Formax 3950 Series Operator's Manual

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Series

/2007

OPERATOR MANUAL

First Edition

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Operator's Manual

3950 Series

CONTENTS

1. GENERAL 5

2. SPECIFICATIONS 6

3. PROPER HANDLING OF THE MACHINE 7

4. SAFETY INSTRUCTIONS 9

5. SAFETY FEATURES 13

6. BASIC COMPONENTS OF THE MACHINE 14

7. SPACE REQUIREMENTS 15

8. OPERATING POSITIONS 15

9. ELECTRICAL CONNECTION 16

10. AIR FEEDER PBA 38 17

11. FLAT PILE FEEDER FSA 36 23

12. REGISTER TABLE 33

13. BUCKLE FOLD UNITS 35

14. ROLLER TABLE 37

15. DELIVERIES 39

Fanned Deliveries AM 52, AMS 52 39 Small Format Vertical Stacker SKM 36 40

16. AUTOMATIC SETTING 43 Operator Panel 43 Setting the Counter - Main Menu COUNTER 46

Clearing the Total Counter 46 Setting the Batch Counter 47 Set Kicker for Batch Counting 49

Paper Transport Control, Double Sheet Detection - Main Menu MONITORING 52

Paper Transport Control 52 Double Sheet Detection 53

Setting the Fold Length - Main Menu SET-UP 54

Standard Folds 54 Special Folds 61

Job Saved 72 Setting the Suction Length - Main Menu SET-UP 83 Saving of Job Data - Main Menu SAVING 86 Display of the Actual Job - Main Menu JOB 91 Correction of Fold Lengths - Menu FOLD LENGTH 92 Setting the Fold Rollers - Menu ROLLER GAP 93 Setting the Delivery Rollers - Menu DELIVERY 98 Choosing the Measuring System and the Language 100 Fold Plate Setting: Three Methods 101 Display of Malfunctions 104 Service Functions 105

17. OPERATION AND TRIAL FOLDS 109

18. FINE ADJUSTMENTS AND CORRECTIONS 111

19. PERFORATING-, SCORING- AND SLITTING TOOLS 115

20. POSSIBLE MALFUNCTIONS AND THEIR REMEDIES 121

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Operator's Manual

3950 S eries

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Operator's Manual

3950 Series

General

1. GENERAL

General Description

The machines of the 3950 Series folder line are professional buckle folders with an infeed width of up to 38 cm. They can be equipped with one or two fold units. The fold units may be used in-line or at right angles. There is a choice between suction- and flat pile feeders.

Folding Principle

The infeed rollers (1) and (2) transport the sheet to be folded into the fold plate (3). As soon as it comes up against the adjustable stop (4), the sheet forms a buckle (5) because the infeed rollers keep on moving. The loop gets bigger until the sheet is seized by rollers (2) and (6); this is where the actual fold occurs. The rollers draw the folded sheet from the fold plate and the infeed rollers and move it on.

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Operator's Manual

3950 series

General

2. SPECIFICATIONS

Paper size: Maximum Minimum

WxL WxL

Air feeder FD 3950: 38 x 65 cm 7* x 12 cm

*(less if paper is guided on one side only)

Flat pile feeder FD 3950 P 38 x 65 cm 10 x 12 cm

Fold length min.: 3.5 cm

1.8 cm with fold unit for small formats

Speed: 200 m/min

Paper weight: 40 - 250 GSM for single fold

Electrical: Voltage:3x400V/50Hz/N/PE or

3x208V/60Hz/PE Current consumption: max. 10A Power consumption:

- 1st fold unit with feeder: 0.9 kW

- 2nd fold unit with roller table: 0.9 kW

- Delivery: 0.1 kW

- Pump: 2 x 1.1 kW

Ambient conditions: Room temperature: 15 - 40°C

Air humidity: 50 - 90%

Weight (net): 1st fold unit with PBA 38, register table 270 kg

2nd fold unit, roller table 230 kg Delivery A 38 25 kg Delivery AM 52 60 kg Small format vertical stacker SKM 36 60 kg Pump 2 x 17 kg

Noise emission: Sound power level of the emission values

measured at specific sections of the machine (machines with flat pile feeder):

- Feeder section: 83 dB (AI)

- Delivery section: 85 dB (AI)

Measured according to DIN 45 635, part 27

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Operator's Manual 3950 Series General

3. PROPER HANDLING OF THE MACHINE

The machines of the 3950 Series folder line are built for folding paper. They may also be used for perforating, scoring, slitting, cutting and counting paper using the proper attachments. They are unsuitable for handling other materials such as foil, plastics and textiles. The manufacturer / distributor is not responsible for damages resulting from such 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.

Installation of the machine, i.e. assembling as well as electrical and pneumatic work should be carried out only by skilled personnel authorized by the manufacturer or his 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. The interval between inspections including safety-related functions depend on the machine usage. For regular one-shift-operation, one inspection per year is recommended.

The machine needs a flat surface for installation. The machine weight should be considered when choosing a location for the machine.

The levelling screws in the undercarriage of the machine can compensate for an uneven floor to a certain degree. To ensure stability during operation the machine should be secured by means of the levelling screws.

The line voltage must correspond to the voltages on the serial plate.

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.

The terms "right" and "left" in the following text always refer to the direction of paper travel. Therefore the left side is the operator side.

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Operator's Manual

3950 Series

General

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:

Top! - Transport in upright position only!

Protect from humidity!

Fragile! Handle with care!

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.

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.

4.2 Fundamental Safety Instructions

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.

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Operator's Manual 3950 Series General

Organizational Measures

The operator's manual must always be available near the machine. In addition to reading the operator's manual, observe and instruct the user in all other generally applicable legal and other mandatory regulations relevant to accident prevention and environmental protection. The operator's manual must be supplemented by instructions covering the duties involved in supervising and notifying special organizational features, such as job organization, working sequences or the personnel entrusted with the work. Personnel entrusted with work on the machine must have read the operator's manual and in particular the chapter on safety before beginning the work. Reading the instructions after work has begun is too late. This applies especially to persons working occasionally on the machine, e.g. during setting up or maintenance.

Check, at least from time to time, whether the personnel is carrying out the work in compliance with the operator's manual and paying attention to risks and safety factors. For reasons of safety, long hair must be tied back or otherwise secured, garments must be close-fitting and no jewelry - such as rings - may be worn. Injury may result from being caught on moving parts. Observe all safety instructions and warnings attached to the machine. See to it that safety instructions and warnings attached to the machine are always complete and perfectly legible. In the event of safety-relevant modifications or changes in the performance of the machine during operation, stop the machine immediately and report the malfunction to the competent person.

Never make any modifications, additions or conversions which might affect safety without the manufacturer's approval. Adhere to prescribed intervals or those specified in the operator's manual for routine checks and inspections.

Selection of Personnel, Basic Responsibilities

Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for operation, set-up, maintenance and repair. Work on the electrical system and equipment of the machine must be carried out only by a skilled electrician in accordance with electrical engineering rules and regulations.

Standard Operation

Avoid any operational mode that might be detrimental to safety. Take the necessary precautions to ensure that the machine is used only in a safe and reliable state. Operate the machine only if all protective and safety-oriented devices, such as removable safety devices, emergency stops, sound proofing elements, are in place and fully functional. In the event of malfunctions stop the machine immediately and prevent further use. Have any defects rectified immediately. Before starting up or setting the machine in motion, make sure that nobody is in danger.

Special Work, Maintenance, Repair

Observe the adjusting, maintenance and inspection activities and intervals set out in the operator's manual, including information on the replacement of parts and equipment. Pull the power plug for maintenance and repair work or before opening the control box. If the machine is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by attaching a warning sign to the main switch. Always tighten any screw connections that have been loosened during maintenance and repair.

Special Dangers

The electric equipment of machines is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

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Operator's Manual 3950 Series General

Product-Specific Safety Instructions

Exercise caution in the vicinity of the perforating- and slitting knives! They have sharp edges for proper function! SERIOUS INJURY MAY RESULT!

Exercise caution in the vicinity of rotating shafts and rollers! Hair, loose garments and jewellery may get caught! SERIOUS INJURY MAY RESULT!

4.3 Cleaning and Maintenance

Regular and proper cleaning contributes to a long life of the machine and a consistent quality. Therefore it is important to clean the machine in regular intervals and above all to remove paper dust. The interval between maintenance jobs depends on the workload. It is recommended to clean the machine once a week.

Before cleaning the machine always pull the power plug!

Exercise caution in the vicinity of the perforating- and slitting knives! They have sharp edges for proper function! SERIOUS INJURY MAY RESULT!

Use only the special cleaning fluid from Formax for cleaning the fold rollers.

Do not use any solvents such as Acetone or Toluol. They would damage the nonmetal parts of the rollers.

Remove paper- or print powder dust from all fixed and moveable parts of the machine.

Clean the photodetector with a brush.

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.

Clean the air filter of the compressor and the pump using brushes or air.

The maintenance-free flat belt drive needs no lubrication of any kind.

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Operator's Manual 3950 Series General

5. SAFETY FEATURES

The machines of the 3950 Series folder line are equipped with various safety features. They ensure the safety of the persons working with the machine.

The following safety features are found on these machines:

1 Fixed cover at the fold roller infeed section 2 Swing-up noise covers 3 Safety handwheels 4 Emergency stop buttons

THIASBÄUERLE

MATHIASBÄUERLE

Possible remaining risks are pointed out in the respective paragraphs of this manual.

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Operator's Manual 3950 Series General

6. BASIC COMPONENTS OF THE MACHINE

As a result of its modular design, the 3950 Series offers a wide range of applications and configurations to suit the requirements of the user.

The following components are available:

- FD 3950PF Flat pile feeder - FSA

- FD 3950 & FD 3950 EX Bottom feed, top loading air feeder - PBA

- 1st buckle fold unit (automatic setting) with register table (CAS 38)

- 2nd buckle fold unit (automatic setting) with roller table (CAS 38)

- 3rd buckle fold unit (manual setting) with roller table (38) - separate operator's manual

- Mobile knife fold unit MS 45 (manual setting) - separate operator's manual

- Fold unit for small formats KF 31 (manual setting)

- Fanned delivery AM 52

- Fanned delivery AMS 52

- Small format vertical stacker SKM 36

The model designations of the machines give an idea about the technical specifications at a glance.

Examples:

FD 3950

38 Infeed width 38 cm

4 1st buckle fold unit with 4 fold plates

2 2nd buckle fold unit with 2 fold plates

PBA Suction feeder PBA 38

FD 3950PF

38 Infeed width 38 cm

4 1st buckle fold unit with 4 fold plates

4 2nd buckle fold unit with 4 fold plates

FSA Flat pile feeder FSA 38

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Operator's Manual 3950 Series General

7. SPACE REQUIREMENTS

When choosing a location for the machine, please bear in mind that additional space for the operator, for service and for pallets is needed in the feedand delivery areas.

2700

800

1900

2500

FD 3950 FD 3950 / FD 3950R

8. OPERATING POSITIONS

There is no fixed operator position at the machines. The operator must move between the following positions:

1 Feeder section for loading the unfolded paper 2 Operator panel for set-up 3 Delivery section for removing the folded paper

In addition, the machines should be accessible from any other position for cleaning, resetting, jam clearance, service jobs, etc.

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Operator's Manual 3950 Series General

9. ELECTRICAL CONNECTION

Operator panel, fold units and delivery are interconnected with cables. Plugs and sockets allow variable connections.

Do not bend or twist the cables sharply or place heavy objects on them they may get damaged!

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!

At the rear of the base of each fold unit you will find the sockets for connecting the various fold units and accessories.

Buckle fold unit 1

1 Socket for the connection cable to the

operator panel

2 Receptacle 230V for accessories 3 Socket for the connection cable of the

second fold unit or the delivery

4 Safety switch 5 Connection cable of the pump 6 Connection cable of the pump 7 Power cord 400V

123 4

567

Buckle fold unit 2

8 Connection cable for connection to the

socket at the first fold unit

9 Socket for the connection cable of the

delivery

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.

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Operator's Manual 3950 Series

FD 3950

10. AIR FEEDER PBA 38

Principle of Operation

The air feeder PBA 38 consists of a feeder and a register table. 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.

Description

Components and operating elements of the air feeder PBA 38:

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 3950 Series FD 3950

Setting the Format

When setting the format, care should be taken that the sheets are fed

approximately from the center.

Ł Loosen the handles (1) by turning them

counter-clockwise.

Ł Set the left feed guide to half sheet width

with the help of the scales (2).

Ł Tighten the handles (1) again.

Ł Place a stack of about 50 sheets on the

feed table.

Ł 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.

Ł Tighten the handles (4) at the right feed guide.

Setting the Sheet Separation

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

Ł Loosen the lock screw (7).

Ł Turn the knob (8) until the figure "6" on a red

background appears in the window (9).

Ł Tighten the lock screw (7).

Now the suction segment is in its zero position (10).

If the width of the paper is less than 7 cm, only one paper guide can be used.

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Operator's Manual 3950 Series FD 3950

Most types of paper with a weight of 80 to 90 GSM can be separated in this position. For different paper grades, other figures must be set in the window:

- Paper grades below 80 GSM: 7 - 9

- Paper grades above 90 GSM: 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:

Ł Loosen the screw (4).

Ł Insert a screwdriver in the hole (5).

Ł Pull out the plate.

Ł Tighten the screw (4).

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Operator's Manual 3950 Series FD 3950

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, loose garments and jewellery may get caught! 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!

Ł Close the valve (2) for setting the minimum effect.

Ł Start the machine.

Ł 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.

Ł Switch off the machine.

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Operator's Manual

3950 Series FD 3950

Air

Ł Open the valves (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.

Ł Turn the handwheel until the openings of the suction drum (3)

are exactly above the openings of the suction segment (4).

Ł 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:

Ł Place a stack of about 50 sheets on the feed table.

Ł Start the machine.

Ł 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.

Exercise caution in the vicinity of rotating shafts and rollers! Hair, loose garments and jewellery may get caught! 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!

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Operator's Manual 3950 Series FD 3950

Sheet Gap

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 below 20 cm are to be folded, the sheet 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:

Adjustment of small formats below a length of 20 cm.

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.

Positioning the Paper Stack

Ł Fan the paper stack well to avoid double sheets.

Ł Place the stack on the feed table.

Ł Position the rear paper stop. It prevents the paper from sliding off the table.

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Operator's Manual 3950 Series FD 3950PF

11. FD 3950PF - FLAT PILE FEEDER FSA 38

Principle of Operation

The flat pile feeder FSA 38 with rear edge separator is suitable for separating different 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. Sheet separators lift the uppermost sheet by approx. 2 cm. 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.

Description

Components and operating elements of the flat pile feeder FSA 38:

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

3950 Series FD 3950PF

Setting the Format

Loading the Pile Table

Ł Tilt up the front stop (1).

Ł 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.

Ł Turn on the main switch at the folder.

Ł 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.

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.

567

Ł Tilt up the rear edge separator (10).

Ł 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

3950 Series FD 3950PF

Moving the Paper Stack to Work Position

When the pile table is loaded, the paper stack must be brought to the work position.

Ł 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.

Ł Set the gap to 8 mm by turning the setting screw (3).

A scale (4) facilitates this setting.

Ł Lower the front stop (5) and slide

it against the paper stack.

This tiltable stop can also be replaced by a stop rod (6). The stop rod is attached to the pile table with a lock screw (7). The tiltable stop (5) must then be moved up so that it does not interfere with the stop rod.

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

3950 Series FD 3950PF

Exchanging the Suction Drum

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:

Ł Pull off the cover (2).

Ł Loosen the screw (3) and remove the

suction drum.

Ł Install the PUR suction drum.

Ł Tighten the screw (3).

Ł Replace the cover (2).

Adjusting the Suction Segment

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.

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Operator's Manual

3950 Series FD 3950PF

Setting the Rear Edge Separator

Ł Lower the rear edge separator (1).

Ł Loosen the lock lever (2).

Ł 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).

Ł Tighten the separating head by turning the lock lever (2) clockwise.

Ł Slide the left and right hold-down rods (6)

towards the outer edge of the paper stack (approx. 1 cm inside the edge).

Ł Adjusting the pressure of the hold-down

rods: Heavy paper grades: Slide the weight (7) up. Light paper grades: Slide the weight down.

Ł 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

3950 Series FD 3950PF

Ł 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).

Adjusting the Stripper Springs

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.

If double sheets occur, the stripper fingers must be adjusted in such a way that they reach further into the stack.

Making the Sucker Cups Inoperative

For short formats it is often advantageous to work without rear edge separators. In this case the sucker cups can be made inoperative.

Ł Move the sucker cups to the top position (6).

Ł Push the lock lever (7) backwards. This will

lock the sucker cups in the top position.

Ł 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

3950 Series FD 3950PF

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.

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Operator's Manual

3950 Series FD 3950PF

Additional Blower

An additional single blower (1) (optional) 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.

Side Blowers

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.

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Operator's Manual

3950 Series FD 3950PF

Format setting:

Ł 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.

Ł Move the lateral cross-bar until the side stop

(4) touches the stack.

Ł Adjust the air nozzles in such a way that they

are approx. 1 to 2 cm away from the side resp. rear edge.

Ł Adjust the angle of the air flow by turning the

air nozzles so that about 10 sheets are separated.

1-2 cm

The amount of air can be fine-adjusted by means of valves (5).

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

3950 Series FD 3950PF

Side Stop, Righthand Side

A special side stop at the right-hand side is part of the "side blower" kit. This stop should be used when the paper tends to drift sideways.

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

3950 Series

12. REGISTER TABLE

Setting the Format Flat Pile Feeder

Make sure that the feeder is set to the correct format. Proceed as follows:

Ł Loosen the lock screw (1) of the register rail by

turning it counter-clockwise.

Ł Turn the handwheel (2) until the paper stop pin (3)

just touches the edge of the paper stack.

Ł Retighten the lock screw (1) by turning it clockwise.

Ł Set the rear paper support (11) to paper width,

using the scale and pointer.

Ł Distribute the hold-down bars (5) across the sheet

width. Place one hold-down bar in front of the suction drum (6).

Setting the Format Air Feeder PBA

Ł Loosen the lock screw (1) by turning it counter-clockwise.

Ł 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).

Ł Tighten the lock screw (1) by turning it clockwise.

Ł 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.

If the paper is less than 15 - 16 cm wide, the paper guide plate (4) must be removed.

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3950 Series RegisterTable

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:

Paper grades below 60 GSM: Plastic balls Paper grades from 60 - 150 GSM: Plastic balls, every 6th should be a steel ball Paper grades above 150 GSM: Mainly steel balls

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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Operator's Manual

3950 Series

Buckle Fold Units

13. BUCKLE FOLD UNITS

The buckle fold units have an infeed width of 38 cm and are equipped with 4 automatic fold plates AFT 38. The automation of these fold plates comprises the automatic positioning of the fold plate stops and the automatic closing of the deflectors. It is not necessary to remove the fold plates and to insert the deflectors when changing the fold.

Description

1 Noise covers 2 Fold roller adjustment knobs 3 Handwheel 4 Main switch 5 Operator panel 6 Transfer bridge 7 Roller table 8 Alignment rail 9 Fold rollers

10 Delivery shafts

MATHIASBÄUERLE

Fold Plate Positions

In the fold unit CAS 38/4 (1st or 2nd fold unit) there are four positions for the fold plates:

In the fold unit CAS 38/2 (2nd fold unit only) there are two positions for the fold plates:

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.

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Operator's Manual

3950 Series

Buckle Fold Units

Installing the Fold Plates

Connecting 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!

Setting Elements of the Fold Plates

Ł 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.

Ł 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, "+"

Ł 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

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.)

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Operator's Manual

3950 Series

Roller Table

14. ROLLER TABLE

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:

Ł Loosen the clamp screws (2) by turning

them counter-clockwise.

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

Ł Tighten the clamp screws by turning them clockwise.

Ł 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.

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

Ł Change the angle of the bridge.

Ł Tighten the Allen screws.

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

Ejector Rollers

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:

Ł Turn the handwheel until the set screws of the

ejector rollers are visible (7).

Ł Loosen the Allen screws with a 2-mm Allen key.

Ł Shift the ejector rollers to the required position.

Ł Tighten the Allen screws.

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Operator's Manual

3950 Series

Roller Table

Hold-Down Bars

Ball Cage

On the roller table, the sheets are transported to the next fold unit by means of rollers which are positioned at an angle with respect to the register rail. When changing the format, set the register rail as follows:

Ł Loosen the handle (1) by turning it counter-

clockwise.

Ł Set the register rail (2) according to paper size

with the help of the scale (3).

Ł Tighten the handle (1) by turning it clockwise.

The infeed angle can be adjusted at the knurled screw (4) with the appropriate locating screw (5) and scale (6).

Hold-down bars (7, 8) prevent the sheets from jumping up during transport across the roller table.

Ł Loosen the knurled screws (9).

Ł Move the outer hold-down bar (7) in such a way

that it is located over the outer edge of the sheet.

Ł Distribute the other hold-down bars over the

width of the sheet.

By loosening knurled screws (10) the hold-downs can be extended for additional guiding.

Load the ball cage (11) with plastic or steel balls. Type and number of balls depend on the format and type of paper.

A minimum number of balls should always be used. Balls not needed for a particular job should be removed to reduce belt wear.

It is recommended to use the following balls:

Paper grades below 60 GSM: Plastic balls Paper grades from 60 - 150 GSM: Plastic balls, every 6th should be a steel ball Paper grades above 150 GSM: Mainly steel balls

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Operator's Manual

3950 Series

Deliveries

15. DELIVERIES AM 52, AMS 52, SKM 36

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!

The fanned deliveries AM 52 and AMS 52 are mobile. Their height is adjustable by means of a gas-filled shock-absorber.

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

Fanned Deliveries AM 52, AMS 52

Setting the Transfer Height

Ł Loosen the lock screw (4) by

turning it counter-clockwise.

Ł Lift or lower the delivery table.

Ł Tighten the lock screw (4) by

turning it clockwise.

Setting the Format

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:

Ł 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). Choose less pressure for thin paper below 80 GSM and more pressure for paper above 180 GSM.

Electrical Connection

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

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Operator's Manual

3950 Series

Deliveries

Small Format Vertical Stacker SKM 36

The vertical stacker is mobile and height-adjustable by means of a gas-filled shock absorber. An additional control box (1) allows stopping and starting the machine (2) and paper feed (3) to facilitate setting the hold-down rollers.

Setting the Transfer Height

Ł Loosen the handle (4) by turning it counter-

clockwise.

Ł Lift or lower the delivery table.

Ł Tighten the handle by turning it clockwise.

Setting the Format

Support rails (5) and guide rails (6) are clamped to the cross rods by leaf springs. They are easily removable and can be moved to any position. Set for paper size as follows:

Ł Set the left and right guide rail (6) to paper

width.

Ł Move the support rails (5) accordingly.

Ł Loosen the left and right clamp screws (9) and

set the hold-down rail (7) to the height of the folded paper, using the scale (8). Retighten the clamp screws. Use screws (10) for fine tuning the hold-downs.

If the sheets are not guided properly by the transport belts after the setting, adjust them as follows:

Ł Loosen the Allen screws of the belt

rollers (11).

Ł Distribute the belt rollers across the

sheet width.

Ł Retighten the Allen screws.

Ł Set the idler rollers (12), belt tensioners

(13) and the lower belts (14) to paper size.

The upper and lower belts must run on top of each other.

Ł Position the back-up plate (15) in the

support rails.

The back-up plate must be adjusted according to the folded stock size.

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Operator's Manual

3950 Series

Deliveries

Setting the Paper Thickness

Use the setting wheels (1, 2) to set the gap between upper and lower belts to the thickness of the folded stock.

Positioning the Kicker

A kicker (3) can be added to the SKM 36. In order to use the kicker for counting batches, it must be set to paper size:

Ł Loosen the knurled screw (4).

Ł Move the kicker so it is positioned 5 mm

away from the passing paper.

Ł Retighten the knurled screw (4).

Ł Position the stop (5) on the opposite side taking into account paper width

and stroke of the kicker.

Ł Plug the cable from the kicker into the socket on the bottom of the stacker.

This will cause the kicker to be recognized.

The message KICKER appears in the display.

ON OFF

Move the setting wheels (1, 2) on either side by the same amount.

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!

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Operator's Manual

3950 Series

Automatic Setting

16. AUTOMATIC SETTING

Operator Panel

The machines of the 3950 Series are equipped with a central operator panel. It is here where the communication between operator and machine takes place 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.

Description

Setting elements and keys with the following functions:

456

0123

F1 F2 F3 F4 F5

F9 F10

F11 F12

Computer Automated System

555

12 3 4 5 6 7

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

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Operator's Manual

3950 Series

Automatic Setting

F1 F5F2 F3 F4

Description of the Display

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

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: Ł COUNTER Setting of total and batch counting Ł MONITORING Activation of double sheet detection and paper travel control Ł SET-UP Automatic setting of fold lengths / Input of setting infor-

mations

Ł SAVING Saving of repetitive jobs Ł 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.

TOTAL: JOB NO:

OUTPUT:

REMAINDER:

MONITORING: DOUBLES:

TRANSPORT:

OFF OFF

00000

0000

00000000

MONITORING SAVING

COUNTER SET-UP JOB

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Operator's Manual 3950 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.

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:

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.

JOB SAVED:

FORMAT (mm):

LENGTH: WIDTH:

FOLD IN FOLD UNIT:

9999

111 111

1: 2:

AFTER ENTERING NUMBER:

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

FOLD SET-UP

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Operator's Manual

3950 Series

Automatic Setting

Setting the Counter - Main Menu COUNTER

Main Menu COUNTER

1. Press key C The BASIC menu is displayed.

2. Press key F1 The COUNTER menu is displayed.

F1 F2 F3 F4

BATCH: INTERVAL: TOTAL:

0111

00000111

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

3. Press key F4 The total counter is cleared.

Clearing the Total Counter

F1 F5F2 F3 F4

TOTAL: JOB NO:

OUTPUT:

REMAINDER:

MONITORING: DOUBLES:

TRANSPORT:

OFF OFF

00000

0000

00000000

MONITORING SAVING

COUNTER SET-UP JOB

COUNTER

AFTER ENTERING NUMBER:

SELECT

CLEAR TOTAL

F1 F2 F3 F4

BATCH: INTERVAL: TOTAL:

0111

00000000

COUNTER

AFTER ENTERING NUMBER:

SELECT

CLEAR TOTAL

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Operator's Manual

3950 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:

Ł the desired number of sheet per batch (preselection)

Ł 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.

F1 F2 F3 F4

BATCH: INTERVAL: TOTAL:

0050

00000000

COUNTER

AFTER ENTERING NUMBER:

SELECT

CLEAR TOTAL

5. Press key The new batch is saved.

F1 F4F2 F3

BATCH: INTERVAL: TOTAL:

0050

00000000

COUNTER

AFTER ENTERING NUMBER:

SELECT

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

batch counting can be entered.

CLEAR TOTAL

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Operator's Manual

3950 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.

F1 F4F2 F3

BATCH: INTERVAL: TOTAL:

0050

00000000

COUNTER

AFTER ENTERING NUMBER:

SELECT

CLEAR TOTAL

7. Press key The new interval is saved.

F1 F2 F3 F4

BATCH: INTERVAL: TOTAL:

0050

00000000

COUNTER

AFTER ENTERING NUMBER:

SELECT

CLEAR TOTAL

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.

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Operator's Manual 3950 Series Automatic Setting

Main Menu COUNTER

Set Kicker for Batch Counting

The kicker serves to mark a preselected number of sheets (batch) by pushing the last sheet sideways, which makes it easy to distinguish between the individual batches.

1. Press key C The BASIC menu is displayed.

F1 F5F2 F3 F4

TOTAL: JOB NO:

OUTPUT:

REMAINDER:

MONITORING: DOUBLES:

TRANSPORT:

OFF OFF

00000

0000

00000000

MONITORING SAVING

COUNTER SET-UP JOB

2. Press key F1 The COUNTER menu is displayed.

F1 F2 F3 F4

BATCH: INTERVAL: TOTAL:

0111

00000111

COUNTER

AFTER ENTERING NUMBER:

SELECT

CLEAR TOTAL

KICKER

ON OFF

The kicker is used in conjunction with a small format vertical stacker SKM 36.

The plug of the kicker must be connected to the socket at the bottom of the vertical stacker for small formats.

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Operator's Manual 3950 Series Automatic Setting

Main Menu COUNTER

3. Press key F2 The kicker is switched on.

F1 F2 F3 F4

BATCH: KICKER ON TOTAL:

0111

00000000

COUNTER

AFTER ENTERING NUMBER:

SELECT

CLEAR TOTAL

KICKER

ON OFF

The display INTERVAL changes to KICKER ON.

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

Example: Batches of 50 sheets.

F1 F2 F3 F4

BATCH: KICKER ON TOTAL:

0050

00000000

COUNTER

AFTER ENTERING NUMBER:

SELECT

CLEAR TOTAL

KICKER

ON OFF

5. Press key The new batch is saved.

F1 F5F2 F3 F4

BATCH: KICKER ON TOTAL:

0050

00000000

COUNTER

SELECT

CLEAR TOTAL

KICKER

ON OFF

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Operator's Manual 3950 Series Automatic Setting

Main Menu COUNTER

6. Press key C Back to BASIC menu.

F1 F5F2 F3 F4

TOTAL: JOB NO:

OUTPUT:

REMAINDER:

MONITORING: DOUBLES:

TRANSPORT:

OFF OFF

00000

0000

00000000

MONITORING SAVING

COUNTER SET-UP JOB

KICKER ON

In Menu BASIC, the display KICKER ON below the JOB NO shows that the kicker

is active.

When working with a fanned delivery, the kicker cannot be used.

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Operator's Manual 3950 Series Automatic Setting

Main Menu MONITORING

1. Press key C The BASIC menu is displayed.

Paper Transport Control, Double Sheet Detection - Main Menu MONITORING

F1 F5F2 F3 F4

TOTAL: JOB NO:

OUTPUT:

REMAINDER:

MONITORING: DOUBLES:

TRANSPORT:

OFF OFF

00000

0000

00000000

MONITORING SAVING

COUNTER SET-UP JOB

2. Press key F2 The MONITORING menu is displayed.

F1 F5F2 F4

MONITORING

DOUBLES: OFF TRANSPORT: OFF

SWITCH ON / OFF

DOUBLES TRANSPORT

ON OFF ON OFF

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

Paper Transport Control

F1 F5F2 F4

MONITORING

DOUBLES: OFF TRANSPORT: ON

SWITCH ON / OFF

DOUBLES TRANSPORT

ON OFF ON OFF

Page 49

Operator's Manual 3950 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

DOUBLE SHEET DETECTION ON

PAPER THICKNESS (mm):

0.10

7. Switch off the main motor and the pump.

8. Press key C Back to BASIC menu.

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.

Page 50

Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Setting the Fold Length - Main Menu SET-UP

The automatic setting of the 3950 Series makes it possible that all stops driven 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 3x

Z-fold 4x

Letter fold

Double parallel fold

Open gate fold

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Operator's Manual 3950 Series Automatic Setting

F1 F5F2 F3 F4

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

one symbol to the other.

TOTAL: JOB NO:

OUTPUT:

REMAINDER:

MONITORING: DOUBLES:

TRANSPORT:

ON ON

00000

0000

00000000

MONITORING SAVING

COUNTER SET-UP JOB

Main Menu SET-UP

Standard Folds

1. Press key C The BASIC menu is displayed.

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

F1 F5F2

SET-UP

SELECT WITH FUNCTION KEYS

JOB SAVED

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

GAP

DELIVERY

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

F1 F5F3

STANDARD FOLDS

FOLD UNIT:

SPECIAL STANDARD

FOLD UNIT FOLD SET-UP

AFTER SELECTING FOLD:

SUCTION LENGTH

Page 52

Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Standard Folds

Setting

example: A DIN A3 (297 x 420 mm) sheet is to be folded as follows:

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.

F1 F5F3

STANDARD FOLDS

FOLD UNIT:

FOLD UNIT FOLD SET-UP

AFTER SELECTING FOLD:

5. Press key The selected fold is confirmed.

F1 F5F3

STANDARD FOLDS

FOLD UNIT:

FOLD UNIT FOLD SET-UP

AFTER ENTERING NUMBER:

FORMAT LENGTH (mm):

111

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

F1 F5F3

STANDARD FOLDS

FOLD UNIT:

FOLD UNIT FOLD SET-UP

AFTER ENTERING NUMBER:

FORMAT LENGTH (mm):

420

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

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.

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Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Standard Folds

7. Press key The new format length is saved.

F1 F5F3

STANDARD FOLDS

FOLD UNIT:

FOLD UNIT FOLD SET-UP

SET-UP OR CHOOSE FOLD UNIT

FORMAT LENGTH (mm):

420

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

F1 F5F3

STANDARD FOLDS

FOLD UNIT:

FOLD UNIT FOLD SET-UP

AFTER SELECTING FOLD:

Since, in our example, a letter fold is to be made in the second fold unit, the cursor must be shifted to the respective fold symbol.

F1 F5F3

STANDARD FOLDS

FOLD UNIT:

FOLD UNIT FOLD SET-UP

AFTER SELECTING FOLD:

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

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Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Standard Folds

10. Press key The new format length is saved.

F1 F5F3

STANDARD FOLDS

FOLD UNIT:

FOLD UNIT FOLD SET-UP

AFTER ENTERING NUMBER:

FORMAT WIDTH (mm):

111

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

11. Enter format width (297) The new format width is displayed.

F1 F5F3

STANDARD FOLDS

FOLD UNIT:

FOLD UNIT FOLD SET-UP

AFTER ENTERING NUMBER:

FORMAT WIDTH (mm):

297

12. Press key

F1 F5F3

STANDARD FOLDS

FOLD UNIT:

FOLD UNIT FOLD SET-UP

SET-UP OR CHOOSE FOLD UNIT

FORMAT WIDTH (mm):

297

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.

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Operator's Manual 3950 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.

F1 F5F3

STANDARD FOLDS

FOLD UNIT:

FOLD UNIT FOLD SET-UP

SETTING FOLD STYLE

FORMAT WIDTH (mm):

297

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).

Page 56

Operator's Manual 3950 Series Automatic Setting

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

Main Menu SET-UP

Standard Folds

MEASURE PAPER THICKNESS

DOUBLE SHEET DETECTION ON

PAPER THICKNESS (mm):

0.10

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

F1 F5F2

SET-UP

SELECT WITH FUNCTION KEYS

JOB SAVED

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

GAP

DELIVERY

SPECIAL STANDARD

16. Switch off main motor and pump.

17. Press key C Back to BASIC menu.

SUCTION LENGTH

Page 57

Operator's Manual 3950 Series Automatic Setting

F1 F5F2 F3 F4

TOTAL: JOB NO:

OUTPUT:

REMAINDER:

MONITORING:

DOUBLES: TRANSPORT:

ON ON

00000

0000

00000000

MONITORING SAVING

COUNTER SET-UP JOB

Main Menu SET-UP

Special Folds

1. Press key C The BASIC menu is displayed.

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

F1 F5F2

SET-UP

SELECT WITH FUNCTION KEYS

JOB SAVED

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

GAP

DELIVERY

SPECIAL STANDARD

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.

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.

SUCTION LENGTH

Page 58

Operator's Manual 3950 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.

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

ENTER NOMINAL VALUES

-PLATE:

ACT: NOM:

The display shows ACT (Actual) as the current fold length (e.g. 111.1)

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

Example: A sheet in format DIN A3 (297 x 420 mm) is to be folded.

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

This translates into the following fold plate settings:

1st fold unit Fold plate 1: 140 mm (Z-fold) Fold plate 2: 141 mm

Fold plate 3: 0 mm Fold plate 4: 0 mm

2nd fold unit Fold plate 1: 198 mm (Letter fold) Fold plate 2: 99 mm

Fold plate 3: 0 mm Fold plate 4: 0 mm

111.1

140

141

420

198 297

4. Enter the fold length for the first fold unit, first fold plate Example: 140

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

AFTER ENTERING NUMBER:

-PLATE:

ACT: NOM:

111.1

140

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Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Special Folds

5. Press key The fold length is saved.

6. Press key F2 Fold plate 1 is called up.

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm) FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

ENTER NOMINAL VALUES

-PLATE:

ACT: NOM:

111.1 140

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

ENTER NOMINAL VALUES

-PLATE:

ACT: NOM:

111.1

7. Enter fold length for the first fold unit, second fold plate Example: 141

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

AFTER ENTERING NUMBER:

-PLATE:

ACT: NOM:

111.1 141

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Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Special Folds

8. Press key The fold length is saved.

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

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

ENTER NOMINAL VALUES

-PLATE:

ACT: NOM:

111.1

141

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

ENTER NOMINAL VALUES

-PLATE:

ACT: NOM:

111.1

10. Enter fold length for the first fold unit, third fold plate Example: 0

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

AFTER ENTERING NUMBER:

PLATE:

ACT: NOM:

111.1

000

Page 61

Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Special Folds

11. Press key The fold length is saved.

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

ENTER NOMINAL VALUES

PLATE:

ACT: NOM:

111.1

000

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

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm) FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

ENTER NOMINAL VALUES

-PLATE:

ACT: NOM:

111.1

13. Enter fold length for the first fold unit, fourth fold plate Example: 0

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

-PLATE:

ACT: NOM:

111.1

000

AFTER ENTERING NUMBER:

Page 62

Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Special Folds

14. Press key The fold length is saved.

15. Press key F1 The second fold unit is displayed.

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

ENTER NOMINAL VALUES

-PLATE:

ACT: NOM:

111.1

000

16. Enter fold length for the second fold unit, first fold plate Example: 198

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

AFTER ENTERING NUMBER:

-PLATE:

ACT: NOM:

111.1

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

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

AFTER ENTERING NUMBER:

-PLATE:

ACT: NOM:

111.1

198

Page 63

Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Special Folds

17. Press key The fold length is saved.

18. Press key F2 Fold plate 2 is called up.

F5F2 F3 F4

SET-UP SPECIAL FOLD (mm) FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

ENTER NOMINAL VALUES

-PLATE:

ACT: NOM:

111.1

198

F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

ENTER NOMINAL VALUES

-PLATE:

ACT: NOM:

111.1

19. Enter fold length for second fold unit, second fold plate Example: 99

F5F2 F3 F4

SET-UP SPECIAL FOLD (mm) FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

AFTER ENTERING NUMBER:

PLATE:

ACT: NOM:

111.1

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Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Special Folds

20. Press key The fold length is saved.

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

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm) FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

ENTER NOMINAL VALUES

-PLATE:

ACT: NOM:

111.1

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

ENTER NOMINAL VALUES

-PLATE:

ACT: NOM:

111.1

22. Enter fold length for second fold unit, third fold plate Example: 0

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

AFTER ENTERING NUMBER:

PLATE:

ACT: NOM:

111.1

000

Page 65

Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Special Folds

23. Press key The fold length is saved.

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

F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

ENTER NOMINAL VALUES

-PLATE:

ACT: NOM:

111.1

000

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm) FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

ENTER NOMINAL VALUES

-PLATE:

ACT: NOM:

111.1

25. Enter fold length for the second fold unit, fourth fold plate Example: 0

F5F2 F3 F4

SET-UP SPECIAL FOLD (mm) FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

AFTER ENTERING NUMBER:

-PLATE:

ACT: NOM:

111.1 000

Page 66

Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Special Folds

26. Press key The fold length is saved.

F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

ENTER NOMINAL VALUES

PLATE:

ACT: NOM:

111.1

000

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

27. Press key F5

F1 F5F2 F3 F4

SET-UP SPECIAL FOLD (mm)

FOLD UNIT:

FOLD UNIT

PLATE - + SET-UP

SETTING FOLD STYLE

PLATE:

ACT: NOM:

111.1

000

The display SETTING FOLD STYLE is flashing until the setting is

completed. Then the following display appears:

START TWO SHEETS

MEASURE PAPER THICKNESS

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

Page 67

Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Special Folds

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.

DOUBLE SHEET DETECTION ON

MEASURE PAPER THICKNESS

PAPER THICKNESS (mm):

0.10

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

F1 F5F2

SET-UP

SELECT WITH FUNCTION KEYS

JOB SAVED

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

GAP

DELIVERY

SPECIAL STANDARD

30. Switch off the main motor and the pump.

31. Press key C Back to BASIC menu.

SUCTION LENGTH

Page 68

Operator's Manual 3950 Series Automatic Setting

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.

F1 F5F2 F3 F4

TOTAL: JOB NO:

OUTPUT:

REMAINDER:

MONITORING: DOUBLES:

TRANSPORT:

ON ON

00000

0000

00000000

MONITORING SAVING

COUNTER SET-UP JOB

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.

F1 F5F2

SET-UP

SELECT WITH FUNCTION KEYS

JOB SAVED

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

GAP

DELIVERY

SPECIAL STANDARD

SUCTION LENGTH

Page 69

Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Job Saved

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

F1 F5F2 F3 F4

JOB SAVED:

FORMAT (mm): LENGTH: WIDTH:

111

1111

111

FOLD IN FOLD UNIT

1: 2:

AFTER ENTERING NUMBER:

JOB CONTENTS

------------ SELECT ------------------- FOLD SET-UP

The display shows the number of the job which was last saved or recalled from the memory. If another job is to be set up, enter the number under which it is saved.

Example: A crossfold DIN A3 (297 x 420 mm) was saved under job number 9999.

This fold is to be set up again.

4. Enter the job number Example: 9999

F1 F5F2 F3 F4

JOB SAVED:

FORMAT (mm): LENGTH: WIDTH:

111

9999

111

FOLD IN FOLD UNIT

1: 2:

AFTER ENTERING NUMBER:

JOB CONTENTS

--------------- SELECT ---------------- FOLD

SET-UP

The length and width still refer to the previous job.

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Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Job Saved

5. Press key The format and fold are displayed.

F1 F5F2 F3 F4

JOB SAVED:

FORMAT (mm): LENGTH: WIDTH:

420

9999

297

FOLD IN FOLD UNIT

1: 2:

JOB CONTENTS

------------- SELECT ------------------ FOLD SET-UP

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

Ł Fold lengths only continue with key F4

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

different paper weight.

Ł 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.

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.

F1 F5F2 F3 F4

JOB SAVED:

9999

DELIVERY SPEED SHEET GAP

07 08 06

MANUAL SETTING

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

786

Delivery Speed Sheet gap

JOB CONTENTS

----------------- SELECT ------------- FOLD SET-UP

Page 71

Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Job Saved

8. Press key F3 Display ROLLER GAP.

F1 F5F2 F3 F4

JOB SAVED:

ROLLER GAP (mm)

1/1

MANUAL SETTING

+ - CONTENTS AUTO+

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

FOLD UNIT: GAP:

0.10

0.00

NOM:

ACT:

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.

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 NOM and ACT value 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

Page 72

Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Job Saved

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

F1 F5F2 F3 F4

JOB SAVED:

ROLLER GAP (mm)

1/1

MANUAL SETTING =

+ - CONTENTS AUTO+

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

FOLD UNIT: GAP:

0.10

NOM:

ACT:

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

F1 F5F2 F3 F4

JOB SAVED:

FORMAT (mm): LENGTH: WIDTH:

420 297

9999

FOLD IN FOLD UNIT

1: 2:

JOB CONTENTS

-------------- SELECT --------------- FOLD SET-UP

AFTER ENTERING NUMBER:

Page 73

Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Job Saved

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

F1 F5F2 F3 F4

JOB SAVED:

FORMAT (mm): LENGTH: WIDTH:

420 297

9999

FOLD IN FOLD UNIT

1: 2:

JOB CONTENTS

-------------- SELECT ---------------- FOLD SET-UP

SETTING FOLD STYLE

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

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

F1 F5F2

SET-UP

SELECT WITH FUNCTION KEYS

JOB SAVED

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

GAP

DELIVERY

SPECIAL STANDARD

SUCTION LENGTH

12. Press key C Back to BASIC menu.

Page 74

Operator's Manual 3950 Series Automatic Setting

Displaying the Contents of Memory

Main Menu SET-UP

Job Saved

1. Press key C The BASIC menu is displayed.

F1 F5F2 F3 F4

TOTAL: JOB NO:

OUTPUT:

REMAINDER:

MONITORING:

DOUBLES: TRANSPORT:

ON ON

00000

0000

00000000

MONITORING SAVING

COUNTER SET-UP JOB

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.

F1 F5F2

SET-UP

SELECT WITH FUNCTION KEYS

JOB SAVED

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

GAP

DELIVERY

SPECIAL STANDARD

SUCTION LENGTH

Page 75

Operator's Manual 3950 Series Automatic Setting

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

F1 F5F2 F3 F4

JOB SAVED:

FORMAT (mm): LENGTH: WIDTH:

111 111

1111

FOLD IN FOLD UNIT

1: 2:

AFTER ENTERING NUMBER:

JOB CONTENTS

------------- SELECT ----------------- FOLD SET-UP

4. Press key F1

By pressing key F1 (JOB) several times,

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

F1 F5F2 F3 F4

JOB SAVED:

FORMAT (mm): LENGTH: WIDTH:

333 333

3333

FOLD IN FOLD UNIT

1: 2:

AFTER ENTERING NUMBER:

JOB CONTENTS

-------------- SELECT ----------------- FOLD SET-UP

5. Enter the identification number Example: 9999

F1 F5F2 F3 F4

JOB SAVED:

FORMAT (mm): LENGTH: WIDTH:

111 111

9999

FOLD IN FOLD UNIT

1: 2:

AFTER ENTERING NUMBER:

JOB CONTENTS

-------------- SELECT ---------------- FOLD SET-UP

The length and width still refer to the previous job.

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

Main Menu SET-UP

Job Saved

Page 76

Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Job Saved

6. Press key

F5F2 F3 F4

JOB SAVED:

FORMAT (mm): LENGTH: WIDTH:

420 297

9999

FOLD IN FOLD UNIT

1: 2:

JOB CONTENTS

------------- SELECT ------------------ FOLD SET-UP

7. Press key F3 The CONTENTS menu is displayed.

F1 F5F2 F3 F4

JOB SAVED:

DELIVERY SPEED SHEET GAP

07 08 06

9999

JOB CONTENTS

---------------- SELECT -------------- FOLD

SET-UP

MANUAL SETTING

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

786

Delivery Speed Sheet gap

Page 77

Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Job Saved

9. Press key F3

F1 F5F2 F3 F4

JOB SAVED:

ROLLER GAP (mm)

1/1

MANUAL SETTING

+ - CONTENTS AUTO+

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

FOLD UNIT: GAP:

0.10

0.00

NOM:

ACT:

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

F1 F5F2 F3 F4

JOB SAVED:

FORMAT (mm): LENGTH: WIDTH:

420 297

9999

FOLD IN FOLD UNIT

1: 2:

JOB CONTENTS

------------ SELECT ------------------ FOLD SET-UP

AFTER ENTERING NUMBER:

Page 78

Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Job Saved

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

F1 F5F2 F3 F4

JOB SAVED:

FORMAT (mm): LENGTH: WIDTH:

420 297

9999

FOLD IN FOLD UNIT

1: 2:

JOB CONTENTS

------------- SELECT ----------------- FOLD SET-UP

SETTING FOLD STYLE

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

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

F1 F5F2

SET-UP

SELECT WITH FUNCTION KEYS

JOB SAVED

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

GAP

DELIVERY

SPECIAL STANDARD

SUCTION LENGTH

12. Press key C Back to BASIC menu.

Page 79

Operator's Manual 3950 Series Automatic Setting

Main Menu SET-UP

Suction Length

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.

F1 F5F2 F3 F4

TOTAL: JOB NO:

OUTPUT:

REMAINDER:

MONITORING:

DOUBLES: TRANSPORT:

ON ON

00000

0000

00000000

MONITORING SAVING

COUNTER SET-UP JOB

Page 80

Operator's Manual 3950 Series Automatic Setting

F1 F5F2

SET-UP

SELECT WITH FUNCTION KEYS

JOB SAVED

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

ROLLER GAP

DELIVERY

SPECIAL STANDARD

SUCTION LENGTH

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

Main Menu SET-UP

Suction Length

3. Press key F7 The suction length is displayed.

FEEDER

SUCTION LENGTH (mm):

150

AFTER ENTERING NUMBER:

4. Enter suction length (90) The new suction length is displayed.

FEEDER

SUCTION LENGTH (mm):

090

AFTER ENTERING NUMBER:

Page 81

Operator's Manual 3950 Series Automatic Setting

5. Press key

Main Menu SET-UP

Suction Length

F1 F5F2

SET-UP

SELECT WITH FUNCTION KEYS

JOB SAVED

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

ROLLER GAP

DELIVERY

SPECIAL STANDARD

SUCTION LENGTH

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.

Page 82

Operator's Manual 3950 Series Automatic Setting

Main Menu SAVING

1. Press key C The BASIC menu is displayed.

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

F1 F5F2 F3 F4

TOTAL: JOB NO:

OUTPUT:

REMAINDER:

MONITORING:

DOUBLES: TRANSPORT:

ON ON

00000

0000

00000000

MONITORING SAVING

COUNTER SET-UP JOB

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

F1 F5F2 F3 F4

SAVE JOB NUMBER OF ALREADY SAVED

JOBS:

MAXIMUM:

JOB NO:

0000

AFTER ENTERING NUMBER:

DATA INPUT

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).

Page 83

Operator's Manual 3950 Series Automatic Setting

3. Press key F3

Main Menu SAVING

F1 F5F2 F3 F4

FOLD UNIT FOLD

DATA INPUT

FOLD UNIT:

AFTER SELECTING FOLD:

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).

F1 F5F2 F3 F4

FOLD UNIT FOLD

DATA INPUT

FOLD UNIT:

AFTER SELECTING FOLD:

5. Press key The fold symbol is saved.

F1 F5F2 F3 F4

FOLD UNIT FOLD

DATA INPUT

FOLD UNIT:

AFTER ENTERING NUMBER:

111

FORMAT-LENGTH (mm):

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

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Operator's Manual 3950 Series Automatic Setting

Main Menu SAVING

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

F1 F5F2 F3 F4

FOLD UNIT FOLD

DATA INPUT

FOLD UNIT:

AFTER ENTERING NUMBER:

420

FORMAT-LENGTH (mm):

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.

F1 F5F2 F3 F4

FOLD UNIT FOLD

DATA INPUT

FOLD UNIT:

AFTER SELECTING FOLD:

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

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Main Menu SAVING

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

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

F1 F5F2 F3 F4

FOLD UNIT FOLD

DATA INPUT

FOLD UNIT:

AFTER SELECTING FOLD:

9. Press key The fold symbol is saved.

F1 F5F2 F3 F4

FOLD UNIT FOLD

DATA INPUT

FOLD UNIT:

AFTER ENTERING NUMBER:

111

FORMAT WIDTH (mm):

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

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

F1 F5F2 F3 F4

FOLD UNIT FOLD

DATA INPUT

FOLD UNIT:

AFTER ENTERING NUMBER:

297

FORMAT WIDTH (mm):

Enter the format width for the job which has been set up (example: 297).

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.

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Main Menu SAVING

11. Press key

SAVE JOB NUMBER OF ALREADY SAVED

JOBS:

MAXIMUM:

JOB NO:

0000

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

SAVE JOB NUMBER OF ALREADY SAVED

JOBS:

MAXIMUM:

JOB NO:

9999

OVERWRITE?

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

13. Press key

SAVE JOB NUMBER OF ALREADY SAVED

JOBS:

MAXIMUM:

JOB NO:

9999

SAVING COMPLETED

15. Press key C Back to BASIC menu.

AFTER ENTERING NUMBER:

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

SAVE JOB NUMBER OF ALREADY SAVED

JOBS:

MAXIMUM:

JOB NO:

9999

AFTER ENTERING NUMBER:

14. Press key

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Operator's Manual 3950 Series Automatic Setting

Main Menu JOB

Display of the Actual Job - Main Menu JOB

1. Press key C The BASIC menu is displayed.

F1 F5F2 F3 F4

TOTAL: JOB NO:

OUTPUT:

REMAINDER:

MONITORING:

DOUBLES: TRANSPORT:

ON ON

00000

0000

00000000

MONITORING SAVING

COUNTER SET-UP JOB

2. Press key F5 Display of the actual job.

ACTUAL JOB:

FORMAT (mm) LENGTH: WIDTH:

FOLD IN FOLD UNIT:

1111

420 297

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

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Operator's Manual 3950 Series Automatic Setting

Correction of Fold Lengths - Menu FOLD LENGTH

Menu FOLD LENGTH

1. Press key The FOLD LENGTH menu is displayed.

F1 F5F2 F3 F4

FOLD LENGTH (mm)

FOLD UNIT:

PLATE:

ACT:

207.0

NOM:

CORRECT WITH +/-

UNIT PLATE - + SET-UP

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.

2. Press key C Back to BASIC menu.

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Operator's Manual 3950 Series Automatic Setting

Setting the Fold Rollers - Menu ROLLER GAP

Menu Roller Gap

1. Press key C The BASIC menu is displayed.

F1 F5F2 F3 F4

TOTAL: JOB NO:

OUTPUT:

REMAINDER:

MONITORING:

DOUBLES: TRANSPORT:

ON ON

00000

0000

00000000

MONITORING SAVING

COUNTER SET-UP JOB

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.

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

F1 F5F2

SET-UP

SELECT WITH FUNCTION KEYS

JOB SAVED

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

ROLLER GAP

DELIVERY

SPECIAL STANDARD

SUCTION LENGTH

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Operator's Manual 3950 Series Automatic Setting

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Operator's Manual 3950 Series Automatic Setting

Setting the Fold Rollers - Menu ROLLER GAP

Menu Roller Gap

1. Press key C The BASIC menu is displayed.

F1 F5F2 F3 F4

TOTAL: JOB NO:

OUTPUT:

REMAINDER:

MONITORING:

DOUBLES: TRANSPORT:

ON ON

00000

0000

00000000

MONITORING SAVING

COUNTER SET-UP JOB

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

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

F1 F5F2

SET-UP

SELECT WITH FUNCTION KEYS

JOB SAVED

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

ROLLER GAP

DELIVERY

SPECIAL STANDARD

SUCTION LENGTH

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Operator's Manual 3950 Series Automatic Setting

Menu ROLLER GAP

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

F1 F5F2 F3 F4

ROLLER GAP (mm)

FOLD SET-UP DONE?

+ - AUTO+ LEARN

CONFIRM:

4. Press key

F1 F5F2 F3 F4

ROLLER GAP (mm)

FORMAT LENGTH (mm):

+ - AUTO+ LEARN

AFTER ENTERING NUMBER:

420

5. Press key

F1 F5F2 F3 F4

ROLLER GAP (mm)

FORMAT WIDTH (mm):

+ - AUTO+ LEARN

AFTER ENTERING NUMBER:

297

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Operator's Manual 3950 Series Automatic Setting

Setting the Fold Rollers - Menu ROLLER GAP

Menu Roller Gap

1. Press key C The BASIC menu is displayed.

F1 F5F2 F3 F4

TOTAL: JOB NO:

OUTPUT:

REMAINDER:

MONITORING:

DOUBLES: TRANSPORT:

ON ON

00000

0000

00000000

MONITORING SAVING

COUNTER SET-UP JOB

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

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

F1 F5F2

SET-UP

SELECT WITH FUNCTION KEYS

JOB SAVED

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

ROLLER GAP

DELIVERY

SPECIAL STANDARD

SUCTION LENGTH

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Operator's Manual 3950 Series Automatic Setting

Menu ROLLER GAP

Description of the display messages:

GAP 5/2

5 Roller 5

2 Setting knob

on far side

GAP1/1

1 Roller 1

1 Setting knob

on operator side

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.

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Operator's Manual 3950 Series Automatic Setting

Menu ROLLER GAP

Individual Corrections

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

F1 F5F2 F3 F4

FOLD UNIT:

GAP:

1/1

NOM:

0.10

MANUAL SETTING

ROLLER GAP (mm)

+ - AUTO+ LEARN

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

1. Press key F8 Menu ROLLER GAP is displayed.

ACT:

0.10

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

F1 F5F2 F3 F4

FOLD UNIT:

GAP:

1/1

NOM:

0.10

MANUAL SETTING

ROLLER GAP (mm)

+ - AUTO+ LEARN

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

ACT:

0.15

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.

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Operator's Manual 3950 Series Automatic Setting

Menu DELIVERY

Setting the Delivery Rollers - Menu DELIVERY

1. Press key C The BASIC menu is displayed.

F1 F5F2 F3 F4

TOTAL: JOB NO:

OUTPUT:

REMAINDER:

MONITORING:

DOUBLES: TRANSPORT:

ON ON

00000

0000

00000000

MONITORING SAVING

COUNTER SET-UP JOB

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

F1 F5F2

SET-UP

SELECT WITH FUNCTION KEYS

JOB SAVED

———— FOLD ————

ROLLER GAP

DELIVERY

SPECIAL STANDARD

3. Press key F5 The DELIVERY menu is displayed.

DELIVERY ROLLER POSITION (cm)

FOLD SET-UP DONE ?

CONFIRM:

SUCTION LENGTH

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Operator's Manual 3950 Series Automatic Setting

101

Fold Plate Setting: Three Methods

In the previous chapters we have described the different menus and their possibilities. 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

SPECIAL FOLD

STANDARD FOLD

Choose the type of fold by symbols

CONTENTS

SET-UP SET-UP

FOLD SET-UP

Display of data for shingled delivery, speed and sheet gap

Display of format and fold

Search the job in the memory

JOB SAVED

Enter all fold lengths via the keyboard

Enter the job-no. and confirm

Format and fold are displayed

F4F4

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Operator's Manual 3950 Series Automatic Setting

102

Roller Gap: Three Methods

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

menu SET-UP.

F1 F5F2

SET-UP

SELECT WITH FUNCTION KEYS

JOB SAVED

———— FOLD ————

ROLLER GAP

DELIVERY

SPECIAL STANDARD

SUCTION LENGTH

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

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

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.

F1 F5F2 F3 F4

FOLD UNIT:

GAP:

1/1

NOM:

0.10

MANUAL SETTING

ROLLER GAP (mm)

+ - AUTO+ LEARN

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

ACT:

0.15

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

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Operator's Manual 3950 Series Automatic Setting

103

Different Possibilities for Displaying the Roller Gap:

Setting up the roller gap?

Menu BASIC

Menu SET-UP

ROLLER GAP

Find job in memory

Set-up

Learn

JOB SAVED

Question:

Fold set-up

done?

Paper thickness

learned?

Format length

and width

yes

Enter job no. and confirm

Display of format and fold

yes

CONTENTS

Display of data for shingled delivery, speed and sheet gap

Display of data for roller gap

NOM: ACT:

Display of data for roller gap

NOM: ACT:

Display of data for roller gap

NOM: ACT:

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Operator's Manual 3950 Series Automatic Setting

104

Display of Malfunctions

ERROR SHEET GAP WHEN FEEDING FROM FEEDER

Display of Malfunctions

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

1. Location of malfunction

2. Cause of malfunction

3. Measures to clear the malfunction

Examples for the identification of malfunctions:

INCREASE SHEET GAP OR IMPROVE SHEET TRANSPORT ON REGISTER TABLE

CONTINUE WITH KEY C

REMOVE CAUSE

CONTINUE WITH KEY C

ERROR SHEET TRANSPORT IN FOLD UNIT II

AT LEAST ONE SHEET WAS DELAYED

REMOVE CAUSE

CONTINUE WITH KEY C

ERROR PHOTODETECTOR IN INFEED SECTION FOLD UNIT I IS COVERED

REMOVE DOUBLE SHEET

CONTINUE WITH KEY C

ERROR DOUBLE SHEET

STANDARD FOLDS

FOLD UNIT:

WRONG ENTRY MINIMUM: MAXIMUM:

CHECK

ERROR FOLD UNIT 1 PAPER JAM DRIVE OR ENCODER

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.

Call a service technician.

CONTINUE WITH KEY C