Horizon AFC-566F User Manual

Page 1

CROSS FOLDERCROSS FOLDER

AFC-566F

*UM203051*

Important Information

• This manual is designed to help you to install, operate and maintain the AFC566F Cross Folder. Please read and understand this manual, and keep it in a safe and convenient place.

• Do not operate the AFC-566F until you read and understand the instructions in this manual.

• Horizon International Inc. shall not be liable for incidental consequential damages resulting from: improper or inadequate maintenance by th e customer, unauthorized modification or misuse, or operation outside of the env ironmen tal specifications for the product.

• Horizon International Inc. pursues a policy of continuing improvement in design and performance of the product. Therefore, the product design and specifications are subject to change without prior notice and without our legal obligation.

• All rights are reserved. No part of this manual may be photocopied, reproduced or translated to another language without the prior written consent of Horizon International Inc.

170228/566F/32E/TI,TM,AT/F7/ICS5.5/PXI

UM203051-32(000)

Page 2

Safety Precautions

Safety precautions are indicated in this manual as follows:

The term WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

The term CAUTION indicates a potentially hazardous situation which, if not avoided, may result in serious injury, or damage to the machine.

This symbol indicates a note which includes important information. Follow the note to operate the machine safely.

This symbol indicates a prohibited action. Do not perform any prohibited action.

This symbol indicates an essential procedure. Follow the procedure to operate the machine safely.

Important

Attention

Note

Additional Information

• This lists the range of acceptable values and operating conditions.

• This information will help you to avoid problems with the machine or help you learn how to operate the machine.

• Refer to this note when you operate the machine.

• This explains a mechanism in the machine .

Page 3

Operating Safety Precautions

WARNINGS for Operation

The machine must be operated by just one person at a time.

Keep your hands and fingers away from the rotor and any moving parts during operation. Otherwise moving parts can cause severe personal injury.

Rotating parts may catch your hair or clothing. Arrange your hair in a bun or wear suitable clothing. Otherwise rotating parts can cause severe personal injury.

Do not remove or bypass any safety features. Moving parts can cause severe personal injury.

Press the Emergency Stop button before turning the handwheel. A sudden accidental start of the machine can cause severe personal injury.

Turn off the power switch before adjusting the machine unless instructed otherwise. If the Start button is pressed, the machine may move suddenly and cause severe personal injury.

Turn off the power switch before resetting the circuit breakers. Otherwise, the machine may start suddenly, causing severe personal injury.

CAUTIONS for Operation

Be sure to install the buckle chutes and conveyors correctly. Otherwise, the machine may be damaged.

If the power is turned off, wait at least ten seconds before turning the power on again.

When you are moving the perforation blades sideways, be sure to raise the upper perforation shaft before moving the blades. After moving the blades, return the upper perforation shaft to its original position. If you do not do this, the blades may be damaged.

Do not place any objects under the feed table. Otherwise, the feed table may be damaged.

III

Page 4

WARNINGS for Installation

Be sure to attach the cables, hoses, tubes in the areas where a foot cannot be caught.

Page 5

Warning Label Locations and Meanings

23051

10101B1

There are electrical parts inside. Be careful when you open the cover. Otherwise, electrical shock may be caused.

Do not approach your hands and fingers while the belt is rotating. Otherwise your hands and fingers may be caught by the rotating belt.

Do not touch the perforation blade with bear hand. Make sure to wear cutting proof gloves when handling the perforation blade. Otherwise sharp blade can cause severe personal injury.

Do not approach your hands and fingers while the roller is rotating. Otherwise your hands and fingers may be caught by the rotating roller.

Do not insert your hands and fingers inside the cover. There are gears inside and your hands and fingers may be caught by the gears.

When you lower the suction head bar, be careful not to catch your finger.

Do not insert your fingers into the slit of the feed head while the feed table is moving. Otherwise, the moving table can cause severe personal injury.

Do not approach your hands and fingers to the su ctio n h ead while the suction head is moving to the minimum or maximum position. Otherwise your hands and fingers may be caught by the suction head.

Page 6

CONTENTS

Important Information................................................................................................I

Safety Precautions...................................................................................................II

Operating Safety Precautions.................................................................................III

Warning Label Locations and Meanings.................................................................V

1. Machine Description

1-1 Machine Description .......................................................................................1

1-1-1 Overall View 1 .............................................................................. ........................ .... ..............1

1-1-2 Overall View 2 .............................................................................. ........................ .... ..............2

1-1-3 Overall View 3 .............................................................................. ........................ .... ..............3

1-1-4 Suction Head Section 1 ................................................................................................... ......4

1-1-5 Suction Head Section 2 ................................................................................................... ......5

1-1-6 Feed Rotor Section ............................................... ....................... ........................ ........ ..........6

1-1-7 Side Air and Feed Table ................................................................................................. .......7

1-1-8 Register Guide Section ........... .................. ....................... ........................ ...................... .. ......8

1-1-9 Buckle Chute Section .................................................................................................... .........9

1-1-10 Perforation and Scoring Section .................................................................................... ....10

1-1-11 Knife Fold Section ................. ........................ ................. ........................ ................... .........11

1-1-12 Buckle Chute Below Knife ............................................................................................. .. ..12

1-1-13 Conveyor Section ................................................................................... .................... ........13

1-1-14 Power Box and Control Box ..............................................................................................14

1-1-15 Pump Section ........................................................................................................... ..........15

1-1-16 Control Panel ......................................................................................................................16

1-1-17 Sub Control Panel ..............................................................................................................17

1-1-18 Remote Controller ................. .............................. ....................... .............................. ..........18

1-2 Touch Panel Description...............................................................................19

1-2-1 Initial Screen .......................................................................................................... ...............19

1-2-2 Main - Function Screen ................................................................................. ................ ......19

1-2-3 Main - Condition Screen .....................................................................................................20

1-2-4 Main - Options Screen ...................................................................... ........................ .... ......21

1-2-5 Set Up - Fold Pattern Screen ............................................................. ........................ ....... ...22

1-2-6 Set Up - Guide-Buckle Screen ............................................................................................23

1-2-7 Set Up - Register Mark Position Entering Screen ...............................................................24

1-2-8 Set Up - Roller Gap Screen .................................................................................................25

1-2-9 Set Up - Roller Gap Micro-Adjusting Screen ............................... .................. ......................26

1-2-10 Set Up - Check/Instruction Screen .................................................................................... 27

1-2-11 Set Up - Reset Screen .................................................................................................. .....28

1-2-12 Memory Screen ..................................................................................................................29

1-2-13 Properties Screen .......................................................................................................... ....30

1-2-14 Properties - Administrator Setting Screen .........................................................................31

2. Overview of Setup Procedure

2-1 Overview of Basic Setup...............................................................................33

2-2 Overview of Fine-Tuning...............................................................................34

3. Basic Setup

3-1 Turn On the Power Switch............................................................................37

Page 7

3-2 Setting the Fold Pattern and Sheet Size.......................................................38

3-3 Setting the Positions of the Guides and Buckle Chutes................................41

3-4 Loading the Sheets on the Table..................................................................43

3-5 Setting the Suction Head..............................................................................46

3-6 Setting the Register Guide............................................................................50

3-7 Setting the Perforation Blades......................................................................51

3-8 Setting the Knife Fold Section.......................................................................53

3-9 Setting the Conveyor Section .......................................................................54

4. Fine-Tuning Adjustments

4-1 Setting the Belt Speed..................................................................................57

4-2 Feed One Sheet in Setup Mode ...................................................................58

4-3 Checking the Sheet Feeding Angle ..............................................................59

4-4 Adjusting Fold Skew in Parallel Folding........................................................60

4-5 Adjusting Parallel Shifts in Parallel Folding...................................................65

4-5-1 Adjusting the positions of the buckle stoppers separately ..................................................65

4-5-2 Adjusting the positions of the buckle stoppers at once ......................................................66

4-6 Matching the Perforation Line to the Fold.....................................................67

4-7 Setting the Perforation Blades and Scoring Blades......................................71

4-8 Setting the Knife Fold Section.......................................................................75

4-9 Adjusting Fold Skew on Buckle Chute below Knife ......................................77

4-10 Adjusting Fold Shifts on Buckle Chute below Knife......................................81

4-11 Checking the Fold Quality.............................................................................82

4-12 Other Adjustments........................................................................................83

4-12-1 Feed rotor section adjustment ...........................................................................................83

4-12-2 Buckle gate adjustment ................................................................................ ................. .....85

4-12-3 Gap adjustments inside the buckle chutes ...................................... ........................ ..........86

4-12-4 Gap adjustments between the buckle chutes and fold rollers ..........................................87

4-12-5 Stopper angle adjustment ..................................................................................................88

4-12-6 Fold knife angle adjustment ......................................................................... ................... ...89

4-12-7 Adjustment of the hold-down roller pressure in the fold section .......................................90

5. Starting and Running the Job

5-1 Setup the Main Screen .................................................................................91

5-1-1 Setup the Function Screen ........................................................................... ................... ...91

5-1-2 Set up the Condition Screen ...............................................................................................92

5-2 Starting Folding .............................................................................................95

6. Troubleshooting

6-1 If an Error Icon Appears on the Screen ........................................................97

6-2 If a System Error Code Appears on the Screen..........................................101

6-3 Problems in the Feed Section.....................................................................104

6-3-1 The suction piston does not pick up the sheet ..................................................................104

6-3-2 The feed rotor does not rotate ...........................................................................................105

6-3-3 The vacuum piston moves slowly ......................................................................................105

6-3-4 The feed table does not move up and down .....................................................................105

6-3-5 The right end of the sheet moves ......................................................................................105

6-4 Problems in the Register Guide Section.....................................................106

6-4-1 Sheet does not move up against the register guide, or hits the register guide too hard .106

VII

Page 8

6-4-2 Large size sheets are not fed straight ...............................................................................106

6-5 Problems in the Buckle Chute Section........................................................107

6-5-1 The sheet does not enter the buckle chute .......................................................................107

6-5-2 The folds are not square to the edges of the sheet .................................................. ........108

6-5-3 The sheets are wrinkled parallel to the fold line .................... .............................. ..............109

6-5-4 The sheets are wrinkled across the fold line ........ ................. ........................ ....................109

6-5-5 One of the folding lines is unstable .................................................................................... 109

6-5-6 The sheet remains inside the buckle chute .......................................................................110

6-6 Problems in the Scoring Section.................................................................111

6-6-1 The scoring line does not run straight ...............................................................................111

6-6-2 The perforation line does not run in the center .................................................................111

6-7 Problems in the Knife Section.....................................................................112

6-7-1 The sheets are scratched or smeared ....................................................................... ........112

6-7-2 The fold knife creases the sheets ...................................................................................... 112

6-7-3 The sheets are not folded exactly on the perforation line .................................................112

6-7-4 The folded edge of the signature swells up .......................................................................113

6-7-5 The knife does not work .....................................................................................................113

6-7-6 The roller below the knife does not rotate ..................................................... ....................113

6-8 Other Problems...........................................................................................114

6-8-1 The sheets are not arranged correctly on the delivery conveyor .....................................114

6-8-2 The delivery conveyor does not run .................................................................... ..............114

6-8-3 The pump pressure does not increase when you turn the regulator knob ......................115

6-8-4 The pump does not run ......................................................................................................115

6-8-5 The motor does not run when the Start button is pressed ............................ ....................115

6-8-6 The display does not appear when the main power is turned on .....................................115

6-8-7 The gate fold buckle chute does not operate ....................................................................116

6-8-8 Sheets cannot be fed continuously ....................................................................................116

6-9 General Folding Problems and Remedies..................................................117

6-10 If a Message Screen is Displayed...............................................................122

7. Maintenance

7-1 Cleaning the Vacuum Piston.......................................................................123

7-2 Disassembling and Cleaning the Pump Filter.............................................125

7-3 Cleaning the Fold Roller .............................................................................126

7-4 Lubrication ..................................................................................................127

7-4-1 Lubricating the Grease Nipple ...........................................................................................127

7-4-2 Lubricating the Conveyor Drive Chain ...............................................................................128

7-5 Removing and Installing the Perforation Shaft............................................129

7-6 Removing the Buckle Chute .......................................................................130

7-7 Installing the Perforation Blade...................................................................132

7-8 Cleaning the Double Feed Detect Photoelectronic Sensor.........................135

7-9 Cleaning and Replacing the Air Filter in the Control Box............................136

7-10 Replacing the Carbon Blades of Pump.......................................................137

7-11 Replacing the Battery for the Remote Controller........................................138

8. Installation

8-1 Machine Installation....................................................................................139

8-1-1 Placing the Machine ................................................................................. .................... ......139

8-1-2 Level Adjustment .............................................................................................................. ..140

8-1-3 Installing the Delivery Section Front Cover ..................... ........................ .................. ........140

VIII

Page 9

8-2 Pump Power Cable Connection..................................................................141

8-3 Pump Power Cable Connection..................................................................142

8-4 Installing the Conveyor and Accessories....................................................143

8-5 Installing the Conveyor and Accessories....................................................144

8-6 Connecting the Power Cables ....................................................................145

8-7 Pump Rotation Direction.............................................................................145

8-8 Date and Time Setup..................................................................................146

8-9 Checks After Installation.............................................................................146

9. Appendix

9-1 Specifications..............................................................................................147

9-2 Accessories.................................................................................................148

9-3 Consumables..............................................................................................152

9-4 Options .......................................................................................................153

9-5 De-commissioning and Dismantling............................................................154

9-6 Static and Dynamic Load Testing...............................................................155

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This page is intentionally left blank.

Page 11

1-1-1 Overall View 1

1-1 Machine Description

1-1-1

Overall View 1

The directions in this manual are indicated as follows:

Left

Right

Rear, Back

Front, Operator Side

23051 10101A1

Page 9

Buckle Chutes 1, 3, and 5

Pump Section

Suction Head Section

The vacuum piston pulls up the top sheet, and separates it from other sheets. The suction head section changes position automatically to match the sheet length.

Page 4

Power Switch

Page 8

Control Panel (LCD)

This panel is used to control the folding operation.

Page 16

Page 15

Conveyor Section

Page 13

Sub Control Panel Section

Page 17

Feed Rotor Section

This rotor feeds one sheet at a time to the register guide.

Page 6

Buckle Chutes 2, 4, and 6

1. Machine Description

Machine Description

/ Machine Description

Page 12

1-1 Machine Description

1-1-2

Overall View 2

Knife Folding Section

Page 11

Parallel Folding Exit Section

Handwheel for Knife Fold Roller

This wheel is used to turn the fold roller below the knife. When the wheel is pulled out and rotated, the fold roller can be turned manually. When the wheel is pressed in, the roller is not engaged with the wheel.

Cross Folding Exit Section

Buckle Chutes K1 and K2

Handwheel

When the wheel is pulled out and rotated, the fold rollers can be turned manually. When the wheel is pressed in, the rollers are not engaged with the wheel.

Feed Table

The maximum stack height is 740 mm (29.1").

Feed Table Knob

This wheel moves the feed table to the front and rear.

The handwheel may turn suddenly and cause injury. Press the Emergency Stop button before turning the handwheel.

WARNING

1-1-2 Overall View 2

23051

10102A1

Page 13

1-1-3

Overall View 3

1-1 Machine Description

23051

10103A1

Control Box Fan - Air Filter

This fan cools the control box. The air filter must be cleaned regularly.

Power Box

This contains circuit breakers.

Page 14

Door for Buckle Chute Below the Knife

Open this door to remove buckle chute K2. If this cover is opened while operation, the machine stops.

Control Box

This contains the circuit breakers.

Page 14

Power Connector to Round Feeder (option)

Power Connector to Gate Fold Buckle Chute (option)

Conveyor Power Connector Communication Connector to

Press Stacker (option)

1-1-3 Overall View 3

Top Cover

If this cover is opened while operation, the machine stops.

Machine Description

/ Machine Description

Page 14

1-1-4

Suction Head Section 1

1-1 Machine Description

23051

Sheet Hold-down Weights

These weights help to control the sheet. Attach or remove weights to match the type of sheet.

Set Register Pin Locking Knob Suction Piston Height Adjusting

Knob

This knob is used to adjust the space between the suction cup and the top of the stack.The standard space is about 1mm (0.04”).

Set Register Pin

Fit the pin against the back of the stack.

Air Guide

This guide holds the sheet lightly and prevents the separation air from leaking out to the sides.

Blower Air Nozzle

The blower air exits.

Grip Area Adjusting Knob

Turn the knob clockwise to move the grip area forward.

Sheet Hold Angle Adjusting Knob

Turn the knob clockwise to increase the angle.

Blower Air Position Adjusting Knob

This knob is used to adjust the height of the blower air nozzles.

Sheet Hold-down Pressure Adjusting Knob

This knob adjusts the pressure produced by the sheet holddown bar against the sheet. The higher the setting on this knob, the greater the holddown pressure.

Sheet Hold-down Bar

This holds down the rear edge of the stack.

The suction head section adjusts position automatically during changeover to match the sheet length.

1-1-4 Suction Head Section 1

Blower Air Pressure Adjusting Knob

Separation Air Pressure

Air Guide

Suction Head Stop Switch

When the vacuum piston picks up the sheets which width is narrow, the suction head can rise a little, and the gap between the vacuum piston and sheets can widen. In this case, turn off this switch so as not to move the vacuum piston.

When lowering the feed table, the suction head raises even if this switch is turned off. And when raising the feed table with this switch turned off, the suction head does not lower and cannot catch the sheet. Be sure to turn this switch on before raising the feed table.

Page 15

1-1-5

Suction Head Section 2

1-1 Machine Description

23051

10105A1

Separator

This separator holds the sheet edge lightly and prevents the sheet from double feeding. Adjust the grip area according to the sheet weight.

Outlet for Separation Air

Separation air is blown between the uppermost sheet lifted by the vacuum piston and the lower sheet which is held by the separator.

Support Release Lever

Suction Head Support

Lifting Handle

Suction Head Arm

This supports the arm when it is raised.

Communication Connector for Round Feeder (option)

Connector for Suction Head

Lock Nut

Piston Set Screw

Vacuum Piston

This piston catches the top sheet and lifts it up.

Suction Cup

If this is torn, replace it.

1-1-5 Suction Head Section 2

Machine Description

/ Machine Description

23051 10105B1

Page 16

1-1 Machine Description

1-1-6

Feed Rotor Section

Feed Rotor

This pulls against the leading edge of the sheet. The vacuum operates through the oval-shaped holes on the outside of the rotor.

Double Feed Detect Ultrasonic Sensor

This is the sensor for double (multiple) feed detection. If this sensor detects double feeding, the machine stops the folding operation.

Front Air Nozzle

When feeding heavy sheets, extra air can be supplied here to help the feed rotor.

Feed Table Sensor Adjusting Knob

When this knob is turned clockwise, the table sensor is raised.

Feed Table Sensor

This sensor detects the top of the stack. The standard distance between the feed rotor and the top sheet is about 9 to 1 1 mm.

Double Feed Stop Plate Adjusting Knob

Table Sensor

When the feed table Down button is pressed, the table lowers until it reaches this sensor. When there are sheets on the table and the Down button is pressed, the table stops with the top of the stack even with the sensor. Press Down again to lower the table all of the way.

Double Feed Stop Plate

Normally you should not have to change this setting. If double feeding occurs repeatedly, move this plate to the higher position.

Valve Housing

This housing pulls the air from the side of the feed rotor.Changing the position of this valve housing can change the grip position on the sheet.

1-1-6 Feed Rotor Section

Double Feed Detect Photoelectronic Sensor

This is the sensor for double (multiple) feed detection. If this sensor detects double feeding, the machine stops the folding operation.

Page 17

1-1-7

Side Air and Feed Table

1-1 Machine Description

Front air: Maximum Side air: Off

Front air: Off Side air: Maximum

23051

10107A1

Table Guide

Feed Table Wheel

This wheel moves the feed table front or back. When this wheel is turned clockwise, the table moves to the rear.

The rear edge of the stack must be held by this guide. This guide adjusts position automatically to match the sheet width.

1-1-7 Side Air and Feed Table

Front/Side Air Adjusting Knob

Side Air Hose

When large and heavy sheets are used, and sheets are not fanned using only the front air, set the side air hose to fan the sheet edge.

Machine Description

/ Machine Description

Page 18

1-1-8

1-1 Machine Description

23051

10108A1

Feed Scale Pin

Put the pin into the outer hole. Adjust the position of the table so that this pin sits against the front edge of the stack.

Sheet Edge Guide

Press this button to stop the machine.

Sheet Holder

These holders prevent the sheet from lifting. Install or remove holders to match the sheet size.

Adjust the guide angle using this knob so that the sheet is driven through the guide. Turn the knob clockwise to move the right side of the guide to the front.

Set this guide so that it supports the edge of the sheet. This prevents the sheet edge from dropping and causing a sheet jam.

Transport Balls

There are Nylon balls and steel balls. The sheet is driven through the guide by these balls and the transport belt under the balls.

Each sheet is driven through this guide by a transport belt and the transport balls.

Emergency Stop Button

1-1-8 Register Guide Section

Page 19

1-1-9

Buckle Chute Section

1-1 Machine Description

Push down on the lever, and insert one sheet between the lever and the knob. Turn this adjusting knob to adjust all of the roller gaps at once. The roller gap will be increased if the knob is turned clockwise. Press the Thickness Calibration button, and then press the Adjusting Start button to reflect the adjusted thickness to the roller gap. (See page 25.)

Buckle Chute Locking Lever

When removing the buckle chute, release the buckle chute using this lever.

Buckle Stopper and Deflector

This stopper is set automatically to match the sheet size and fold pattern. The stopper setting position can be adjusted on the screen.

Buckle Stopper Adjusting Knob

This knob moves only the end of the stopper on the operator side of the machine.The angle of the stopper is adjustable.

Locking Knob for Buckle Stopper Adjusting Knob

Loosen this knob to turn the stopper adjusting knob.

Fixed Knob

This knob is driven by a motor. Do not turn it by hand.

Gate Scale

If the sheet is curled downward and does not enter the buckle chute, turn this knob to extend the gate.

Gate Adjusting Knob

Adjusting Knob

Lever

Gate

1-1-9 Buckle Chute Section

Sheet

Sheet Thickness Detector

Machine Description

/ Machine Description

0-1

23051 10109A1

0.2mm (200Ǵm)

-1

Page 20

Perforation and Scoring

Section

1-1 Machine Description

23051

10110A1

Using Thin Scoring Groove

Using Thick Scoring Groove

Drive Rollers (4pcs)

These rollers drive each sheet.If the sheets curl because of perforations, install upper and lower drive rollers to correct the curl.

Upper Scoring Wheel

Lower Scoring Wheel

Blade Holder A

Perforation, and Scoring Blade Install the blades as required.

Blade Holder B

Perforation Blade 6 mm x 4 mm Normal (0.236" X 0.157")

Perforation Blade

2.5 mm x 0.8 mm Normal (0.098" X 0.031")

3.2 mm x 0.8 mm Option (0.126" X 0.031")

1.4 mm x 0.8 mm Option (0.055" X 0.031")

Slitter Blade Diameter 54 mm (2.13”) Option Diameter 52 mm (2.05”) Option Diameter 51 mm (2.01”) Option

Install the blades with the correct orientation on the shaft (facing the right way).

Each blade is split into two halves, and is supplied this way. Always use the two halves together.

Drive Rollers

The sharp edges of the blades can cause severe personal injury. Wear cutting proof gloves or wrap the blade with cloth when handling.Also, install/ remove the blades after pressing the Emergency Stop button.

WARNING

1-1-10 Perforation and Scoring Section

When aligning the upper and lower scoring wheels, raise the upper and lower perforation shafts so the wheels do not hit.

See 1-2-8 for details.

Upper Scoring Wheel

Lower Scoring Wheel

Perforation Shaft Lifting Lever

Turn this lever in the direction shown by the arrow to lift the upper perforation shaft.

This lever is installed on both the front and the rear. Use the levers when you adjust the positions of the perforation blades and the scoring wheels.

Page 21

1-1 Machine Description

1-1-11

Knife Fold Section

1-1-1 1 Knife Fold Section

Fold Knife

A sheet which moves to the knife fold section is stopped by these stoppers, and then the sheet is folded by the knife. The position of the knife stoppers can be set automatically to match the sheet size and fold patterns. When not using the knife, raise the stoppers.

Hold-Down Brush

Locking Knob for Buckle Stopper Adjusting Knob

Loosen this knob to turn the stopper adjusting knob.

Fixed Knob

This knob is driven by a motor. Do not turn it by hand.

Buckle Stopper Adjusting Knob

The angle of each stopper is adjustable.This knob adjusts just the stopper on the operator side.

Jam Detect Sensor

This triggers the fold knife and detects any sheet jams.

Hold-Down Roller

This roller holds the tail edge of the sheet. Do not change the position.

The standard position is the middle of the scale.

Locking Knob

Fold Knife Angle Adjusting Knob

Rear Knife Guide

Knife Stoppers

Front Knife Guide

Transport Roller

Set these rollers to transport the sheets smoothly during parallel folding.

When the knife stopper is raised, raise and lean the knob, and loose your hold of it. The knife stopper will be locked while raising.

Knife Stopper Holding Pin

Machine Description

/ Machine Description

23051

10111A1

Page 22

1-1-12

Buckle Chute Below Knife

1-1 Machine Description

23051

10112A1

Gate Adjusting Knob

Delivery Belt

These change position to match the sheet length so that the sheet is delivered smoothly.

Buckle Chute K1

(Buckle chute K2 is on the rear of the machine)

Buckle Chute K1 Stopper Adjusting Knob

This part of the knob moves only the right end of the stopper.

Locking Knob for Buckle Stopper Adjusting Knob

Buckle Chute Locking Knob

If the sheet does not enter the buckle chute, turn this knob to extend the gate.

Gate Scale

The standard position is the middle of the scale.

Loosen the knob to remove the buckle chute.

Buckle Chute K1 Stopper, Deflector

1-1-12 Buckle Chute Below Knife

Page 23

1-1-13

Conveyor Section

1-1 Machine Description

LOW HIGH

RUN STAND-BY

SPEED CONTROL UNIT

POWER ALARM

23051

10113A1

1-1-13 Conveyor Section

Slide Arm

Move this arm to change the catch roller position.

Conveyor Belt

Stacker Section

The amount of stacker drive can be changed to match the folded sheet.

Height Adjusting Wheel

Turn this wheel and match the conveyor section height to the exit section height.

Height Adjust Handle Locking Lever

Catch Rollers

Adjust the positions of these rollers to match the length of the delivered folded sheet.

Conveyor Switch

Speed Control Knob

The speed of the conveyor can be changed using the speed control knob.

Angle Adjustment Knob

This side can be angled to deliver sheets smoothly.

Select RUN to use the conveyor. When RUN is selected, the conveyor is operated for five seconds after the folding operation stops.

Option: LCV-54

Machine Description

/ Machine Description

Page 24

1-1 Machine Description

Power Box and

Control Box

Switch (red): off

Switch (black): on

Press the black button.

To reset

Resetting Circuit Breakers

Resetting Circuit Protector

Tripped Condition

Off

Push farther down

It will return to the original position.

23051

10114A1

Q10: Main Inverter Circuit Breaker

Q12: Circuit Breaker for Drive Motor Below Knife

Q20: Feed Table Motor Circuit Breaker

Q21: Pump Circuit Breaker Q00: Main Power Circuit Breaker

Q12: Knife Servo Amplifier Circuit Breaker

Q30: Circuit Protector for Gate Fold Buckle Chute

Q50: Circuit Protector for Conveyor

Q11: Main Motor Circuit Breaker

Q01: Circuit Protector

1-1-14 Power Box and Control Box

Control Box

Power Box

Page 25

1-1 Machine Description

1-1-15

Pump Section

To Feed Rotor

To Suction Head (Vacuum Piston)

1-1-15 Pump Section

Pressure Gauge

This gauge is used to check the air pressure. Control the air pressure using the pressure regulator knob. In normal use, this is set to about 0.03 to 0.04 MPa (4.5 to 6 psi). Do not set the air pressure higher than 0.07 MPa (10 psi).

Vacuum Regulator Knob

Pressure Regulator Knob

Vacuum Gauge

This gauge is used to check the vacuum. Control the vacuum using the vacuum regulator knob. In normal use, this is set to about

- 0.04 MPa (-6 psi) with a sheet pulled against the suction head. Do not set the vacuum lower than -0.07 MPa (-10 psi).

Machine Description

/ Machine Description

To Front Air

To Feed Rotor

To Suction Head (Blower, Separation Air)

To Suction Head

To Suction Head (Vacuum Piston)

(Vacuum Piston)

23051

10115A1

Page 26

1-1 Machine Description

1-1-16

Control Panel

1-1-16 Control Panel

Motor Stop/Feed Stop Button

If this button is pressed once while folding operation, the machine stops the feeding. If the button is pressed again, the motor stops.

Motor Start/Feed Start Button

If the button is pressed once while the feed table Up button is lit, the motor runs. If it is pressed again, a sheet is moved into the fold section for the folding operation. This button lights while the sheets are feeding and blinks in the Setup mode.

Touch Panel

This panel is used to control the machine.

Page 19-31

Test Feed Button

While the transport motor is running, press this button to feed one sheet.

Reverse Jog Button

When this button is pressed, the sheets move in the reverse direction.

Normal Jog Button

When this button is pressed, the sheets move in the normal direction.

Feed Table Down Button

When this button is pressed, the feed table starts to lower until it comes to the table sensor position. Press the button again, and the table lowers to the lowest point. If the Down button is pressed while the table is rising, the table stops rising.

Feed Table Up Button

When this button is pressed, the feed table raises and stops at the upper limit and the vacuum pistons lower. If the Up button is pressed while the table is lowering, the table stops lowering.

If the Motor Stop/Feed Stop button is pressed twice in short period, the machine stops while the sheets are left inside. Stop the motor after all sheets inside the machine are delivered.

Remote Control Signal Receiver

23051

10116A1

Page 27

1-1 Machine Description

1-1-17

Sub Control Panel

1-1-17 Sub Control Panel

Normal Jog Button

When this button is pressed, the sheets move in the normal direction.

Knife One Cycle Button

When this button is pressed, the knife moves once. This button operates only when the knife is turned on (when this button is lit).

Emergency Stop Button

Press this button to stop all machine operation.

Machine Description

/ Machine Description

Motor Start / Feed Start Button

If the button is pressed once while the feed table Up button is lit, the motor runs. If the button is pressed again, a sheet is moved into the fold section for the folding operation. This button lights while the sheets are feeding and blinks in the Setup mode.

Motor Stop / Feed Stop Button

- If this button is pressed once while folding operation, the sheet stops moving into the fold section. If the the button is pressed again, motor stops.

- If the control panel displays an error screen, pressing this button instead of the button on the screen can clear the error.

Test Feed Button

While the transport motor is running, press this button to feed one sheet and stop it at the knife fold section.

23051

10117A1

Page 28

1-1 Machine Description

1-1-18

Remote Controller

SELECT

23051

10118A1

Roller Gap Fine-Tune Screen Set up- Guide and Buckle Chute Screen

Change using this button

8080

23051

10118B1

SELECT

23051 10118C1

10 m

Receiver

Projector

Jog Dial

This dial changes the value of the selected item. The value is changed in one second. After the dial is turned.

Item Movement Button

Press this button to select the item to be adjusted. (The system steps through the list in just one direction.)

Feed Stop Button

Test Feed Button

Feed Start Button

Screen Select Button

Press this button to change the screen displayed on the touch panel.

The remote controller can adjust items on the following screens :

The roller gap which is currently selected on the remote controller is shown here. Turn the jog dial to change the roller gap.

The roller gap which is currently selected on the remote controller is shown in blue.

Roller Gap Shown In Blue

This is the item that is currently selected by the remote controller.

Item Highlighted In Green

-The setting for the guides and stoppers can be changed. Each jog = 0.1mm.

-The setting for the roller gaps can be changed. Each jog = 5

µm (0.005mm).

If the jog dial is turned while you press this button, the selected item changes. You can also use the jog dial to go through the list in the opposite direction.

AA Batteries

1-1-18 Remote Controller

You can start the feed using this button. (You cannot start the main motor using the remote controller.)

Infrared Ray Projector

Point this part to the signal receiver on control panel to use the remote control.

This remote control can be used only after the home positioning operation has completed.

Remote Available Range

Use the remote controller within the following range.

Page 29

1-2-1 Initial Screen

1-2 Touch Panel Description

1-2-1/1-2-2

Main -Function Screen

Cross

When the power is turned on, this screen is displayed first. Next, the Fold Pattern screen appears.

Feed Counter

This displays the total number of forms fed during the job. The number increases by one each time a form is fed even the power is turned off. When (clear) is pressed, the number will be set back to 0.

Remaining Sheet Number Display

The number of sheets remaining is displayed here. This is the rough indication to calculated the remaining run time, so even the number becomes 0, the machine does not stop.

pXnet Screen Button

This button displays the screen shown

below only when the pXnet system is being used.

Operation Speed Indicator

The current operation speed is indicated here.

End of Job Button

Press this button after job has been completed.

Remaining Time Indicator

The remaining time is calculated, based on the operation speed and the number of sheets, and is displayed here.

Job Indicator

The current job appears here.

Pause Time

Enter the pause time here.

Preset Mode Select Buttons

: The sheets are fed continuously without

using the preset function.

: When the number of fed sheets

reaches the preset count number, the feeding action pauses for a set time. This creates a gap between the sets on the delivery conveyor.

: When the number of fed sheets

reaches the preset count number, the feeding action stops.

Preset Counter

The machine can be set to pause or sound a buzzer after feeding a preset number of sets. Input the preset number on the left. The number on the right decreases by one each time a form is fed. When (clear) is pressed, the number will be set back to 0.

Batch Counter

Enter the number of sets in the batch here. The feed will stop when the machine has completed that number of sets.

###

Pause Button

Complete Button

Work Count

Rejected Count

Each sheet is counted as it passes through the feed rotor, even if the sheet is not delivered completely because of a jam.

(the pause function) is not avail ab l e if

the optional TST-37 Press Stacker is connected.

###

Machine Description

1-2-2 Main - Function Screen

/ Touch Panel Description

Page 30

1-2-3 Main - Condition Screen

1-2-3

Condition Screen

1-2 Touch Panel Description

You can change these settings while the machine is running.

If the belt speed is drastically changed, the folding quality may deteriorate. Do a test feed to check the folding quality before running the machine.

Feed Rotor Suction Length

When (default) is pressed,

the suction length is set to 3/10 of the sheet length.

Belt Speed

This sets the speed of the fold roller and transport belt. Max. 240 meters per minute (The maximum speed depends on the fold pattern.) Min. 30 meters per minute

Knife DelayTime

The feed interval is automatically made longer when the knife delay time is increased.The taller the level bars on the display, the longer the knife delay time.. When the delay time is set to the minimum, the knife lowers at the moment when the sheet hits the knife stopper..

Feed Interval

:Thevalue from 10 to 999

(0.5" to 39.3") can be input.

Thevalue fr

(0.5"to 90.5") can be input. The minumum value is shorter length b

y 50 mm (1.97") than the sheet length.

When (default) is pressed interval is set to match the delay time of the knife.Initially, select . Ifyouwant to shorten the feed interval a lot, select . However, this mayresult in uneven feeding if the sheets are slippery.

om 10 to 2,300

, the

Double (Multiple) Feed Detection

Icons below are display only when photoelectronic detection is selected.

Conveyor RunningTime

Continuous (Conveyor runs along with main motor): Set how long the delivery conveyor (LCV-54) is running after the main motor stops.

Intermittent (Conveyor runs along with sheet delivery): Set how long the delivery conveyor is running after the sheet is delivered. (When the motor starts moving, conveyor does not start moving at same timing.)

23051 10203A1

Not Used Ultrasonic Detection : Double feeding is detected by the

ultrasonis sensor.Two-part form cannot be detected correctly by this sensor. In that case, use the photoelectronic sensor.

Photoelectronic Detection: Double feeding is detected by the photoelectronic sensor.According to the printed condition (paint or color), this sensor may misdetect the double feeding. In that case, use the ultrasonic sensor.

Set the brightness of the double feed detecting

lamp. When detecting thick sheets (100 gsm or thicker) or sheets with lots of dark printing, use the brighter setting.

: Set the sensitivity of the double feed detection.

The bigger the level bar is, the higher the sensitivity.

- If the sensor misdetects the correct feeding as double, decrease the sensitivity.

- If double feeding is not detected and passes through, increase the sensitivity.

Page 31

1-2-4 Main - Options Screen

1-2-4

Options Screen

1-2 Touch Panel Description

Gate Fold Buckle Chutes (GFB-56)

If you are using one of the GFB-56 buckle chutes, press the button so that it turns blue. If you are not using a GFB-56 unit, press the button again.

Feed Unit

The icon of the feed unit connecting the machine appears on the screen.

Machine Description

/ Touch Panel Description

Other Folders

The folder connected to this machine is shown here.

23051

10204A1

Stacker

The stacker connected to this machine is shown here. The setting listed below is available only when the optional PST-40 press stacker is connected.

This displays the number of sheets included in each set.

Offset Mode

Shift; The stacker offsets a batch of sheets when it reaches the preset

set count number.

Kick; The stacker offsets one sheet when it reaches the preset set

count number.

Page 32

1-2-5 Set Up - Fold Pattern Screen

1-2-5

Fold Pattern Screen

1-2 Touch Panel Description

23051

10205A1

Fold Pattern Setting

Select the fold pattern from 17 possible patterns.

Custom Fold Pattern

To use a custom fold pattern that is not included in the 17 standard fold patterns, press this button. You can enter the positions for the guides and buckle chutes manually to match the fold pattern.

Sheet Length/Width

Press one of the sections, and the Numeric Keypad screen appears. Enter the dimension. Sheet size: Max. 850.0 X 558.0 (mm) or 34.0" X 21.965"

Min. 148.0 X 128.0 (mm) or 5.830" X 5.040"

OK Button

Once this button has been pressed, the fold pattern and sheet size are entered, and the Guide/Buckle screen appears.

Sheet Surface/Reverse Select Button

To reverse the sheet, press this button. The symbol in the box changes to .

Numeric Keypad Screen

Keyboard Screen

Up to 20 letters can be entered.

Alphabetical Key Layout

QWERTY Key Layout

Page 39

Page 33

1-2-6 Set Up - Guide-Buckle Screen

1-2-6

Guide-Buckle Screen

1-2 Touch Panel Description

23051

10206A1

Displayed in Green

If a value is changed using the and buttons, the value is set automatically after one second. Press the buttoncontinuouslyto change the value in hign speed.

When the Test Feed button ispressedin this mode and one sheet is fed, the sheet stops just before reaching theknife. With the knife bladeisclose to the sheet,it is easierto

position the perforation.

Changeover Start Button

Press this button when the settings on this screen are OK. The machine will prepare for the setup using these settings.The roller gaps are adjusted at the same time.

SettingValueInput

Press the areafor the valueyou wantto change, and the Numeric Keypad screen is displayed. Enter the new value, then press the ChangeoverStart button to set up the machine for the new value.

Press to increase the setting

by 0.1 mm (0.005").

Press to decrease the setting

by 0.1 mm (0.005").

Micro- Adjusting Buttons

:Each mechanism moves

directly to the setting position.

:Each mechanism returns to

the home position and then moves to the setting position.

Suction Head /Table Guide Manual Change

Though the suction head and table guide are set in position automatically, this button allows for

manualcontrol. When set for manual control, the suction head and table guide are not adjusted automatically during changeover. (The manual control functionfor the suction head and table guide is used when using the optional

roundfeeder.)

RegisterMark Position EnteringScreen

Press this button to open the Register Mark Position Entering screen. See page 24 for details.

Roller Gap Locking Button

When you change the value for number of sheets on the Setup - Roller Gap screen, and then enter a value for the buckle stopper using the Numeric keypad screen, the roller gap is re-calculated and the value for the number of sheets returns to the default value. Press this button if you do not want to change the value for the number of sheets on the Setup - Roller Gap screen. Alternatively, you can also change only the value for the buckle stopper using the Fine Adjusting buttons.

Accordion-fold Adjusting Button

Press this button to open the Accordion-foldAdjusting screen.You can correct the parallel shifts of accordion-folded sheets by adjusting all the buckle stopper at once.See page 66 for details.

Knife Manual Setup

The knife is turned on or off automatically as required for the fold pattern. When is pressed, the following screen is displayed. Select whether to return the number of sheets to the default value.

The item selected on the remote controller is displayed in green.

Setup Mode

If all parts do not go to their home positions, the button operates in the same way

as the button. If the fold quality is poor, go th Chapter 6.

When changing the setting for buckle stopper after the sheet number in roller gap has been changed in Roller Gap screen, use the Mico-Adjusting buttons. If the value is changed using Numeric Keypad screen, the roller gap is recalculated and the sheet number entered in Roller Gap screen may be returned to the default value.

This screen shows the calculated machine settings in a list, based on the settings on the Fold Pattern screen and on the sheet size. The settings can be fine-tuned using this screen.

Machine Description

/ Touch Panel Description

Page 34

1-2-7 Set Up - Register Mark Position Entering Screen

1-2 Touch Panel Description

EnteringScreen

23051

10207D1

Go back to the Setup - Guide-Buckle Screen

When you press this button, the guides and buckle shutes do not move tot match the changed register mark position.

Entering a Value

When you want to change the value, press this area to open the Numeric Keypad screen. Enter a new value. After entering a new value, press to set the guides and buckle chutes automatically to match the new register mark position.

Default Button

When you press this button, the following screen is displayed.



O K

Press this to return the values to the default.

Press this to carry over the values to indicated on the screen.

You can enter the values for register mark position.

Page 35

1-2-8 Set Up - Roller Gap Screen

1-2-8

Roller Gap Screen

1-2 Touch Panel Description

Use this function to move the upper blade over the lower blade, or when aligning the upper and lower scoring wheels.

If the actual roller gaps and the settings do not match, press

once to reset the gaps to the home positions.

This screen shows the gap between each pair of rollers, measured by the number of sheets, according to the settings indicated on the Fold Pattern screen. The gap between each pair of rollers can be adjusted automatically to the desired number of sheets.

This opens the Roller Gap Fine-Tune screen. (See the next page for details.)

Default Value Set/Indication Button

The machine calculates these settings using the sheet dimensions and fold pattern.

These areas indicate the buckle chutes and knives being used.

Increase the Gap

Each time this button is pressed, the roller gaps increase by one sheet. (Actually, the roller gaps do not change

until the button is

Gap Setting Auto

This section shows the gap between the rollers, measured by the number of sheets.

Decrease the Gap

Each time this button is pressed, the roller gaps decrease by one sheet. (Actually, the gaps do not change until the button is pressed.)

Roller Gap Adjusting Start Button

Press this button to set the new gaps after changing the values of the roller gaps.



: Send each roller directly to the gap setting.

: Send each roller to the home position, then to the gap setting.



pressed.)

Machine Description

/ Touch Panel Description

The upper perforation shaft is lifted, and the upper and lower perforation blades are separated. When upper perforation shaft is lifted, this button is indicated in orange color.

The upper perforation shaft

When moving the upper blade over the lower blade

23051 10207B1

Upper Perforation Blade

Lower Perforation Blade

returns to the original height.

Upper Scoring Wheel

Lower Scoring Wheel

23051

10207A1

Page 36

Each roller gap can be fine-tuned separately using this screen.

Roller Gap Micro -

Adjusting Screen

1-2 Touch Panel Description

23051

10208A1

The left side below the knife

The right side below the knife

The rear of the parallel folding area

Roller Gap

One sheet thickness x the number of sheets

Roller Gap Micro- Adjusting Value

Both/One Side Select Button

Press this to calibrate the thickness of one sheet. The gaps will not actually change until you return to the Roller Gap screen and press the Adjusting Start button.

Sheet thickness which is inserted in the sheet thickness detector (page 9) is displayed here. When changing to the different sheets or the sheet thickness has been changed by adjusting knob, press the Thickness Calibration button to update the displayed value. To reflect this value to the roller gap, press on the Roller Gap screen.

These select the rollers to be adjusted.

Press this button to return to the Roller Gap screen.

Thickness Zero- Point Adjusting Button

Press this button without a sheet on the sheet thickness detector. The zero-point will be reset.

Roller Number

Return Button Roller Select Button

Each roller gap is measured by the number of sheets

Thickness Measuring Button

: Adjust only one side : Adjust both sides at once

You can also select the roller to be adjusted directly.

300

The front of the parallel folding area

Example: The roller gap is 295 m.

Example: The roller gap is 305 m.

Roller Gap Micro- Adjusting Button

Minimum adjusting value 5 m

-5

Thickness of One Sheet

Setting the Value for the Roller Gap

Case of roller gap

1-2-9 Set Up - Roller Gap Micro-Adjusting Screen

Page 37

1-2-10 Set Up - Check/Instruction Screen

1-2-10

Check/Instruction

1-2 Touch Panel Description

23051

10209A1

Side Guides for Small Sheets

23051

10209D1

Automatic setup

OK Button

Press this button after the checks are completed. The Guide Buckle screen appears and the mechanisms move to their set positions.

Cancel Button

Press this button to return to the Guide/Buckle screen.

Check/Instruction Screen 1 Check/Instruction Screen 2

Before each mechanism is setup automatically to match the fold pattern and sheet size, the Check/Instruction screen appears. This lists the parts on the machine that must be checked befor e changeover.

Check Item Operation

(1) Check that all the

sheet guides are removed.

There are three types of sheet guides. Remove the sheet guides before doing the automatic setup. After doing the automatic setup, install the sheet guides to match the sheet size. When using small sheets, the sheet guides are not needed. For longer sheets, install or replace

the guides. (2) Lower the feed table. This prevents the suction head from hitting the table when the table moves. (3) Set the knife fold stop-

per and lower it.

Remove the knife fold stopper before doing the automatic setup.

If you will be doing knife folding, install the knife stopper after the automatic setup.

Remove or raise the knife fold stopper.

(4) If the distance from

the knife to the side edge of the sheet is less than 95 mm (3.8"), install the front and rear side guides at the positions shown.

Remove the side guides before doing the auto-

matic setup. If the distance from the knife to

the side edge of the sheet is less than 95 mm

(3.8") after the automatic setup is done, the

knife side guides may not automatically move

close enough to the sheets. In this case, install

the side guides for small sheets. If the distance

from the knife to the edge of the sheet is 95

mm (3.8") or more, the knife guides are set

automatically.

95mm

23051

10209E1

23051

10209C1

Machine Description

/ Touch Panel Description

Page 38

1-2-1 1 Set Up - Reset Screen

1-2-11

Reset

1-2 Touch Panel Description

23051

10210A1

All Reset Button

This button resets all fourteen mechanisms at the same time.

Single Function Reset Buttons

Each button resets one of the mechanisms.

Condition Indicator

After each reset function is completed, the symbol appears.

If the reset is not completed for some reason, the symbol appears.

If all section turns , the Check / Instruction screen

appears.

The AFC-566F includes fourteen parts that can be reset automatically. This screen is used to check that these parts are reset correctly.

Page 39

1-2-12 Memory Screen

1-2-12

Memory Screen

1-2 Touch Panel Description

23051

10211A1

Job No. Input Button Numeric Key Screen

appears. Input the required job number.

Fold Pattern Icon Indication

This icon indicates the fold pattern.

Sheet Length x Width (By 0.1 mm/0.005")

Job Name

Job Date

The screen scrolls upward by four jobs. The screen scrolls upward by one job. The screen scrolls downward by one job. The screen scrolls downward by four jobs.

Memory Delete

When this button is pressed, the following screen appears to confirm that you really want to delete the job.

Memory Write

Press here to store or memorize the job using the job number listed to the left. If the same job number has been used before, the older job information will be overwritten. The job information will be stored and the Completion screen will appear.

Memory Recall

Press here to recall the job you selected in the list. The machine parts will not move to their set positions yet.

Job Number

- This section stores information for each job based on a job number.

- Up to 200 jobs can be saved.

If the scroll button is kept pressing time, it scrolls the screen faster.

This section stores, recalls and deletes the settings for memorized jobs. All the settings on the following screens can be saved as one job:

- Main - Function screen

- Main - Condition screen

- Set up - Fold pattern screen

- Set up - Roller Gap screen

- Set up - Guide Buckle screen

Machine Description

/ Touch Panel Description

Page 40

1-2-13 Properties Screen

1-2-13

Properties Screen

1-2 Touch Panel Description

23051

10212A1

: ON : OFF

This value is displayed only when photoelectronic sensor is selected. When light amoutn is set to .

the sensor is OK if value in the range between 140 and 145 is displayed here. If the value out of the range is displayed, clean the sensor..

S o ftware V ersion

The current software versions of various parts of the machine appear here.

Please report these numbers in case of a

service calll.

This displays the input condition of the sensor and switch signal.

Sensor, Switch Input Monitor

Double Feed Detect Photoelectronic Sensor

Job Record

This presents the daily machine operating conditions.

Error Record

This presents a report of any errors.

Ser vice

This goes to the Service screen. This button should only be used

by service personnel.

Serial Number

The serial number of this machine appears here.

Total Feeding Counts

The total number of the sheets run through the machine appears here.

Total Run Time

The total run time of the machine (in hours) appears here.

Time Setting

This indicates the current time.

The time can be reset.

Da te S etting

This indicates the current data. The data can be reset. Press this area, and the Numeric Keypad screen appears. Input the date using the Numeric Keypad screen.

F eed T able Sensor

Sheet Loading Position Sensor

F eed T able Lowering Error Detect Switch

F eed T able Lower Limit Switch

Knif e Timing Sensor

Double Feed Detect Ultrasonic Sensor

Table Slow-down Sensor

Suction Head Support Detect Switch

Administ ra tor Settings

Enter the password to open the

Administr

ator setting screen.

See page

31.

This screen displays information about this machine: date setting, machine operating history, serial number, and software version. This screen also has buttons that go to other screens. The Monitor screen shows the input signals from the sensors. The Job Record screen and Error Record screen report on the operation of the machine.

Page 41

1-2-14 Properties - Administrator Setting Screen

1-2 Touch Panel Description

Administrator Setting

Screen

23051

10207D1

GAP



This is used to set the time to display the alarm for cleaning the vacuum pump filter. When the machine operating time has come up to a set time, a message screen will be displayed on the next power-up. See page 121 for details. Use the screen as an indicator for frequency of cleaning. When you press on the message screen, the count returns to zero.

Filter Cleaning Alarm for Pump

Filter Cleaning Alarm for Cooling Fan

This is used to set the time to display the alarm for cleaning the air filter of control box. When the power-on hours reach a set time, a message screen will be displayed on the next power-up. See page 121 for details. Use the screen as an indicator for frequency of a cleaning. When you press on the message screen, the count returns to zero.

Lubrication Alarm

This is used to set the time to display the alarm for lubricating. When the machine operating time has come up to a set time, a message screen will be displayed on the next power-up. See page 121 for details. Use the screen as an indicator for frequency of lubricating. When you press b on the message screen, the count returns to zero.

This screen is used to set up the alarm function which tells the time for filter replacement and lubrication by message.

Machine Description

/ Touch Panel Description

Page 42

This page is intentionally left blank

Page 43

2. Overview of Setup Procedure

2-1 Overview of Basic Setup

The complete setup consists of the basic setup (page 37) and the fine-tuning adjustments (page 57). Begin by doing the basic setup for the job, then fine-tune the sections of the machine while it is actually running sheets.

1. Turning on the Power Switch -

Page 37

3 3 4

Fold Pattern Screen

Keyboard Screen

Guide-Buckle Screen

Overview of Setup Procedure

2. Insert one sheet into the sheet thickness detector.

Page 38

3. Setting the Fold Pattern, Sheet Size, and Job Name on the Touch Panel Screen -

(Or recalling a saved job on the touch panel screen.)

Page 38

4. Setting the Positions of the Guides and Buckle Chutes -

Page 41

5. Loading the Sheets on the Table -

Page 43

6. Setting the Suction Head -

Page 46

Overview of Basic Setup

23051

20101A1

7. Setting the Register Guide -

Page 50

8. Setting the Perforation Blades -

Page 51

9. Setting the Knife Fold Section -

Page 53

10. Setting the Conveyor Section -

Page 54

13071 20101B1

Page 44

1. Setting the Belt Speed -

2-2 Overview of Fine-Tuning

23051

20201C1

23051

20201D1

Roller Gap Screen

Roller Gap Fine-Tune Screen

For Fine-

-Tuning Adjustments

Page 57

CondiitonScreen

23051

20201A1

2. Feeding One Sheet in Setup Mode -

Page 58

3. Checking the Sheet Feeding Angle -

Page 59

GuideandBuckleChuteScreen

23051

20201B1

4. Correct Fold Skew in Parallel Folding -

Page 60

Page 45

Overview of Setup Procedure

2-2 Overview of Fine-Tuning

Knife Stopper

Rear Side Guide

Front Side Guide (Operator Side)

5. Correct Parallel Shifts in Parallel Folding -

Page 65

6. Matching the Perforation Line to the Fold Knife -

Page 67

GuideandBuckleChuteScreen

23051

20201E1

23051

20201F1

Overview of Fine-Tuning

7. Setting the Perforation Blades and Scoring Blades -

Page 71

8. Setting the Knife Fold Section -

Page 75

13071 20201G1

23051

20201H1

Page 46

9. Correct Fold Skew on Buckle Chute Below

2-2 Overview of Fine-Tuning

23051

20201I1

Roller Gap Screen

Roller Gap Micro-Adjusting Screen

For Fine-

-Tuning Adjustments

23051

20201K1

Knife -

Page 77

10. Correct Parallel Shifts on Buckle Chute

Below Knife -

Page 81

11. Checking the Fold Quality -

Page 82

12. Other Adjustments.

GuideandBuckleChuteScreen

13071 20101G1

23051

20201J1

- Feed rotor section adjustment 4-12-1....................................................................... ... .... Page 83

- Buckle gate adjustment 4-12-2......................................................................................... Page 85

- Gap adjustments inside the buckle chutes 4-12-3........................................................... . Page 86

- Gap adjustments between the buckle chutes and fold rollers 4-12-4.............................. Page 87

- Stopper angle adjustment 4-12-5 ..................................................................................... Page 88

- Fold knife angle adjustment 4-12-6 .................................................................................. Page 89

- Adjustment of the hold-down roller pressure in the fold section 4-12-7............................ Page 90

Page 47

3. Basic Setup

3-1 Turn On the Power Switch

Initial Screen

Setup - Fold Pattern Screen

23051

30101A1

Cross

Turn on the power switch.

- The LCD display presents the Initial screen. Next, the Fold Pattern screen is displayed.

Basic Setup

Turn On the Power Switch

Page 48

There are two ways of doing this:

3-2 Setting the Fold Pattern and Sheet Size

A: Set the fold pattern and sheet size for a new job.

If the folding pattern you wish to start is not listed among the seventeen available patterns, press on the screen. If is pressed, the sheet is reversed.

If is pressed, the deflector in buckle chute 1 is set to reverse the sheet. When is pressed, the fold patterns,

, ,and cannot be selected.

Setup - Fold Pattern Screen

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30201A1

Fold Pattern

Input Sheet Size

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30201J1

A: Set the fold pattern and sheet size for a new job.

Recall a saved job. (See page 40)

Set the fold pattern and sheet size using the Fold Pattern screen.

Select the fold pattern.

Input the sheet size.

- Press the value box, and the Numeric Keypad screen appears. Enter the sheet size.

Max.: 850.0 x 558.0 (mm) (34.0 " x 21.965 ") Min.: 148.0 x 128.0 (mm) (5.830 " x 5.040")

Press on Set-up Fold Pattern screen.

The selected fold pattern and the input sheet size are entered. If 8-page cross fold, 12-page cross fold or 16page cross fold is selected, the Register Mark Position Entering Screen is displayed. If another custom fold pattern has been selected, the Sheet Insertion Instruction screen appears on the display. Go to step 5 on the next page.

Enter the register mark position.

The register mark is entered automatically, but should be changed if necessary.

After entering the settings, press OK.

Press OK to return to the values that were originally displayed.

Page 49

Press the Zero Setup button with no

3-2 Setting the Fold Pattern and Sheet Size

The keyboard screen does not appear in the following cases:

- If the Zero Setup button is pressed after a sheet is inserted

- If is pressed without pressing the Thickness Measuring button

- If the Thickness Measuring button is pressed without inserting a sheet

Sheet Insert Instruction Screen

23051 30201I1

One sheet

Zero Setup Button

Thickness Measuring Button

Thickness Measuring Detector

Keyboard Screen

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30201B1

Up to 20 letters

QWERTY Key Layout

Alphabetical Key Layout

If the stopper position for a buckle chute is set to 0, the deflector will be set and that chute will not be used.

sheets to set the value zero.

Insert the sheet into the sheet thickness detector.

- Prepare a strip of the sheet that you will fold.

- Push down the lever and insert the strip of the sheet into the sheet thickness detector.

Press the Thickness Measuring button.

The mesured value is displayed beside the button.

Press on Sheet Insertion Instruction screen.

The keyboard screen appears on the display.

Basic Setup

Setting the Fold Pattern and Sheet Size

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30201C1

Enter the job name.

- When you enter the job name, it will be displayed in job history . You do not have to enter the job name.

- If you do not enter the job name, the job is saved without a job name.

- Up to 20 letters can be entered.

Press

The Guide-Buckle screen appears on the display.

- If the custom fold pattern function has been selected, see steps to . If you are not

using the custom fold pattern, go to page 41.

Do this only if you are using a custom fold pattern (X button): Enter the stopper positions for any buckle chutes which will be used.

Setup - Guide - Buckle Screen

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Page 50

Enter the position for the knife stopper.

3-2 Setting the Fold Pattern and Sheet Size

The knife stopper is automatically moved to the maximum setting for knife folding.

The knife guides are automatically set to match the sheet width.

Setup - Guide - Buckle Screen

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B: Recalling a saved job.

Memory Screen

Setup - Guide - Buckle Screen

Completion Screen

Recall Confirmation Screen

13071 30201G1

The knife is initially set to On. If you are not using knife folding, select Off in the knife manual setup area.

Press the tab on the screen.

Find the job you want by using the arrow buttons on the right side of the screen.

- Or input the required job number using the Job No. Input button.

Setup - Guide - Buckle Screen

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Select the job number you want and press .

The Recall Confirmation Screen appears.

Press OK.

The job is recalled, and the Completion Screen appears.

Press OK.

The Guide-Buckle screen appears.

Page 51

Press on the Guide-Buckle screen.

3-3 Setting the Positions of the Guides and Buckle Chutes

CAUTION

Do not place anything under the feed table. The table may hit the obstruction and damage the machine.

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Sheet Guide in the Knife Fold Section

Knife Stopper

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Sheet Holder

- Check/Instruction Screen 1 appears before the machine starts the setup of the guides and buckle chutes.

Setup - Guide - Buckle Screen

Check/Instruction Screen 1

Check the following before moving the guides and buckle chutes.

(1) Lower the feed table. Press the Feed Table

Down button on the control panel. Lower the table until the space between the feed table and the suction head is about 50 mm (2”). Remove any sheets on the feed table.The table guide may hit the sheets during the automatic setup.

(2) Remove the knife stopper. (3) Remove the sheet guide in the knife fold sec-

tion.

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Basic Setup

Setting the Positions of the Guides and Buckle Chutes

(4) Remove the sheet holder in the register sec-

tion.

Page 52

Press OK on Check/Instruction

3-3 Setting the Positions of the Guides and Buckle Chutes

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Knife Stopper

Error Screen

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Error Code

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Side Guide For Small Sheets

Sheet Guides in the Knife Fold Section

Check/ Instruction Screen 2

Roller Gap Screen

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Screen 1.

- All the roller gaps are set at once.

- All the guides and buckle chutes move. Check/ Instruction Screen 2 appears afte r th e au to matic setup is finished.

- If the cover is opened during changeover, the machine stops immediately. In that case, close

the cover and press on the GuideBuckle screen to perform the changeover again.

(1)If you are not using knife folding, remove the

knife stopper. If you are using knife folding, set the knife stopper.

(2)Install the side guides for small sheets if the

sheet width is less than 95 mm (3.8"). Remove the side guides for small sheet if the sheet

width is 95 mm (3.8") or more. (3) Install the sheet guides in the knife fold section. (4) If a mechanism fails to reach to the home posi-

tion, the Error Screen appears. Use the error

code to tell which mechanism did not reach the

correct setting. Fins out why the part could not

move to the correct position.

Press OK on Check/Instruction Screen 2.

- The Roller Gap screen appears.

Page 53

Lower the feed table.

3-4 Loading the Sheets on the Table

The table can be stopped from lowering by pressing the Feed Table Up button while the table is moving.

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Suction Head Bar

Support

Support Locking Bar

Fan the sheets correctly. Load the sheets so they are aligned with the table guide. Align the head edge of the stack with the feed head.

The maximum stack height is 740 mm (29.1"). The maximum stack weight is 250 kg / 551 lb.

When you load the coated papers of 545 x 788 mm / 21.5" x 31.0" at the maximum, the weight is about 330 kg / 726.9 lb. Be careful not to exceed the maximum load.

WARNING

When lowering the suction head bar, be careful not to catch your finger.

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Align the corner

Table Guide

Feed Head

- Press the Feed Table Down button on the control panel. The table will lower.

Raise the suction head bar and support.

- Put the notch of the support over the rod.

Basic Setup

Loading the Sheets on the Table

Load the sheets on the table.

Lower the suction head bar.

- Lift the suction head bar a little, turn the support locking bar, raise the stay and lower the suction head bar.

Page 54

Raise the feed table.

3-4 Loading the Sheets on the Table

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If the stack is not arranged correctly, and the set register pin does not fit against the tail edge of the stack, straighten the stack. If the stack is not arranged correctly, the feeding action may become uneven.

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Feed Standby Screen

CAUTION

Do not adjust the suction head while the feed table is in stanby position. Otherwise, the suction head may hit the piled sheets.

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Set Register Pin

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Guide-Buckle Screen

- Press the Feed Table Up button on the control panel.

Check the position of the suction head while the table is rising.

- Position the suction head so that the set register pin just touches the tail edge of the stack.

- If you need to adjust the position of the suction head, adjust it by following the steps below.

1. Lower the feed table by 20 mm (0.79”).

2. Adjust the position using Guide-Buckle screen.

3. Raise the feed table.

Page 55

Check the position of the feed scale

3-4 Loading the Sheets on the Table

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Feed Table Knob

Insert the feed scale pin into the outer hole.

Check that the feed scale pin just touches the stack.

Feed Scale Pin

Locking Knob

Air Guide

Sheet Hold-down Bar

pin in relation to the stack.

- Insert the feed scale pin into the outer hole.

- Check that the feed scale pin just touches the stack.

- If necessary, adjust the position of the table by turning the feed table knob.

T o move the sheets to the rear

(1) Increase the value for the “table guide” by

required amount using Guide-Buckle screen.

The table guide moves to the rear.

(2) Turn the feed table knob and move the sheet to

the rear.

Basic Setup

T o move the sheets to the front

(1) Turn the feed table knob and move the sheet to

the front.

(2) Decrease the value for the “table guide” by

required amount using Guide-Buckle screen.

The table guide moves to the front.

Position the sheet hold-down bars.

- If the sheets are thin or narrow, move the bars inward.

- If the sheets are thick or wide, move the bars outward.

If necessary, attach and adjust the air guides.

- Set the guides to match the sheet size.

- When small size sheets are used, remove the air guide.

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Loading the Sheets on the Table

Page 56

Set the separator.

3-5 Setting the Suction Head

Adjust the separator using the grip area width adjusting knob and the sheet hold angle adjusting knob.

If double feeding occurs frequently, increase the grip area (direction shown by arrow 1) or loosen the locking screw first, then increase the separator angle (direction shown by arrow 2). For thin sheets, reduce the sheet hold angle.

(1):Grip Area Width Adjusting

Knob

(2):Sheet Hold Angle Adjust-

ing Knob

Separator

Locking Screw

If the vacuum piston feeds two sheets because the sheets are porous, raise the vacuum piston.If the vacuum piston fails to feed a sheet because the sheet is heavy, lower the vacuum piston.

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Suction Cup Height Adjusting Knob

Vacuum Piston Down

Vacuum Piston

- Adjust the separator so that the grip area is about 4 mm (about 0.16").

2 1

Set the height of the vacuum piston.

- In normal use, adjust the vacuum piston using

- To reduce the gap, turn the knob clockwise.

the suction cup height adjusting knob so that the gap between the sheets and the vacuum piston is about 1 mm (0.04").

4mm

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Page 57

Start the pump.

3-5 Setting the Suction Head

Vacuum Regulator Knob

Vacuum Gauge

Pressure Regulator Knob

Pressure Gauge

In normal use, both of the blower pressure adjusting knobs are set evenly. If the sheets are distorted on both sides of the suction cup because the sheets are curved, adjust the gap using the blower pressure adjusting knobs.

If the blower pressure is too strong, this can cause double feeding.

MAX

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10 to 15 Sheets

Blower Position Adjusting Knobs

Blower Pressure Adjusting Knobs

Separator

Separation Air

Blower Air Nozzle

- Press the Feed Start button on the control panel once.

- The air blowers will start, and the vacuum piston will grip the top sheet and lift it.

Adjust the pump pressure.

- Adjust the vacuum and the pressure regulator knobs so that the vacuum gauge is set to - 0.04 MPa (-5.8 psig) and the pressure gauge is set to 0.03 to 0.04 MPa (4.4 to 5.8 psig).

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Basic Setup

Setting the Suction Head

Adjust the blower pressure.

- Adjust the blower air using the blower position adjusting knobs and the blower pressure adjusting knobs. About 10 to 15 sheets at the top of the stack should be separated.

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Page 58

Adjust the separation air.

3-5 Setting the Suction Head

Separation Air Pressure Adjusting Knob

-When the mark on the knob is moved upward as far as possible, the air blowers produce the maximum output.

-About 10 sheets at the top of the stack should be separated.

MAX

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Front Air Adjusting Knob

Front Air Nozzles

- Adjust the separation air so that the head of the top sheet is lifted by the air so that it touches the feed rotor.

Adjust the front air.

MAX

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10 sheets

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Page 59

Set the side air outlet if necessary.

3-5 Setting the Suction Head

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Front/Side Air Adjusting Knob

Front air: Maximum Side air: Off

Front air: Off Side air: Maximum

- The large and heavy sheets may not be separated because the air does not reach to the end of the sheet. Use the side air to separate the edges of the sheets.

Basic Setup

Setting the Suction Head

After adjusting the air , press the Feed Stop button on the control panel.

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Page 60

Set the sheet edge guide.

3-6 Setting the Register Guide

The sheet edge guide prevents the edge of a sheet from catching on the gap of the side lay table.The smaller the area wh ere the sheet edge guide covers a sheet, the less interference there is with the sheet transfer.

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Sheet Edge Guide

These are especially important for light sheets. Use of these holders depends on the stiffness of the sheet.

Sheet Holder

-Arrange the steel and plastic balls to control the sheet smoothly. See the drawing to the right. When the top of the sheet is touching the stopper in the first buckle chute, place plastic balls near the bottom of the sheet. If the sheet is large or heavy, replace these with steel balls.

-If the sheets rise too close to the register guides, reduce the number of steel balls or replace them with the plastic balls. If the sheets do not rise far enough, increase the number of transport balls. If the sheets are caught in the ball holes, insert the plastic balls. See the following section, "Setting the Register Guide."

Buckle Stopper

End of Sheet

Ball

- Set the guide to match the far edge of the sheet.

Set the sheet holders.

- Set the sheet holders to match the sheet width.

Set the transport balls.

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Page 61

- If the perforation blades are not installed, install

3-7 Setting the Perforation Blades

Moving the upper blade over the lower blade

Upper Perforation Blade

Lower Perforation Blade

-Press the Emergency Stop button before starting this operation.Otherwise, the machine may start suddenly and cause severe personal injury.

-Wear cutting proof gloves during this o peration. Otherwise, a sharp blade can cause severe personal injury.

-Do not touch the blades.

WARNING

When you press this button, this button turns orange. The upper perforation shaft is lifted, and the upper blade is separated from the lower blade.

The upper perforation shaft returns to the original height. Return the perforation shaft after moving the upper blade sideways and away from the lower blade. Otherwise, the blades can hit each other and be damaged.

If you are doing perforating:

The perforation mechanism is aligned with the fold knife.

13071 30701D1

The position of the perforation line can be adjusted by changing the sheet position, as described in page 59 .

Upper Blade

Lower Blade

This line is aligned with the fold knife. Align the upper blade with this line.

them in the blade holder. See section 7-7.

Basic Setup

Use the functions shown to the right to move the upper blade over the lower blade.

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Setup - Roller Gap Screen

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Setting the Perforation Blades

Fit the tip of the upper blade against the top of the lower blade, and then tighten the assembly.

13071 30701C1

Page 62

Set the drive rollers evenly against

3-7 Setting the Perforation Blades

23051 30701E1

Upper Drive Roller

Lower Drive Roller

If you are not doing perforating:

Lower Blade

Upper Blade

More than 4 mm (0.4”)

Upper Drive Roller

Lower Drive Roller

the perforation blade.

Move the upper blade and lower blade apart by 10 mm (0.4").

Move the upper drive rollers and lower drive rollers apart.

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Page 63

Check the knife stoppers.

3-8 Setting the Knife Fold Section

When the sheet width is less than 95 mm (3.8"), attach the knife side guide for small sheets at the positions indicated on the SetupGuide - Buckle Screen.

Setup - Guide - Buckle Screen

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Side Guide

Match the arrow with the scale

Only when the sheet width is less than 95 mm (3.8"):

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Transport Rollers

Loosen this screw (4mm) and move the transport roller.

Parallel Folding Knife Folding

Loosen

- When not doing knife folding, remove the knife stoppers.

- When doing knife folding, install the knife stoppers.

Basic Setup

95mm

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When performing parallel folding

- Set the transport rollers.

- Install these rollers in positions where they prevent the sheets from lifting, so the sheets move smoothly.

When performing knife folding

- Loosen the locking screw and remove the transport roller.

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Setting the Knife Fold Section

Page 64

Install the conveyor in the correct

3-9 Setting the Conveyor Section

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Knife Folding

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Parallel Folding

Height Adjusting Wheel

Angle Adjusting Knob

position for the fold pattern.

- Install the conveyor in position to receive the folded sheets.

Adjust the height and the angle of the conveyor to match the delivery position of the folded sheets.

- Angle a conveyor table a little, so that the tail end of the sheet falls and it is delivered smoothly without interrupted by the next sheet.

- To adjust the angle of the conveyor table, turn the angle adjusting knob lifting the table a little.

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Page 65

Set the catch rollers to match the

3-9 Setting the Conveyor Section

Catch Roller

Locking Knob

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LOW HIGH

RUN STAND-BY

SPEED CONTROL UNIT

POWER ALARM

Conveyor Switch

Speed Adjusting Knob

length of the delivered sheet.

- Set the catch rollers so that each delivered sheet is immediately held between the catch roller and the transport belt.

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13071 30901D1

30901D1

Basic Setup

Setting the Conveyor Section

Set the conveyor switch to Run.

- If the speed adjusting knob is set to LOW (fully counterclockwise), the conveyor does not drive. Turn the knob to the middle position at least.

Now the basic setup is complete. See Chapter 4 for instructions on fine adjustments.

Page 66

This page is intentionally left blank.

Page 67

4. Fine-Tuning Adjustments

4-1 Setting the Belt Speed

If the speed is set correctly, the perforation line will run straight. Also if the speed is slow, the delivered sheets will be arranged neatly.

If the belt speed is changed after the other sections of the machine have been adjusted, the folding quality may deteriorate. Set the belt speed first. If you change the belt speed, be sure to check the folding quality.

The belt speed may need to be changed depending on the paper quality, printing, and the folding pattern.

Feed some sheets, check the fold qual ity, and make fine adjustments if necessary.

Set the speed of the fold rollers and transport belts.

Main - Condition Screen

Fine-Tuning Adjustments

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Setting the Belt Speed

Page 68

Press the Setup - Guide - Buckle tab

4-2 Feed One Sheet in Setup Mode

Setup - Guide - Buckle Screen

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If double feeding or misfeeding occurs, refer to section 6-1, “If an Error Icon Appears on the Screen”, and adjust the feed section again.

See page 97 for details.

Feed a sheet by pressing the Normal Jog button and check that the sheet is aligned correctly with the register guide. If the sheet is not aligned with the register guide, replace the plastic balls with steel balls, or increase the number of balls. If the sheet hits the register guide too hard and is bent, decrease the number of balls, or replace the steel balls with plastic balls.

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e near side of the sheet is aligned correctly.

on the screen.

Press Setup Mode.

The Feed Start button blinks.

Press the Feed Start button.

The feed rotor turns, and the fold rollers and transport belts start to move.

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Press the Test Feed button, then press the Feed Stop button immediately.

- One sheet feeds and stops in the register guide section.

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Page 69

Bring the sheet up to the stopper on

4-3 Checking the Sheet Feeding Angle

-If the reverse side of the sheet is fed, bring the sheet up to the second buckle stopper.

-When the sheet is very close to the buckle stopper, feed the sheet using the handwheel.

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Rear

Front

Handwheel

First Buckle Stopper

If the sheet is n o t tri m m ed correctly (not square), adjust the angle of the buckle stopper. If the angle is not correct, the sheet does not hit at a right angle to the stopper, and the folding is skewed.

See page 88 for details.

When doing knife folding, move the sheet to the fold knife using the Normal Jog button. Continue pressing the Normal Jog button and press the One Cycle button for the knife to deliver the sheet.

If the sheet stops between the perforation / scoring section and the knife fold section

13071 40301E1

If the sheet is scratched or smeared by the steel balls

the first buckle chute using the Normal Jog button on the control panel.

When the sheet touches the first buckle stopper , check that both corners of the sheet touch the buckle stopper at the same time.

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If the rear edge of the sheet touches the stopper first, turn the register guide angle adjusting knob counterclockwise so that the angle changes in the direction shown by the arrow.

Fine-Tuning Adjustments

Checking the Sheet Feeding Angle

Move the sheet to the conveyor using the Normal Jog button.

-See page 90, and increase the pressure of the hold-down roller shown in the illustration.

-See page 90, and decrease the pressure of the hold-down roller shown in the illustration.

Adjust the register guide angle, repeating step 4 in section 4-2.

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Page 70

Normally you can correct skewed folding by adjusting

4-4 Adjusting Fold Skew in Parallel Folding

- In normal operation, set the roller gaps on each side evenly. If the gaps are not even, this can cause the sheet to wrinkle, and the scoring or perforation line will not run straight.

- Only the first folding can be corrected by adjusting the register guide angle. To correct the second folding or others, adjust the roller gap and the buckle stopper angle.

Skewed Folding

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Buckle Chute Support

Bracket

Bolt

The accuracy of the parallel folding may improve as the machine runs.

Rear Side

Front Side

62135

23051

the angle of the register guide. If the skewed folding cannot be corrected by adjusting the angle, perform the following items.

1. Check the buckle chute setting

2. Adjust the roller gap

3. Adjust the angle of the buckle stopper

1. Check the buckle chute setting.

Set the buckle so that the bolt on the buckle support hits the bracket without any gap.

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2. Adjust the roller gap.

Check which side of the sheet being parallel folded is skewed.

If the folding is skewed as shown to the right, adjust the gaps this way:

(1) Make the first gap on the rear wider, or make

the first gap on the front narrower.

(2) Make the second gap on the rear narrower, or

make the second gap on the front wider.

Page 71

To make a rough adjustment

4-4 Adjusting Fold Skew in Parallel Folding

Adjusting each roller gap

Gap

Micro

Adjusting

Button

Both/One Side Select Button

Gap Micro Adjusting Button

(adjusting the number of sheets.)

- In this procedure, roller gap on both sides are adjusted evenly. To adjust the roller gap on either side only, refer to “In case of the fine tune “.

(1) Change the number of sheets on the Setup-

Roller Gap screen.

(2) Press .

Both ends of the roller are adjusted.

In case of the fine - tune (adjusting by 5

µm at minimum.)

(1) Press to display the Roller Gap Fine-

Tune screen.

(2) Select the roller gap to be adjusted.

- Touch the desired roller on the screen or press

or buttons to select the roller gap.

- The selected roller is displayed in blue.

(3) Change the gaps.

Setup - Roller Gap Screen

For Fine - Tuning

Setup - Roller Gap Fine - Tune Screen

8080

-5+5

Fine-Tuning Adjustments

Adjusting Fold Skew in Parallel Folding

: Increase by 5 : Decrease by 5

After you press the or buttons, the

gaps are actually adjusted a few seconds

µm

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later.

: Adjusting one side only : Adjusting both sides at once

Page 72

Adjusting all roller gaps at the same time

4-4 Adjusting Fold Skew in Parallel Folding

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300

-5

300

Setting the Roller Gap

The roller gap is 305µm.

The roller gap is 295

µm.

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Setup - Roller Gap Fine

- T une Screen

-1

0-1

0.2mm (200

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20351 40401K1

Setup - Roller Gap Screen

Thickness of the Sheet

Thickness Measuring Button

Sheet Thickness Adjusting Knob

(1) Display the Roller Gap Fine-Tune screen. (2) Adjust the roller gap using the sheet thickness

adjusting knob.

- Turn the knob to minus direction to widen the gap.

(3) Press the (Thickness Measuring button).

(4) Press on the Roller Gap screen.

- The minimum scale is 20

µm.

The value of the thickness of one sheet will

change.

All roller gap will be actually changed.

Page 73

Try the parallel folding again and

4-4 Adjusting Fold Skew in Parallel Folding

WARNING

Before checking the roller gaps, stop the machine completely.

Setup - Roller Gap Screen

Setup - Roller Gap Fine

- T une Screen

13071 40401H1

1 1 1 1

111 1

Thickness Zero Point Adjusting button

Thickness Measuring button

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One Sheet of Paper (52.2 gsm or 14 lb bond)

Handwheel

Sheet Holder

When checking the other roller gaps, remove the buckle chute. Insert strips of paper as shown below, and check the roller gaps.

check the folding accur acy.

- If the skewed folding still occurs, check the roller pressure on the front and rear rollers in the following procedures.

(1) Reset the “Zero” point of the roller gap.

- Press the Thickness Zero Point Adjusting button on Roller Gap Fine-Tune screen without inserting a sheet into the gap adjusting lever. “Zero” point will be saved.

(2) Insert one sheet of paper (52.2 gsm or 14 lb

bond) into the gap adjusting lever.

(3) Press the Thickness Measuring button on the

Roller Gap Fine-Tune screen.

Fine-Tuning Adjustments

(4) On the Roller Gap Fine-Tune screen, change

the number of sheet to “1“ on each roller.

(5) Press .

- All roller gap are set for one sheet.

(6) Remove the sheet holders in the register guide

section.

(7) Take the same type of paper you will run, and

tear it into strips. Insert one strip into the roller gap.

(8) Adjust the roller gap on the screen so that the

rollers turn slowly when you pull out the strip.

(9) Adjust the roller gap on both sides by the same

amount.

Adjusting Fold Skew in Parallel Folding

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Page 74

3. Adjust the angle of the buckle stopper

4-4 Adjusting Fold Skew in Parallel Folding

Here is the relationship between the sheet grain and the roller pressure:

When the sheet is thin and the sheet grain is parallel to the fold line -

The sheet may not be folded correctly because the sheet is weak. Increase the roller gap.

When the sheet is thick and the sheet grain is perpendicular (90

°) to the fold line -

The fold line may not be stable because the sheet is strong and is not folded tightly. Decrease the roller gap.

When the roller gap in the middle is wider than at the ends:

When gap in the middle is wider because the rollers are worn out, get the correct gap in the middle by tightening the gaps at the ends.

23051 40201G1

Match the deep slit to parallel the fold roller and the stopper.

Buckle Stopper Adjusting Knob

Locking Knob

Fixed Knob

Adjust the buckle stopper angle referring to section 412-5.

Page 75

4-5-1 Adjusting the positions of the buckle stoppers separately

4-5

Adjusting Parallel Shifts in Parallel Folding

Each time you press the or buttons, the stopper position changes. Once the value has been entered using the numeric keys, press to adjust all the stoppers at once.

When changing the setting for buckle stopper after the sheet number in roller gap has been changed in Roller Gap screen, use the Micro-Adjusting buttons. If the value is changed using Numeric Keypad screen, the roller gap is recalculated and the sheet number entered in Roller Gap screen may be returned to the default value.

If the fold position shifts by the same amount on the front and rear, adjust the buckle stopper position.

Change the value for buckle 1 through buckle 6 on the SetupGuide-Buckle screen.

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Setup-Guide-BuckleScreen

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40401G1

Fine-Tuning Adjustments

Adjusting Parallel Shifts in Parallel Folding

If you will not be doing knife folding, all the adjustments are finished.

Check that the knife stopper rises, and go to Chapter 5. When you will be doing knife folding, go to section 4-1.

Page 76

4-5-2 Adjusting the positions of the buckle stoppers at once

4-5 Adjusting Parallel Shifts in Parallel Folding

23051 40501C

The last panel is too short.

The last panel is too long.

Adjusting the difference.

If the last panel of the accordion-folded sheet is longer or shorter than the setting, you can adjust the positions of the buckle stoppers at once using the accordion-fold adjusting function.

Press the Accordion-fold Adjusting button on the Setup- Guide-Buckle screen.

The Accordion-fold Adjusting screen is

displayed.

Enter the correction value. The correction value is the difference between the setting and the actual length of the last panel.

- Enter the value using the Numeric Keypad screen.

- When the last panel is shorter than the buckle, enter a negative value.

Setup - Guide - Buckle Screen

Accordion-fold Adjusting Screen

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40401G1

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40401G1

Press .

The set values for the buckle 1 through 6

are automatically recalculate and the positions of the buckle stoppers are adjusted.

Enter the correction value.

Page 77

There are two different procedures for matching the

4-6 Matching the Perforation Line to the Fold

A: If you are doing perforating

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40601B1

Knife Stopper

Blade Holder Locking Screw

sheet position to the fold knife position: A: If you are doing perforating B: If you are not using perforating

Check that the perforation line matches the knife position.

Feed one sheet using Setup Mode.

- The sheet stops just before it is inserted into the fold knife section.

Move the sheet to a point just before the knife stopper using the Normal Jog button.

Check that the perforation line is aligned with the knife by viewing from point A as shown in the figure to the right.

- Adjust the positions of the blades following the steps below, if necessary.

(1) Adjust the position of the perforation blade.

- Loosen the locking screw of the blade holder and adjust the position of the blade right and left.

(2) Adjust the position of the register guide so that

the perforation line comes on the fold position.

Fine-Tuning Adjustments

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40601A

Matching the Perforation Line to the Fold

Setup - Guide - Buckle Screen

13071

23051

40601E1

40601D1

Page 78

If the perforation line is skewed straightly

4-6 Matching the Perforation Line to the Fold

-Press the Emergency Stop button before making this adjustment. Otherwise, the machine may start suddenly and cause severe personal injury.

-Do not touch the blades.

-Wear cutting proof gloves while making this adjustment. Otherwise, a sharp blade can cause severe personal injury.

WARNING

13071 40601C1

Knife and Perforation Line Shifted Parallel

Perforation Line Skewed Straight

Perforation Line Skewed from the Middle

Check if the deflector is not attach diagonally. Also widen the 6th roller gap on the sheet proceeding side. If the perforation line is still skewed, adjust the buckle chute angle. Refer to section 4-12-4.

If the perforation line is skewed from the middle

Check if the drive roller is set evenly. Also check if the sheet hits the side guides.

Page 79

Check that the desired fold position (register mark)

4-6 Matching the Perforation Line to the Fold Knife

B: If not doing perforating

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40601G1

Knife Stopper

If the fold line is shifted to parallel direction

When the register guide position is adjusted, positions of the knife guide (front and rear) are also adjusted automatically.

matches the fold knife.

Feed one sheet using Setup Mode.

- The sheet stops just before it is inserted into the fold knife section.

Move the sheet to the knife stopper using the Normal Jog button.

Fine-Tuning Adjustments

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40601F

Matching the Perforation Line to the Fold

Check that the desired fold position is aligned with the knife by viewing from point A as shown in the drawing for step 2.

-Adjust the feeding position of the sheet using the screen.

Desired Fold Position (Register Mark)

Setup - Guide - Buckle Screen

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40601H1

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40601I1

Page 80

- The sheet may be catching on the entrance of

4-6 Matching the Perforation Line to the Fold Knife

When the desired fold line (register mark) is skewed in relation to the knife

Knife Guides

- Adjust the front knife guide first, and then adjust the rear knife guide to match the sheet size.

- If the or button for the front knife guide is pressed, the rear knife guide is adjusted in the same direction.

- If the or button for the rear knife guide is pressed, only the rear knife guide is adjusted.

If the perforation line or register mark is skewed in relation to the knife, even though the perforating is not used and the adjustments for the roller gaps are correct, make a fine adjustment to the knife stopper angle.

page 88

one of the knife guides. If the sheet is catching, adjust the knife guide position using the screen.

- Check if the drive roller is set evenly.

- Widen the 6th roller gap on proceeding side.

- If the perforation line is still skewed, adjust the buckle chute angle. Refer to section 4-12-4.

Setup - Guide - Buckle Screen

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40601J1

-The sheet may be transported diagonally while it passes through the fold rollers. A roller gap where the sheet passes through after the deflector may not be set correctly. Example: If the deflectors for buckle chutes 2, 3, 4, 5 and 6 are set as shown in the drawing to the right, make fine adjustments to rollers 3, 4, 5, 6 and 7.

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40601K1

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Page 81

If you will be doing perforating and scoring, follow the

4-7 Setting the Perforation Blades and Scoring Blades

If you perform the perforation or scoring with the unfolded sheet,the perforation or scoring line may not run straight.

- Press the Emergency Stop button before starting this operation. Otherwise, the machine may start suddenly causing severe personal injury.

- Do not touch the blades.

- Wear cutting proof gloves while doing this operation.Otherwise, a sharp blade can cause severe personal injury.

WARNING

Perforation Shaft

Handwheel

steps listed below. If you will not be doing perforating and scoring, go to page 74.

Press Setup Mode on the SetupGuide - Buckle screen.

The Feed Start button blinks.

Press the Feed Start button once.

The motor starts, and the feed rotor and fold rollers turn.

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40701A1

Fine-Tuning Adjustments

Setting the Perforation Blades and Scoring Blades

Press the Test Feed button once, and press the Feed Stop button immediately.

- One sheet feeds, and stops in the register guide section.

Press the Emergency Stop button.

Open the safety cover.

Move the sheet to a point just before the perforation shaft using the handwheel.

CROSS FOLDER

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40701B1

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Page 82

Set the perforation blades and scor-

4-7

Setting the Perforation Blades and Scoring Blades

Perforation blade setup:

Set the upper and lower perforation blades so they just touch each other.

Upper Blade

Lower Blade

Scoring wheel setup:

13071 40701P1

Perforation Shaft Lifting Lever

Upper perforation shaft is lifted.

The quality of the perforating may change depending on the sheet material and sheet thickness. Adjusting the eighth roller gap can change the quality of the perforating.

13071 40701F1

13071 40701Q1

Upper Scoring Wheel

Lower Scoring Wheel Lower Scoring Wheel

Upper Scoring Wheel

Perforation Shaft Lifting Lever

Return the upper perforation shaft

ing wheels in the operating positions.

1. Turn the handwheel so that locking screw

2. Loosen the lower perforation holder, and adjust

3. Loosen the upper perforation holder, and move

- Change the groove on the lower scoring wheel depending on the sheet thickness. For thick sheet, use the thick groove.

- To give thick scoring line, use two upper scoring wheels.

1. Press the Emergency Stop button, and separate

- Lift the upper perforation shaft by turning the perforation shafts lifting levers. The levers are installed on both the front and the rear.

- If no perforation blades are installed, or if other perforation blades should be replaced, refer to section 7-7.

- To change the number of the perforation and scoring blade, remove the perforation shaft referring to section 7-5.

comes to the position to be loosened. the top of the lower blade to the operating posi-

tion, then tighten the holder using the set screw. the blade on the upper holder against the lower

blade, and then tighten the assembly.

the upper and lower perforation shafts.

2. Loosen the upper scoring wheel, and adjust the lower wheel holder to the operating position, then tighten the holder using the set screw.

3. Turn the handwheel so that locking screw comes to the position to be loosened.

4. Loosen the lower scoring wheel, and align the groove of the lower scoring wheel with the position of the upper scoring wheel, then tighten the set screw.

5. Return the upper perforation shaft by turning the perforation shafts lifting levers.

Page 83

(1) Remove the perforation shaft. Refer to section

4-7

Setting the Perforation Blades and Scoring Blades

Setup for optional center cut blade

- Each upper blade is made in two halves. The position of the upper blade can be changed by loosening the holder and moving the spacers.

- Before installing a new set of upper blades, make sure the two halves fit together correctly.

- The slit width is the total of the thickness of the spacers plus 1.6 mm (0.063") for the two upper blades (0.8 mm or 0.031" each).

Upper Blade

Lower Blade

Lower Trim Guide

Screw

Upper Trim Guide

Upper Blade

Holder

If doing perforating in the center of the sheet, set the drive rollers so that the sheets move smoothly.

Drive Roller

When doing perforating

7-5.

(2) Attach the center cut blade to the perforation

shaft, then install the perforation shaft to the machine.

(3) Adjust the slit width by changing the spacers

between the blades.

(4) Adjust the upper blade positions to create the

correct slit.

(5) Align the lower blades to the upper blades and

lock them with the set screws.

(6) Install the upper and lower trim guides on the

support bar. (There are two types of trim guides: 2 mm thickness and 5 mm thickness )

Spacers 1 mm thickness (1 pc) 2 mm thickness (3 pcs) 3 mm thickness (2 pcs) Installed in this order: 1, 3, 2, 2, 3, 2 mm.

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40701H1

Fine-Tuning Adjustments

Setting the Perforation Blades and Scoring Blades

Set the drive rollers.

- If the perforation line is within 12 mm (0.47") of the sheet edge, stabilize the sheet by holding the sheet edge with a drive roller, so that the perforation line will run straight.

- Attach the driver rollers evenly from the perforation blade.

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40701G1

13071 40701I1

Page 84

Adjust the roller gap for the drive

4-7

Setting the Perforation Blades and Scoring Blades

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40701K1

Drive Roller

If not doing perforation and scoring

When not doing perforating or scoring, the drive rollers are not used. Separate the upper and lower drive rollers.

rollers.

- Count the number of sheets that will pass through the drive rollers. Insert this number of strips into the gap adjusting lever. Adjust the roller gap using the gap adjusting knob so that the rollers turn slowly when the strips are pulled out.

Check that the wheels do not interfere with each other.

-Separate the upper and lower blades or wheels.

Perforation Blade Position

Drive Roller Position

13071 40701J1

Scoring Blade Position

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Page 85

Check the position of the side guides and the knife

4-8 Setting the Knife Fold Section

2 4

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40801A1

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40801B1

Handwheel

- If the or button for the front knife guide is pressed, the rear knife guide is also adjusted in the same direction.

- If the or button for the rear knife guide is pressed, only the rear knife gui de is adjusted.

Knife Guide

stoppers in relation to the sheet.

Feed one sheet in Setup Mode. (Press 1, 2 and 3 shown to the right.) Next, press the Feed Stop button (4).

- The sheet stops in the register guide section.

Press the Emergency Stop button.

Move the sheet to a point just before the knife guide using the handwheel.

Fine-Tuning Adjustments

Setting the Knife Fold Section

Check the gap between the sheet and the front knife guide.

Standard gap is 0.5 mm to 1.0 mm (0.02” to 0.04”). If the gap is not within this range, adjust the value for the front knife guide on the Setup-Guid e-Buckle screen.

Setup - Guide - Buckle Screen

Gap

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Page 86

Check that the position of the rear

4-8 Setting the Knife Fold Section

-Set each knife guide so that the leaf springs on the knife guide push against the sheet a little. Change the value for the rear knife guide to adjust the knife guide po si ti o n.

-When the or button for the rear knife guide is pressed, only the rear knife guide is adjusted.

Sheet

Leaf Springs

23051 40801G1

Knife Stopper

knife guide is correct.

Sheet

Setup - Guide - Buckle Screen

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40801E1

Check that both ends of the sheet hit the knife stopper at the same time.

If not, check the following:

- The sheet is hit the knife guides at the entrance of the knife folding section.

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40801F1

Page 87

If skewed folding occurs in the buckle chute below the

4-9 Adjusting Fold Skew

on Buckle Chute below Knife

Normally, the roller gaps should be the same on each side. If the gaps are uneven, this can cause the sheet to wrinkle, and the fold line will not run straight. Even if the roller gaps are set the same on each side, the folded side of the sheet may be delayed. This depends on the sheet material, the sheet thickness, and the sheet grain. If this happens, reduce the roller gap on the folded side a little.

Setup - Roller Gap Fine - Tune Screen

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40901F1

Right SideLeft Side

10th Roller

11th Roller

9th Roller

Setup - Roller Gap Fine - Tune Screen

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40901F1

Right Side

Left Side

10th Roller

11th Roller

9th Roller

knife, adjust the following items. If folding line is shifted parallel, refer to section 4-10.

1. Check the roller gap below knife

2. Adjust the angle of the knife

3. Adjust the angle of the buckle stopper below knife

1. Check the roller gap below knife

Check which side of the sheet being folded is skewed.

If the folding is skewed as shown in the drawing, increase the 9th, 10th roller gap on the right side, or make the gap smaller on the left side.

Fine-Tuning Adjustments

If the folding is skewed as shown in the drawing, increase the 9th, 10th and 11th roller gaps on the left side, or make the gaps smaller on the right side.

Right Side

Left Side

Right Side

The roller pressure is too strong. (The roller gap is too narrow.)

Transport Direction

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40901A1

Adjusting Fold Skew on Buckle Chute below Knife

Transport Direction

Left Side

The roller pressure is too strong. (The roller gap is too narrow.)

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40901B1

Page 88

To make a rough adjustment

4-9

Adjusting Fold Skew

on Buckle Chute below Knife

Adjusting each roller gap

Gap Micro Adjusting Button

Both/one Side Select Button

Gap Micro Adjusting Button

Indicating the Roller Gap

In this example, the roller gap is 305

In this example, the roller gap is 295

(adjusting the number of sheets.)

- In this procedure, roller gap on both sides are adjusted evenly. To adjust the roller gap on either side only, refer to “In case of the fine tune “.

(1) Change the number of sheets on the Setup-

Roller Gap screen.

(2) Press .

Both ends of the roller are adjusted.

Setup - Roller Gap Screen

For Fine - Tuning

Setup - Roller Gap Fine - Tune Screen

In case of the fine - tune (adjusting by 5

µm at minimum.)

(1) Press to display the Roller Gap Fine-

Tune screen.

(2) Select the roller gap to be adjusted.

- Touch the desired roller on the screen or press

or buttons to select the roller gap.

- The selected roller is displayed in blue.

(3) Change the gaps.

: Increase by 5 : Decrease by 5

µm

After you press the or buttons, the

gaps are actually adjusted a few seconds later.

: Adjusting one side only : Adjusting both sides at once

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40401C1

8080

-5+5

300

-5

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40401D1

Page 89

Make a test folding again, and check

4-9

Adjusting Fold Skew

on Buckle Chute below Knife

WARNING

Turn off the main power before checking the roller gap.

The relationship between sheet grain and roller pressure:

When the sheet is thin and the sheet grain is parallel to the fold line -

The sheet may not be folded correctly because the sheet is weak. Increase the roller gap.

When the sheet is thick and the sheet grain is perpendicular (90

°) to the fold

line -

The fold line may not be stable because the sheet is strong and is not folded tightly.

If the gap in the middle of the rollers is wider than the ends:

If the gap in the middle of the rollers is wider because the rollers are worn out, get the correct gap in the middle by tightening the gap at each end.

Handwheel

Gap Adjusting Points

the fold quality.

- If the sheet is still folded incorrectly, the buckle chute may not be installed cor rectly . If th e buckle chute is installed correctly, check the gap on each end of the roller.

1. Remove buckle chutes K1 and K2. page 131

2. On the Roller Gap Fine-Tune screen, change

the number of sheet to “1” on 9th through 12th roller.

3. Press . The roller gaps for the 9th

through 12th rollers are set to one sheet.

4. Make a strip of the same paper, and insert it into

the roller gap.

5. Adjust the roller gap on the screen so that the

rollers move slowly when the strip is pulled out.

6. Increase the roller gap by the same amount on

both sides.

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40901E1

Fine-Tuning Adjustments

Adjusting Fold Skew on Buckle Chute below Knife

Page 90

2. Adjust the angle of the knife.

4-9

Adjusting Fold Skew

on Buckle Chute below Knife

Fold Knife Angle Adjusting Knob

Locking Knob

The standard position is the middle of the scale.

Knife Stopper Adjusting Knob

Locking Knob

Fixed Knob

Buckle K1 Stopper Adjusting Knob

Locking Knob

Fixed Knob

Adjust the fold knife angle referring to section 4-12-6.

3. Adjust the angle of the buckle stopper below knife

Adjust the buckle stopper angle referring to section 412-5.

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Page 91

If a parallel shift occurs, adjust the stopper for that

4-10 Adjusting Fold Shift s

on Buckle Chute below Knife

Each time you press the or but-

tons, the stopper position changes. When a new value is entered using the numeric keys, press to adjust the stopper.

buckle chute.

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41001A1

Change the values for buckle chutes K1 and K2 on the Setup-GuideBuckle screen.

Setup - Guide - Buckle Screen

23051 41001B1

Fine-Tuning Adjustments

Adjusting Fold Shifts on Buckle Chute below Knife

Page 92

The fine adjustments were described in Section 4-10.

4-11 Checking the Fold Quality

If you press the Feed Stop button twice in a short period of time, the machine stops while the sheets are remained inside. Stop the transport motor after all sheets inside the machine are delivered.

After making the fine adjustments, fold some sheets, and check the fold quality.

Cancel the Setup mode.

Press the Feed Start button once.

- The motor starts running.

Press the Feed Start button again.

- The fold operation starts.

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40701A1

Fold some sheets, and then press the Feed Stop button.

The machine stops feeding the sheet.

- Press the Feed Stop button again to stop the transport motor.

Check the fold quality. If the fold quality is satisfactory, go to Chapter 5, “Starting and Running the Job.”

- If the fold quality is poor, go to Chapter 6, “Troubleshooting”, and resolve the problem.

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Page 93

4-12-1 Feed rotor section adjustment

4-12 Other Adjustments

Turn off the main power before starting this operation. Otherwise, the rotating parts can cause severe personal injury.

WARNING

Feed rotor mechanism

Vacuum Groove

Sheet

Feed Rotor

Air Cutoff Valve

Adjustment of space between feed rotor and sheet

Adout 8mm (0.31")

23051

Feed Table Sensor Adjusting Knob

-Air is pulled through the holes on the outside of the feed rotor, and into the groove in the center of the cylinder.

-The feed rotor turns while feeding each sheet.The groove remains in the same position, so the vacuum is produced at the bottom of the feed rotor.

-After the sheet has moved a certain distance, the vacuum is stopped by the air cutoff valve and the sheet is released.

-Set the ratio between the vacuum on time and vacuum off time using the feed rotor suction length setting on the Main-Condition screen.

MainConditionScreen

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41201A1

Fine-Tuning Adjustments

Other Adjustments

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41201C1

-If large or thick sheets are loaded and the vacuum is not strong enough to separate the sheets, move the sheets closer to the feed rotor. If coarse or porous sheets are loaded, provide more space between the sheet and the feed rotor.

-Adjust the space using the feed table sensor adjusting knob.

-In normal operation, the space is 8 mm (0.31") when the feed table reaches the upper limit point.

-When the table sensor is raised, the gap between the sheet and the feed rotor is reduced.

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Page 94

-If double feeding occurs often, raise the plate a bit.

4-12 Other Adjustments

Double feed stop plate adjustment

Double Feed Stop Plate

Adjusting Knob

Suction point

To Center

Left Right

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41201F1

Move the suction point to the right

Move the suction point to the left

Air Cutoff Valve

Set Screw

Valve Housing

Feed Rotor

Suction Point

When setting the valve housing, check that the feed rotor can turn easily and that air does not leak from the joint between the housing and the rotor. Check this by turning the handwheel.

-The standard position of the valve housing is to set the vacuum groove in the center. If the following problems occur, adjust the valve housing position.

-If using thin or curled down sheets: Move the suction point 2 to 3 mm (0.07" to 0.12") to the left. This will feed the front edge so that it prevents the sheet from hitting the entrance of the register guide.

Suction point adjustment

Loosen the set screw and turn the valve housing slightly to set the new position. Then hold the position using the set screw.

-If using thick or curled up sheets: Move the suction point 2 to 3 mm (0.07" to 0.12") to the right, so that the sheet is not caught by the feed rotor or taken around the rotor. The sheet should be straightened so that it will feed reliably.

Page 95

If the sheet can not enter the buckle chute easily,

4-12 Other Adjustments

4-12-2 Buckle gate adjustment

Gate Adjusting Knob

Gate Plate

Gate Scale

Standard Position

Adjust the gate within the range of the gate scale. If the gate exceeds the gate scale, it may hit the fold roller.

CAUTION

adjust the buckle gate.

-Usually it is not necessary to adjust the buckle gate. If the sheets are curled downward and do not enter the buckle section, extend the buckle gate using the gate adjusting knob.

-There are gate adjusting knobs on front and rear. Adjust both knobs evenly.

-The center of the gate scale marks the standard gate position.

Fine-Tuning Adjustments

-Thick sheets will not be folded correctly if the gate is extended too far.

23051 41202A1

Other Adjustments

Page 96

Normally, it is not necessary to adjust the gaps.

4-12 Other Adjustments

4-12-3 Gap adjustments inside the buckle chutes

Measure between the upper guide and the gate for the gap inside the buckle chute. The standard gap setting and the adjustable range are as follows:

- 1st buckle chute - 0.5 mm (0.02") (Adjustable between 0.5 - 1.5 mm [0.02” - 0.06”])

- 2nd buckle chute - 0.8 mm (0.031") (Adjustable between 0.5 - 1.5 mm [0.02” - 0.06”])

- 3rd and 4th buckle chutes - 2.0 mm (0.079") (Adjustable between 1.5 - 2.5 mm [0.06” - 0.1”])

- 5th and 6th buckle chutes - 2.3 mm (0.091") (Adjustable between 1.5 - 2.5 mm [0.06” - 0.1”])

- K1 and K2 buckle chutes - 2.0 mm (0.079") (Adjustable between 1.5 - 2.5 mm [0.06” - 0.1”])

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41203A1

Gap between Gate and Upper Guide

Gap A

Lock Nut

Set Screw

Upper Guide

Gate

As long as the sheet enters the buckle chute, the smaller the gap is set, the more accurately the folds will be made.

Sometimes the fold position for a buckle chute is not consistent. You may be able to correct this by reducing the gap inside the buckle chute. If sheet does not enter the buckle chute smoothly, widen the gap inside the buckle chute.

1. Remove the buckle chute.

2. Loosen the lock nut.

3. Adjust the gap inside the buckle chute by turning

the set screw. (There are four set screws for each buckle chute.) To make the gap wider, turn the screw clockwise.

4. After the adjustment is completed, fasten the lock

nut.

If the sheet is folded as shown in the drawing, the buckle gap may be set too narrow. Make the gap wider.

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Page 97

-Normally it is not necessary to adjust the gap

4-12 Other Adjustments

4-12-4 Gap adjustments between the buckle chutes and fold rollers

The gap can be reduced by turning the bolt in. Allow a minimum gap between the lock nut and bolt of 1 mm (0.04") to prevent the buckle chute and roller from hitting.

CAUTION

-Make the same adjustment on each side.

-If the gap between the buckle chute and fold roller is set too narrow, and the buckle chute is not set correctly , the end of the buckle chute may hit the roller, and thi s can damage the roller.

CAUTION

Buckle Chute Support

Bolt

Lock Nut

between the buckle chute and the fold roller. If the fold does not appear at the correct point, identify the affected buckle chute and change the clearance.

-Change the gap by adjusting the lengths of the bolts on the buckle chute supports.

-When the adjustment is complete, tighten the lock nut.

Fine-Tuning Adjustments

Other Adjustments

More than 1mm (0.04")

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Page 98

-Loosen the locking knob, then the stopper angle can

4-12 Other Adjustments

4-12-5 Stopper angle adjustment

Knife Stopper Adjusting Knob

Locking Knob

Fixed Knob

Buckle K1 Stopper Adjusting Knob

Locking Knob

Fixed Knob

23051 40201G1

Align the deep groove to parallel the fold roller and the stopper.

Buckle Stopper Adjusting Knob

Locking Knob

Fixed Knob

The fixed knob is rotated by a motor. Do not turn it by hand. This will change the home position for the motor.

be adjusted using the stopper adjusting knob. If just the buckle stopper adjusting knob is turned, only the front side of the stopper moves.

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41205B

Page 99

The fold knife is parallel to the roller when the arrow is

4-12 Other Adjustments

4-12-6 Fold knife angle adjustment

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41206B1

Left Side Right Side

Fold Knife Angle Adjusting Knob

Locking Knob

The standard position is the middle of the scale.

in the middle of the scale. Normally it is not necessary to adjust this setting. If the folded side of the sheet is delayed, adjust the fold knife angle by following the procedure listed below:

(1)Loosen the locking knob. (2)Turn the knife angle adjusting knob to adjust the

angle.

- When the knob is turned in the direction shown by the arrow in the figure, the left side of the fold knife moves down.

(3)Tighten the locking knob.

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41206A1

Fine-Tuning Adjustments

Other Adjustments

Page 100

Depending on the sheet weight, the sheet may not

4-12 Other Adjustments

4-12-7 Adjustment of the hold-down roller pressure in the fold section

Hold-down Roller

Adjuster

Increase the roller pressure

reach the knife stopper in the fold section.

Push in the adjuster.

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41207A1

While pushing in, turn the adjuster.

Pull out the adjuster so that the pin holds it in place.

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41207B1

23051

41207C1

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41207D1

Horizon AFC-566F User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1-1 Machine Description

1. Machine Description

1-2 Touch Panel Description

2. Overview of Setup Procedure

2-1 Overview of Basic Setup

2-2 Overview of Fine-Tuning

3. Basic Setup

3-1 Turn On the Power Switch

3-2 Setting the Fold Pattern and Sheet Size

3-3 Setting the Positions of the Guides and Buckle Chutes

3-4 Loading the Sheets on the Table

3-5 Setting the Suction Head

3-6 Setting the Register Guide

3-7 Setting the Perforation Blades

3-8 Setting the Knife Fold Section

3-9 Setting the Conveyor Section

4. Fine-Tuning Adjustments

4-1 Setting the Belt Speed

4-2 Feed One Sheet in Setup Mode

4-3 Checking the Sheet Feeding Angle

4-4 Adjusting Fold Skew in Parallel Folding

4-5

Adjusting Parallel Shifts in Parallel Folding

4-6 Matching the Perforation Line to the Fold

4-7 Setting the Perforation Blades and Scoring Blades

4-8 Setting the Knife Fold Section

4-9 Adjusting Fold Skew

on Buckle Chute below Knife

4-10 Adjusting Fold Shift s

on Buckle Chute below Knife

4-11 Checking the Fold Quality

4-12 Other Adjustments

Horizon AFC-566F User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1-1 Machine Description

1. Machine Description

1-2 Touch Panel Description

2. Overview of Setup Procedure

2-1 Overview of Basic Setup

2-2 Overview of Fine-Tuning

3. Basic Setup

3-1 Turn On the Power Switch

3-2 Setting the Fold Pattern and Sheet Size

3-3 Setting the Positions of the Guides and Buckle Chutes

3-4 Loading the Sheets on the Table

3-5 Setting the Suction Head

3-6 Setting the Register Guide

3-7 Setting the Perforation Blades

3-8 Setting the Knife Fold Section

3-9 Setting the Conveyor Section

4. Fine-Tuning Adjustments

4-1 Setting the Belt Speed

4-2 Feed One Sheet in Setup Mode

4-3 Checking the Sheet Feeding Angle

4-4 Adjusting Fold Skew in Parallel Folding

4-5 Adjusting Parallel Shifts in Parallel Folding

4-6 Matching the Perforation Line to the Fold

4-7 Setting the Perforation Blades and Scoring Blades

4-8 Setting the Knife Fold Section

4-9 Adjusting Fold Skew on Buckle Chute below Knife

4-10 Adjusting Fold Shift s on Buckle Chute below Knife

4-11 Checking the Fold Quality

4-12 Other Adjustments

4-5

Adjusting Parallel Shifts in Parallel Folding

4-9 Adjusting Fold Skew

on Buckle Chute below Knife

4-10 Adjusting Fold Shift s

on Buckle Chute below Knife