ACTUAL and NOMINAL values (see Main Menu SET-UP / Job Saved steps 8-10).

When all rollers in the first and second fold unit are set, the fold plate stops can be moved to their respective positions.

10. Press key F3

JOB SAVED:

FORMAT(in):LENGTH:WIDTH:

0.10

ACT:

0.00

1/1

9999

17 11

FOLD IN FOLD UNIT

AFTERENTERING VALUE:

------------JOB------------------ FOLD

- + CONTENTS

F1F5F2 F3 F4

1: 2:

SET-UP

Operator'sManual 2200 Series

11. Press key F4 The fold plate stops and deflectors are positioned.

AutomaticSetting

Main Menu SET-UP

Job Saved

JOB SAVED:

9999

FORMAT(in):LENGTH:WIDTH:

17 11

FOLD INFOLDUNIT

SETTING FOLD STYLE

------------- SELECT ----------------- FOLD JOB CONTENTS

F1 F5F2 F3 F4

The line SETTING FOLD STYLE is flashing during set-up.

When the set-up is completed, this is signalled by a change of display:

SELECT WITH FUNCTION KEYS

1: 2:

SET-UP

SUCTION LENGTH

----------- FOLD ----------SPECIAL STANDARD

F1 F5F2

JOB SAVED

ROLLER GAP

DELIVERY

12. Press key C Back to BASIC menu.

Operator'sManual 2200 Series

Setting of the Suction Length - Main Menu SET-UP

Adjusting the suction length for the flat pile feeder is necessary when format and type of paper of the new job differ considerably from the previous one. The following rule applies:

- Short sheets, light stock: Short suction length

- Long sheets, heavy stock: Long suction length

If, for instance, very short unfolded sheets are processed, it may happen that two sheets are fed during one suction cycle. In this case a shorter suction length should be chosen. When processing heavy stock, there is a possibility that it is not transported reliably to the register table. Here the suction length should be increased.

A minimum suction length of 20 mm and a maximum suction length of 250 mm can be set.

1. Press key C The BASIC menu is displayed.

AutomaticSetting

Main Menu SET-UP

Suction Length

TOTAL: JOB NO:

00000000

OUTPUT:

00000

REMAINDER:

0000

MONITORING:

DOUBLES: TRANSPORT:

0000

MONITORING SAVING

COUNTER SET-UP JOB

F1 F5F2 F3 F4

ON ON

Operator'sManual 2200 Series

2. Press key F3 The SET-UP menu is displayed.

SET-UP

SELECT WITH FUNCTION KEYS

AutomaticSetting

Main Menu SET-UP

Suction Length

--------- FOLD ------------

SUCTION LENGTH

JOB SAVED

ROLLER GAP

DELIVERY

SPECIAL STANDARD

F1 F5F2

3. Press key F7 The suction length is displayed.

FEEDER

SUCTIONLENGTH(in):

AFTERENTERING VALUE:

5.5

4.Entersuctionlength(4.0) Thenewsuctionlengthisdisplayed.

FEEDER

SUCTIONLENGTH(in):

AFTERENTERING VALUE:

04.0

Operator'sManual 2200 Series

5. Press key

SET-UP

SELECT WITH FUNCTION KEYS

AutomaticSetting

Main Menu SET-UP

Suction Length

SUCTION LENGTH

JOB SAVED

-------- FOLD ------------

ROLLER GAP

DELIVERY

SPECIAL STANDARD

F1 F5F2

If further adjustment is needed after running some sample sheets, this can be done

by pressing key F7 again.

When the job is saved, the information about the individually modified suction length is also saved. During the next set-up process the modified suction length is set automatically.

Operator'sManual 2200 Series

Saving of Job Data - Main Menu SAVING

There is memory space for 60 individual fold jobs. A 4-digit identification number makes it possible to find each job anytime later.

The job cannot be saved before all settings have been completed, i.e. when no further corrections are required for:

- Fold length - Speed

- Sheet gap - Suction length

- Roller gap - Shingling

1. Press key C The BASIC menu is displayed.

AutomaticSetting

Main Menu SAVING

TOTAL: JOB NO:

00000000

0000

OUTPUT:

00000

REMAINDER:

MONITORING:

DOUBLES: TRANSPORT:

ON ON

0000

MONITORING SAVING

COUNTER SET-UP JOB

F1 F5F2 F3 F4

2. Press key F4 The SAVE JOB menu is displayed.

SAVE JOB

NUMBER OF ALREADY SAVED JOBS: JOB NO:

AFTERENTERING VALUE:

JOB

MEMORY

MAXIMUM:

0000

F1 F5F2 F3 F4

The display DATA INPUT only comes on when the job has been set up via the menu SPECIAL FOLDS. When setting up via STANDARD FOLDS or JOB SAVED, the display DATA INPUT does not come on - type of fold and format have already been

recognized. In these cases, continue with entering the job number (item 12).

Operator'sManual 2200 Series

3. Press key F3

DATA INPUT

AutomaticSetting

Main Menu SAVING

FOLD UNIT:

AFTER SELECTING FOLD:

FOLD UNIT FOLD

F1 F5F2 F3 F4

Since in our example a Z-fold was set up in the first fold unit, the cursor must be moved to the respective fold symbol.

4. Press key F3 until the respective fold symbol for the first fold unit (Z-fold) is marked by the cursor (dark rectangle).

DATA INPUT

FOLD UNIT:

AFTER SELECTING FOLD:

FOLD UNIT FOLD

F1 F5F2 F3 F4

5. Press key The fold symbol is saved.

DATA INPUT

The format length of a previous job is shown

FOLD UNIT:

in the display.

FORMAT-LENGTH(in):

AFTER ENTERING NUMBER:

5.5

FOLD UNIT FOLD

F1 F5F2 F3 F4

Operator'sManual 2200 Series

6. Enter the format length (420) The new format length is displayed.

DATA INPUT

AutomaticSetting

Main Menu SAVING

FOLD UNIT:

FORMAT-LENGTH(in):

AFTER ENTERING NUMBER:

FOLD UNIT FOLD

F1 F5F2 F3 F4

Enter the format length for job which has been set up (example: 420).

If a format is entered that cannot be handled by the machine because it is too small or too large, this is recognized by the computer and shown in the display.

7. Press key The second fold unit is called up.

DATA INPUT

FOLD UNIT:

AFTER SELECTING FOLD:

FOLD UNIT FOLD

F1 F5F2 F3 F4

Since a letter fold was set up in the second fold unit, the cursor must be moved to the respective fold symbol.

Operator'sManual 2200 Series

7. Press key F3 repeatedly until the respective fold symbol for the second

fold unit (letter fold) is marked by the cursor (dark rectangle).

DATA INPUT

AutomaticSetting

Main Menu SAVING

FOLD UNIT:

AFTER SELECTING FOLD:

FOLD UNIT FOLD

F1 F5F2 F3 F4

9. Press key The fold symbol is saved.

DATA INPUT

The format width of a previous job is shown in the display.

FOLD UNIT:

FORMATWIDTH(in):

AFTER ENTERING NUMBER:

5.5

FOLD UNIT FOLD

F1 F5F2 F3 F4

10. Enter the format width (297) The new format width is displayed.

DATA INPUT FOLD UNIT:

Enter the format width for the job which has

FORMATWIDTH(in):

been set up (example: 297).

AFTER ENTERING NUMBER:

FOLD UNIT FOLD

F1 F5F2 F3 F4

If a format is entered that cannot be handled by the machine because it is too small or too large, this is recognized by the computer and shown in the display.

Operator'sManual 2200 Series

11. Press key

SAVE JOB NUMBER OF ALREADY SAVED

AutomaticSetting

Main Menu SAVING

JOBS: JOB NO:

AFTER ENTERING NUMBER:

12. Enter the identification number (e.g. 9999)

SAVE JOB NUMBER OF ALREADY SAVED

JOBS: JOB NO:

AFTER ENTERING NUMBER:

13. Press key

SAVE JOB

MAXIMUM:

0000

MAXIMUM:

9999

If the selected memory space is already occupied, the display will ask whether it should be overwritten.

If the memory space is to be overwritten, proceed as follows:

14. Press key

NUMBER OF ALREADY SAVED JOBS: JOB NO:

OVERWRITE?

SAVE JOB NUMBER OF ALREADY SAVED

JOBS: JOB NO:

SAVING COMPLETED

MAXIMUM:

9999

15. Press key C Back to BASIC menu.

Operator'sManual 2200 Series

Display of the Actual Job - Main Menu JOB

1. Press key C The BASIC menu is displayed.

TOTAL: JOB NO:

00000000

AutomaticSetting

Main Menu JOB

0000

OUTPUT:

00000

REMAINDER:

MONITORING: DOUBLES:

TRANSPORT:

ON ON

0000

MONITORING SAVING

COUNTER SET-UP JOB

F1 F5F2 F3 F4

2. Press key F5 Display of the actual job.

ACTUAL JOB: FORMAT(in)LENGTH:WIDTH:

1111

17 11

FOLD IN FOLD UNIT:

In this menu only the format and type of fold of the actual job are displayed. Settings cannot be made at this point.

Operator'sManual 2200 Series

Correction of Fold Lengths - Menu FOLD LENGTH

1. Press key The FOLD LENGTH menu is displayed.

FOLDLENGTH(in)

AutomaticSetting

Menu FOLD LENGTH

FOLD UNIT:

ACT: 8.5 NOM:

CORRECT WITH +/-

UNIT PLATE - + SET-UP

F1 F5F2 F3 F4

In this menu, all necessary corrections of the fold lengths of a set-up job can be made.

Key F1 will switch from the first to the second fold unit and vice versa. Key F2 will display the fold lengths of all fold plates. Key F3 will reduce the fold length in steps of 0.25 mm. Key F4 will increase the fold length in steps of 0.25 mm. Key F5 is inactive, because every correction is immediately transferred to each stop.

Every change of 0.5 mm is displayed.

PLATE:

2. Press key C Back to BASIC menu.

Operator'sManual 2200 Series

Setting the Fold Rollers - Menu ROLLER GAP

AutomaticSetting

Menu Roller Gap

The fold rollers are set on the basis of information from the computer control. The correct gap is calculated taking into account the selected type of fold and the paper weight and is then shown on the display. This setting value must be transferred to the left and right setting knobs (1) associated with each fold roller.

Before setting the fold rollers the fold lengths in all fold plates must already be set.

1. Press key C The BASIC menu is displayed.

TOTAL: JOB NO:

00000000

OUTPUT:

00000

REMAINDER:

MONITORING:

DOUBLES: TRANSPORT:

0000

ON ON

0000

MONITORING SAVING

COUNTER SET-UP JOB

F1 F5F2 F3 F4

2. Press key F3 The SET-UP menu is displayed.

SET-UP

SELECT WITH FUNCTION KEYS

--------- FOLD -----------SPECIAL STANDARD

F1 F5F2

SUCTION LENGTH

JOB SAVED

ROLLER GAP

DELIVERY

Operator'sManual 2200 Series

3. Press key F4 The ROLLER GAP menu is displayed.

4. Press key

Menu ROLLER GAP

ROLLERGAP(in)

FOLD SET-UP DONE?

CONFIRM:

+ - AUTO+ LEARN

F1 F5F2 F3 F4

AutomaticSetting

ROLLERGAP(in)

FORMATLENGTH(in):

AFTERENTERING VALUE:

+ - AUTO+ LEARN

F1 F5F2 F3 F4

Operator'sManual 2200 Series

6. Press key

Menu ROLLER GAP

ROLLERGAP(in)

AutomaticSetting

7. Press key

PAPERTHICKNESS(in):

CONFIRM:

------------- SELECT ------------+ - AUTO+ LEARN

F1 F5F2 F3 F4

ROLLERGAP(in)

FOLD UNIT:

NOM:

MANUAL SETTING

------------- SELECT -------------

0.10

OR LEARN

ACT:

0.10

GAP:

0.10

1/1

+ - AUTO+ LEARN

F1 F5F2 F3 F4

The NOMinal value shown is the calculated value resulting from paper

thickness and fold type.

For correct setting of the fold rollers the ACT (Actual) value must be changed to the NOM (Nominal)

value. This is done by turning the setting knobs (1). All setting knobs have numbers so that the display message can be related to a specific fold roller.

The NOM and ACT values of the individual fold rollers can be displayed by pressing keys F1, F2 or F3.

Key F1 (+): Display of NOM and ACT value for the next roller

(for example, advance from roller 2 to 3)

Key F2 (-): Display of NOM and ACT value for the previous roller

(for example, return from roller 2 to 1)

Key F3 (AUTO+): Automatic advance of NOM and ACT to the fold roller,

for which NOM and ACT do not agree

Operator'sManual 2200 Series

Description of the display messages:

GAP 5/2

5 Roller 5

GAP1/1

1 Roller 1

2 Setting knob

on far side

1 Setting knob

on operator side

AutomaticSetting

Menu ROLLER GAP

8. Turn setting knob 1 (operator side) on the first fold unit until ACT shows the same value as NOM.

Repeat this procedure until all fold rollers are set.

9. Press key C Back to BASIC menu.

Operator'sManual 2200 Series

Menu ROLLER GAP

AutomaticSetting

Individual Corrections

When trial folds show that the setting of the fold rollers should be improved, an individual correction is possible.

1. Press key F8 Menu ROLLER GAP is displayed.

ROLLERGAP(in)

ACT:

GAP:

1/1

0.10

FOLD UNIT:

NOM:

MANUAL SETTING

------------- SELECT --------------+ - AUTO+ LEARN

F1 F5F2 F3 F4

2. Correct the roller gap by means of the setting screws

ROLLERGAP(in)

0.10

ACT:

GAP:

0.15

1/1

FOLD UNIT:

NOM:

MANUAL SETTING

-------------- SELECT -------------

+ - AUTO+ LEARN

F1 F5F2 F3 F4

This means that individual corrections are possible for all roller gaps. For repetitive jobs stored in the memory the corrected value will then be shown

as NOMINAL value.

3. Press key C Back to BASIC menu.

0.10

Operator'sManual 2200 Series

Setting the Delivery Rollers - Menu DELIVERY

1. Press key C The BASIC menu is displayed.

TOTAL: JOB NO:

00000000

AutomaticSetting

Menu DELIVERY

0000

OUTPUT:

00000

REMAINDER:

MONITORING:

DOUBLES: TRANSPORT:

ON ON

0000

MONITORING SAVING

COUNTER SET-UP JOB

F1 F5F2 F3 F4

2. Press key F3 The SET-UP menu is displayed.

SET-UP

SELECT WITH FUNCTION KEYS

———— FOLD ————

SPECIAL STANDARD

SUCTION LENGTH

JOB SAVED

ROLLER GAP

DELIVERY

F1 F5F2

3. Press key F5 The DELIVERY menu is displayed.

DELIVERY ROLLER POSITION (cm)

FOLD SET-UP DONE ?

CONFIRM:

Operator'sManual 2200 Series

4. Press key

DELIVERY ROLLER POSITION (cm)

AutomaticSetting

Menu DELIVERY

NOM:

MANUAL SETTING

5. Set the delivery rollers to the format by using the scale.

6. Press key C Back to BASIC menu.

Operator'sManual 2200 Series

Choosing the Measuring System and the Language

1. Press key F9 The following display appears:

SELECT WITH FUNCTION KEYS

AutomaticSetting

MEASURING UNIT (MM)

MILLIMETER (MM)

INCHES (IN)

LANGUAGE:

GERMAN ENGLISH SPANISH

F1 F5F2 F3

Use key F7 to switch from Inches to Metric. Use key F6 to switch from Metric to Inches.

Press keys F1, F3 or F5 to choose a language.

2. Press key C Back to BASIC menu.

Operator'sManual 2200 Series

Fold Plate Setting: Three Methods

Inthepreviouschapterswehavedescribedthedifferentmenusandtheirpossibilities. It is, however, up to you to choose the menu for setting up a fold job.

The diagram that you find below shows the three possible ways which all produce the same result.

SET-UP?

Menu BASIC

Menu SET-UP

AutomaticSetting

SPECIAL

FOLD

Enter all fold lengths via the keyboard

STANDARD

FOLD

Choose the type of fold

by symbols

JOB SAVED

Enter the job-no. and confirm

Format and fold are displayed

CONTENTS

Display of data for shingled delivery, speed and sheet gap

CONTENTS

Display of format and fold

Search the job in the

memory

FOLD

SET-UP

CF4

FOLD SET-UP

Operator'sManual 2200 Series

RollerGap:ThreeMethods

Calling up the data for the roller gap must always be done from the main

menuSET-UP. (F3)

SET-UP

SELECT WITH FUNCTION KEYS

AutomaticSetting

SUCTION LENGTH

JOB SAVED

———— FOLD ————

SPECIAL STANDARD

F1 F5F2

1. Calling up the menu ROLLER GAP by pressing key F4.

This should be done, when

- the set-up was made by entering the fold lengths (special fold)

- the set-up was triggered by marking the fold symbols (standard folds)

2. Calling up the menu JOB SAVED by pressing key F6.

This applies when

- the set-up is to be made by recalling a job from the memory

If a different paper is used for the job recalled from the memory, the data shown in the display cannot be used.

In this case the roller gap must be set via the menu ROLLER GAP.

ROLLER GAP

DELIVERY

3. Calling up the menu ROLLER GAP by pressing key F8.

ROLLERGAP(in)

FOLD UNIT:

NOM:

MANUAL SETTING

--------------- SELECT ------------+ - AUTO+ LEARN

F1 F5F2 F3 F4

In this menu, the roller gap setting can be corrected and displayed.

0.10

GAP:

ACT:

1/1

0.15

Operator'sManual 2200 Series

Different Possibilities for Displaying the Roller Gap:

Setting up the roller gap?

Menu BASIC

Menu SET-UP

ROLLER GAP

JOB SAVED

AutomaticSetting

Display of data for roller gap

NOM: ACT:

Set-up

Learn

Format length

Paper thickness

Display of data for roller gap

NOM: ACT:

Question:

Fold set-up

done?

yes

Question:

and width

Question:

learned?

yes

Enter job no. and confirm

Display of format and fold

Display of data for shingled delivery, speedandgap

Display of data for roller gap

NOM: ACT:

Find job

in memory

CONTENTS

Operator'sManual 2200 Series

Display of Malfunctions

AutomaticSetting

Display of Malfunctions

ERROR SHEET GAP WHEN FEEDING FROM FEEDER

INCREASE SHEET GAP OR IMPROVE SHEET TRANSPORT ON REGISTER TABLE

CONTINUE WITH KEY C

ERROR PHOTODETECTOR IN INFEED SECTION FOLD UNIT I IS COVERED

The machine is equipped with an operator-convenient malfunction detection system. If malfunctions occur, they are identified by different sensors and the machine is stopped. The display gives information on

Examples for the identification of malfunctions:

1. Location of malfunction

2. Cause of malfunction

3. Measures to clear the malfunction

ERROR SHEET TRANSPORT IN FOLD UNIT II

AT LEAST ONE SHEET WAS DELAYED

REMOVE CAUSE

CONTINUE WITH KEY C

ERROR DOUBLE SHEET

REMOVE CAUSE

CONTINUE WITH KEY C

STANDARD FOLDS

FOLD UNIT: WRONG ENTRY

MINIMUM: MAXIMUM:

ERROR FOLD UNIT 1 PAPER JAM DRIVE OR ENCODER

CHECK

REMOVE DOUBLE SHEET

CONTINUE WITH KEY C

Check whether a paper jam has occurred. If this is not the case, the malfunction may have been caused by an error in the drive or the encoder. If the motor starts briefly and the error display comes on again, the drive is working correctly. This means that the reason is a defect in the encoder. If the motor does not start at all, the drive is defective.

CONTINUE WITH KEY C

Call a service technician.

Operator'sManual 2200 Series

AutomaticSetting

Menu Service

Service Functions

The service menu can be called up by pressing key F12.

It is primarily used by the service technician.

1. Press key F12 The SERVICE menu is displayed.

SERVICE

SUM:

BASIC SETTING PAPER SENSOR:

CLEAR DATA

F1 F5F2 F3

0000001111

OPTIONAL EQUIPMENT:

SYSTEM CONFIG

PROG VERS

TEST

Data (F1) can only be erased by a service technician, this is why a special code

number is needed.

By pressing key F5, information about shingling, speed, gap, etc. can be shown in the

display.

Pressing key F4 will show the program version. By pressing key F3, a menu is called up where machine configurations can be

changed. This is necessary if, for instance, the folder is equipped with a different feeder or a second fold unit.

2. Press key F3

SERVICE

To prevent accidentally changing the machine

CODE:

0000

configuration, a code number must be entered here. This code number

AFTERENTERING VALUE:

is 4250.

3. Enter the code number 4250

SERVICE

CODE:

AFTERENTERING VALUE:

4250

Operator'sManual 2200 Series

4. Press key F5

4. Press key

The type of feeder can be chosen by pressing keys F 1 to F3.

5. Press key C Back to BAS IC menu.

CONFIGURATION

FEEDING:

FLAT PILE FEEDER

F P F P SF

F 1 F 5F 2 F 3 F 4

AutomaticSetting

MenuService

Operator'sManual 2200 Series

The service menu can also be used to check the basic setting of the paper thickness sensor.

1. Press key F12 The SERVICE menu is displayed.

2. Press key F6

BASIC SETTING

ZERO POINT PAPER SENSOR

AutomaticSetting

Menu Service

ZEROPOINT(in):

The zero point of the paper thickness sensor is adjusted by the service technician when first installing the machine. It is possible that the value changes slightly in the course of time, for example because the ambient temperature is not constant. This has no influence on the function.

If, however, values above +0.30 or below -0.09 are displayed, the sensor must be readjusted. The instructions are part of the machine documentation that can be found in the control box. This is indicated on the display when the double sheet detection is being activated.

3. Press key C Back to BASIC menu.

0.00

Operator'sManual 2200 Series

OperationandTrialFolds

16.OPERATIONANDTRIALFOLDS

After alladjustmentshavebeencompletedforaparticularjob,checktheresult

by making a few trial folds.

Exercise caution in the vicinity of rotating shafts and rollers! Hair,loosegarmentsandjewelerymaygetcaught!

SERIOUS INJURY MAY RESULT!

Exercise caution when running the machine with safety covers open and fold plates removed! Do not get close to the rotating fold rollers!

SERIOUS INJURY MAY RESULT!

When making or breaking any electrical connection, always first turn off the main switch or the safety switch on the folder. Non-compliance

may cause damage to electronic components!

Exercise caution at the delivery end of the fold unit! Do not get close to

the rotating delivery shafts! SERIOUS INJURY MAY RESULT!

The operating sequence is as follows:

Place paper on the feed table.

Press key C or switch on main switch.

Set the sheet gap in the delivery section to the medium position by turning this knob.

Set the folding speed to the medium position by turning this knob.

Set the sheet gap on the register table to the medium position by turning this knob.

Switch on the pump by touching this key.

Switch on the main motor by touching this key.

Activate sheet feed by touching this key:

Brief touch: Single sheet Touching key for approx. 2 sec.: Continuous feed

Operator'sManual 2200 Series

Switch off the machine in reverse order:

Sheet feed

Main motor

Pump

OperationandTrialFolds

Operator'sManual 2200 Series

FineAdjustmentsandCorrections

17.FINEADJUSTMENTSANDCORRECTIONS

Speed of the 2nd Fold Unit

slow

fast

Fold Lengths

Skewed Folds

Fold variations may occur if the fold plate stops are not set accurately or if the folding speed is changed. The fold is off across the entire width of the sheets.

Press key and make the fine adjustment via the menu FOLD LENGTH.

A change in the folding speed also changes the fold length. Therefore the set-up speed must be maintained.

Skewed (out-of-square) folds occur when the paper is not fed at right angles with respect to the fold rollers. This can be corrected as follows:

• Mark the leading edge of a sheet and feed it through the folder (1).

• To make the deviation more obvious, exaggerate the skewed fold by hand (2).

• Open the folded sheet and place it in front of the roller infeed section (3).

• By turning the adjustment wheel on the register table (4 theregisterrailmustbe adjusted in such a way that the leading edge of the paper is parallel to the fold rollers.

Operator'sManual 2200 Series

FineAdjustmentsandCorrections

Out-of-Square Paper

Shadow Fold

If the paper is not cut precisely at right angles, the folded sheet may show "points". By turning a setting knob, the fold plate stop can be made parallel to the out-of-square leading edge of the paper.

Make this correction only on the first fold plate.

It is possible to change the parallelism of the stop by turning the knurled knob (1).

• Loosen the knurled knob by means ofa4mm Allen key (2). The angle of the stop is changed by turning the

two knurled knobs. The stop is parallel to the fold rollers when the two half-round marks (3) face each other.

The lower lip can be adjusted by means of a setting knob (4)

Basic position: The wide groove is flush with the top

of the knob.

Accordion Fold

Lower lip advanced:

Small buckle space.

Lower lip set back:

Large buckle space.

• Thin paper grades: Advance the lower lip by turning the knob counterclockwise.

• Heavy paper grades: Set back the lower lip by turning the knob clockwise.

It is possible that heavy paper grades get stuck and form a so-called "accordion fold". In such a case the fold plates must be set back.

• Loosen the Allen screws (5) on both sides of the

fold plate.

• Set back the fold plate by using the scale (6).

• Tighten the Allen screws.

• Change the fold plate stop by the same amount.

Operator'sManual 2200 Series

FineAdjustmentsandCorrections

Creasing

When special types of paper are folded, deviations from the calculated and displayed NOMINAL values may become necessary. Individual corrections can be made by means of the numbered setting knobs at each roller. The fold rollers and delivery shafts with the matching setting knobs are arranged according to the following scheme:

1356

The layout sketch shows a fold unit with 4 fold plates.

The number on the setting knob corresponds with the fold plate bearing the same number.

Roller 1 is the feed roller Roller 2 makes the 1st fold Roller 3 makes the 2nd fold Roller 4 makes the 3rd fold Roller 5 makes the 4th fold Roller 6 is the delivery shaft

The setting knobs are equipped with scales (1). With their help settings with a precision of 0.01 mm are possible. An additional scale (2) indicates adjustments in steps of 0.5 mm. To increase the roller gap, turn the setting knob

counter-clockwise. To reduce the roller gap, turn the setting knob clockwise. When the roller gap is changed by more than 0.5 mm,

1,5

0,5

the values on both scales must be added. Example: 0,5 (2) + 16 (1) = 0,66 mm

Operator'sManual 2200 Series

FineAdjustmentsandCorrections

100

Formax 2200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Setting the Counter - Main Menu COUNTER

Paper Transport Control, Double Sheet Detection - Main Menu MONITORING

Setting the Fold Length - Main Menu SET-UP

Standard Folds

Special Folds

Job Saved

Setting of the Suction Length - Main Menu SET-UP

Saving of Job Data - Main Menu SAVING

Display of the Actual Job - Main Menu JOB

Correction of Fold Lengths - Menu FOLD LENGTH

Setting the Fold Rollers - Menu ROLLER GAP

Setting the Delivery Rollers - Menu DELIVERY

Choosing the Measuring System and the Language

Display of Malfunctions

Service Functions

OperationandTrialFolds

FineAdjustmentsandCorrections