Horizon SmartStacker User Manual
*UM206030*
Sheet Cutter
SmartStacker
User’s Manual
Important Information
- This manual is designed to help you to operate and maintain the Smart-
Stacker. Please read and understand this manual, and keep it in a safe and
convenient place.
- Do not operate the SmartStacker until you read and understand the in-
structions in this manual.
- Horizon International Inc. shall not be liable for incidental consequential
damages resulting from: improper or inadequate maintenance by the cus-
tomer, unauthorized modication or misuse, or operation outside of the
environmental specications for the product.
- Horizon International Inc. pursues a policy of continuing improvement in
design and performance of the product. Therefore, the product design and
specications are subject to change without prior notice and without our
legal obligation.
- All rights are reserved. No part of this manual may be photocopied, repro-
duced or translated to another language without the prior written consent
of Horizon International Inc.
170107/HN,CF,AT,RN/IDCS5.5/ICS5/PXI
UM206030-10(000)
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.
This will help you to avoid an incorrect operation which may cause
Important
Attention
Note
Additional Information
➡
- Horizon International Inc. cannot anticipate every possible situation that might involve a potential
hazard. Therefore, the instructions in this manual and warning labels on the machine are not allinclusive.
- All equipment shall be locked out or tagged out to protect against accidental or inadvertent operation
when such operation could cause injury to personnel. Do not attempt to operate any switch, valve,
or other energy isolating device when it has been locked or tagged out.
- Do not operate the machine when any covers are removed.
- Some of the drawings in this manual show the machine with the covers removed to help in
explaining the details inside the machine.
problems with the machine, or make it necessary to go back to a
previous step.
This explains functional limitations and restrictions on the operation
of the machine.
This indicates a helpful hint.
This indicates additional information which will help you to operate
the machine efciently.
This explains what the machine will do after you operate it as instructed.
2 SmartStacker User's Manual
Glossary
The drawing below shows the terms we will use in this manual.
Job
Stack
Page / Piece
Block
Sheet
26030
10101A1
Page
3SmartStacker User's Manual
Basic Safety Precautions
WARNINGS for Operation
Keep your hands and ngers outside of the safety cover and away from any moving parts
while the machine is running. Otherwise, moving parts can cause severe personal injury.
Work alone when you operate the machine. Letting someone else operate the machine
could cause it to start suddenly without warning, causing severe personal injury.
Do not remove or bypass any safety features. Without these protective features, moving
parts can cause severe personal injury.
Be sure all other operators are clear of the machine before turning the handwheel. If someone else has their hands in the machine, turning the handwheel could cause personal injury.
As the working condition may include exposure to high noise levels which can lead to hearing damage, the employer and operator should ensure that any necessary hearing protection is provided and used by the operator and others in the work area.
Only for optional Sheet Feeder :
• Do not stare into beam of sheet edge indicator (class 1 laser product*1).
Otherwise, light beam can cause severe personal injury.
*1 This laser meets the IEC standards, 60825-1: 2007,class 1 LASER product.
• Use of controls or adjustments or performance of procedures other than these specied
here in may result in hazardous radiation exposure.
Sheet Edge Indicator
4 SmartStacker User's Manual
WARNINGS for Operation
When you lower the feed table, do not place your feet under the table.
Press the Emergency Stop button before turning the drive handwheel. If the machine
accidentally starts suddenly, this can cause severe personal injury.
Turn off the power switch before adjusting the machine unless instructed otherwise. If the
Start button is pressed when the power is on, the machine may cause severe personal injury.
CAUTIONS for Operation
If you turn off the Power switch, wait about ten seconds before turning it on again. Otherwise, a circuit board may be damaged.
If a jam occurs, remove all the jammed sheets before you start the operation again. Otherwise the machine may be damaged.
Do not use the machine for any improper purpose. Otherwise, the performance of the machine cannot be guaranteed.
5SmartStacker User's Manual
Sheet Feeder
Warning Label Locations and Meanings
Feeder
1st Regist
Unit
Identification Label
Taiyo Seiki Co., Ltd.
1600 Aza-Shironoshita, Asahi, Shin-asahi-cho,
Takashima, Shiga 520-1501, Japan
Biwako Factory
Manufactured: 1.2014
1st Process
Unit
Identification Label
Taiyo Seiki Co., Ltd.
1600 Aza-Shironoshita, Asahi, Shin-asahi-cho,
Takashima, Shiga 520-1501, Japan
Biwako Factory
Manufactured: 1.2014
Do not get into under the feed table. Otherwise, you may be injured
Do not approach your hands and ngers while the roller is rotating.
Otherwise your hands and ngers may be caught by the rotating roller.
Do not stare into beam of sheet edge indicator (class 1 laser product*1).
Otherwise light beam can cause severe personal injury.
*1 This laser meets the IEC standards, 60825-1: 2007, class 1 LASER product.
Laser Diode Wavelength: 625-640 nm
Maximum Power: 5 mW
Do not approach your hands and ngers to the suction head while the feed table is
moving. Otherwise your hands and ngers may be caught by the suction head.
There are electric parts inside. Take care when opening the cover.
Otherwise, high voltage can cause severe personal injury.
6 SmartStacker User's Manual
90-degree
Turn Conveyor
Keep your hands and ngers away from the rollers while they are turning.
Otherwise your hands and ngers may be caught by the moving rollers.
Merge
Conveyor
Merge Stacker
Merge Stacker
2nd Process
Unit
Do not approach your hands and ngers while the stack table of the Merge Stacker is
moving. Otherwise your hands and ngers may be caught by the stack table.
There are electric parts inside. Take care when opening the cover.
Otherwise, high voltage can cause severe personal injury.
Keep your hands and ngers away from the belts and rollers while the belts are
moving. Otherwise your hands and ngers may be caught by these parts.
7SmartStacker User's Manual
Contents
Important Information ........................................................................................................................1
Safety Precautions ............................................................................................................................2
Glossary ............................................................................................................................................3
Basic Safety Precautions...................................................................................................................4
Warning Label Locations and Meanings ...........................................................................................6
1 Machine Description
1-1 Features of the Machine .....................................................................................14
1-1-1 SmartStacker Conguration ................................................................................14
1-1-2 Directions described in this manual .....................................................................15
1-1-3 Sheet Flow ...........................................................................................................16
1-1-4 Delivery ................................................................................................................19
1-1-5 Supported Jobs ...................................................................................................22
1-1-6 Capability of Each Line ........................................................................................26
1-1-7 The Role of Panels of the SmartStacker and the FLC ........................................27
1-2 SmartStacker Screen Descriptions .....................................................................28
1-2-1 Run - Main Screen - Part 1 ..................................................................................28
1-2-2 Run - Main Screen - Part 2 ..................................................................................29
1-2-3 Run - Main Screen - Part 3 ..................................................................................30
1-2-4 Run - Main Screen - Part 4 ..................................................................................31
1-2-5 Run - Main Screen - Part 5 (for Merge Stacker) ..................................................32
1-2-6 Run - Main Screen - Part 6 (for B2 Stacker) ........................................................33
1-2-7 Run - Setting Screen - Part 1 ..............................................................................34
1-2-8 Run - Setting Screen - Part 2 (for Merge Stacker) ..............................................35
1-2-9 Run - Setting Screen - Part 3 (for B2 Stacker) ....................................................36
1-2-10 Run - Setting Screen - Part 4 (for B2 Stacker) ....................................................37
1-2-11 Run - Fine Adjustment Screen - Part 1 ................................................................38
1-2-12 Run - Fine Adjustment Screen - Part 2 ................................................................39
1-2-13 Run - Fine Adjustment Screen - Part 3 (for B2 Stacker) ......................................40
1-2-14 Run - Page Size Fine Adjustment Screen - Part 1 (for Merge Stacker) ....................41
1-2-15 Run - Page Size Fine Adjustment Screen - Part 2 (for B2 Stacker) ....................42
1-2-16 Run - Cutter Position Fine Adjustment - 1st Process Unit Fine Adjustment Screen ..............43
1-2-17 Run - Cutter Position Fine Adjustment - 2nd Process Unit Fine Adjustment Screen .............44
1-2-18 Run - Scoring Position Fine Adjustment Screen (Optional) .................................45
1-2-19 Setting - Size Setting Screen - Only for Ofine System- Part 1 ...........................46
1-2-20 Setting - Size Setting Screen - Only for Ofine System - Part 2 ..........................47
1-2-21 Setting - Size Setting Screen - Only for Ofine System - Part 3 ..........................48
1-2-22 Setting - Size Setting Screen - Only for Ofine System - Part 4 (for B2 Stacker) ..............49
1-2-23 Trim Guide Setting Screen ..................................................................................50
1-2-24 Memory - Main Screen - Part 1............................................................................51
1-2-25 Memory - Main Screen - Part 2............................................................................52
1-2-26 Information - Main Screen - Part 1 ......................................................................53
1-2-27 Information - Main Screen - Part 2 ......................................................................54
1-2-28 Information - Input Monitor Screen - Part 1 .........................................................55
1-2-29 Information - Input Monitor Screen - Part 2 .........................................................56
1-2-30 Information - Input Monitor Screen - Part 3 .........................................................57
1-2-31 Information - Input Monitor Screen - Part 4 .........................................................58
8 SmartStacker User's Manual
1-2-32 Information - Input Monitor Screen - Part 5 .........................................................59
1-2-33 Information - Input Monitor Screen - Part 6 (for B2 Stacker) ...............................60
1-2-34 Information - Signal I/O Monitor Screen ..............................................................61
1-2-35 Information - Single Operation Screen - Part 1 ...................................................62
1-2-36 Information - Single Operation Screen - Part 2 ...................................................63
1-2-37 Information - Single Operation Screen - Part 3 ...................................................64
1-2-38 Information - Single Operation Screen - Part 4 ...................................................65
1-2-39 Information - Error History Screen .......................................................................66
1-2-40 Information - Administrator - Main Screen ...........................................................67
1-2-41 Information - Administrator - Administrator Setting Screen - Part 1 ...........................68
1-2-42 Information - Administrator - Administrator Setting Screen - Part 2 ...........................69
1-2-43 Information - Administrator - Input Signal Enable Settings Screen - Part 1 ...........................70
1-2-44 Information - Administrator - Input Signal Enable Settings Screen - Part 2 ...........................71
1-2-45 Information - Administrator - Input Signal Enable Settings Screen - Part 3 ...........................72
1-2-46 Information - Administrator - Motor Enable Settings Screen - Part 1 ..............................................73
1-2-47 Information - Administrator - Motor Enable Settings Screen - Part 2 ..............................................74
1-2-48 Information - Administrator - Motor Enable Settings Screen - Part
1-2-49 Information - Administrator - Adjustment Mode Screen .......................................76
1-2-50 Information - Administrator - Network Conguration Screen ...............................77
1-2-51 Error - Main Screen .............................................................................................78
1-2-52 Error - Unit Screen ...............................................................................................79
3 ....................................75
1-3 Finishing Line Controller Screen Descriptions ....................................................80
1-3-1 Run - Main Screen - Part 1 ..................................................................................80
1-3-2 Run - Main Screen - Part 2 ..................................................................................81
1-3-3 Run - Main Screen - Part 3 ..................................................................................82
1-3-4 Run - Main Screen - Part 4 ..................................................................................83
1-3-5 Run - Main Screen - Part 5 ..................................................................................84
1-3-6 Run - Main Screen - Part 6 ..................................................................................85
1-3-7 Run - Main Screen - Part 7 ..................................................................................86
1-3-8 Run - Main Screen - Part 8 ..................................................................................87
1-3-9 Run - Main Screen - Part 9 ..................................................................................88
1-3-10 Run - Main Screen - Part 10 ................................................................................89
1-3-11 Run - Main Screen - Part 11 ................................................................................90
1-3-12 Run - Main Screen - Part 12 ................................................................................91
1-3-13 Run - Main Screen - Part 13 ................................................................................92
1-3-14 Run - Job Details Screen .....................................................................................93
1-3-15 Run - Diagnostic Tool Screen ..............................................................................94
1-3-16 Setting - General(1) Screen - Part 1 ....................................................................95
1-3-17 Setting - General(1) Screen - Part 2 ....................................................................96
1-3-18 Setting - General(1) Screen - Part 3 ....................................................................97
1-3-19 Setting - General(1) Screen - Part 4 ....................................................................98
1-3-20 Setting - General(2) Screen - Part 1 ....................................................................99
1-3-21 Setting - General(2) Screen - Part 2 ..................................................................100
1-3-22 Setting - Job List Screen ...................................................................................101
1-3-23 Setting - Line Screen .........................................................................................102
1-3-24 Setting - Banner Screen Part 1 ..........................................................................103
1-3-25 Setting - Banner Screen Part 2 ..........................................................................104
1-3-26 Setting - About the FLC Screen .........................................................................105
9SmartStacker User's Manual
2 Procedures for Near Line Operation
2-1 Daily Safety Check ............................................................................................108
2-2 Changeover .......................................................................................................112
2-2-1 Before a Changeover ........................................................................................ 112
2-2-2 Starting the Changeover .................................................................................... 114
2-2-3 Setting the Trim Guides for the Gutter Trim ....................................................... 116
2-2-4 Recalling Fine Adjustment Values .....................................................................117
2-3 Loading the Sheets on the Sheet Feeder ......................................................... 118
2-3-1 Loading the Sheets on the Feed Table ..............................................................118
2-4 Starting a Job ....................................................................................................122
2-5 Pausing and Resuming a Job ...........................................................................123
2-5-1 Pausing and Resuming a Job Using the FLC ....................................................123
2-5-2 Holding and Resuming a Job Using the FLC ....................................................124
2-5-3 Removing Any Blank Pages ..............................................................................126
2-6 Reprint - When using the Merge Stacker ..........................................................127
2-6-1 Selecting the Reprint List Preparation Method ..................................................127
2-6-2 Deciding How to Handle Reprinting ...................................................................128
2-6-3 How the Stack is Delivered If a Jam Occurs .....................................................129
2-6-4 Reprinting the Whole Job from the Beginning ...................................................131
2-6-5 Reprinting Only the Bad Stack ..........................................................................133
2-6-6 Reprinting Only the Bad Block ...........................................................................137
2-6-7 Reprinting Only the Bad Sheet ..........................................................................140
2-7 Error Recovery - When using the B2 Stacker ..........................................................143
2-7-1 How the Sheets are Delivered If a Jam Occurs .................................................143
2-7-2 Resuming the Job ..............................................................................................144
2-8 Changing the Setting of Handy Scanner for FLC ..............................................145
2-8-1 Turning down the beep sound ...........................................................................145
2-8-2 Turning off the automatic scan mode ................................................................145
2-8-3 Returning to default settings ..............................................................................145
3 ProceduresforOfineOperation
3-1 Setting the Control Panel - When using the Merge Stacker................................................148
3-1-1 Setting the Job ...................................................................................................148
3-1-2 Setting the Delivery Action .................................................................................153
3-1-3 Starting a Job ....................................................................................................155
3-2 Setting the Control Panel - When using the B2 Stacker .........................................156
3-2-1 Setting the Job ...................................................................................................156
3-2-2 Setting the Delivery Action .................................................................................159
3-2-3 Starting a Job ....................................................................................................162
3-3 Saving, Loading, and Deleting Jobs ..................................................................163
3-3-1 Saving a Job ......................................................................................................163
10 SmartStacker User's Manual
3-3-2 Loading a Job ....................................................................................................164
3-3-3 Deleting a Job ....................................................................................................165
3-3-4 Protecting the Job Data .....................................................................................166
3-3-5 Exporting the Job Data ......................................................................................167
3-3-6 Recalling Exported Jobs ....................................................................................168
4 Procedures for Inline
Operation
4-1 Daily Safety Check ............................................................................................172
4-2 Changeover .......................................................................................................175
4-2-1 Setting the Trim Guides for the Gutter Trim .......................................................175
4-3 Reprint - When using the Merge Stacker ..........................................................176
4-3-1 How the Stack is Delivered If a Jam Occurs .....................................................176
4-3-2 Restarting the Operation ...................................................................................177
4-4 Post Processing ................................................................................................178
4-4-1 Removing Any Blank Pages ..............................................................................178
5 Fine Adjustments
5-1 Adjusting the Sheet Feeder ...............................................................................180
5-1-1 Adjusting the Position of the Suction Head .......................................................180
5-1-2 Adjusting the Feed Table Position .....................................................................180
5-1-3 Setting the Suction Head ...................................................................................181
5-1-4 Setting the Side Air ............................................................................................185
5-1-5 Adjusting the Table Guide and the Rear Guide .................................................187
5-1-6 Feed Rotor Adjustments ....................................................................................188
5-2 Adjusting the Cutting Positions .........................................................................190
5-2-1 Adjusting the Length and Width of the Finished Size ........................................190
5-2-2 Adjusting the Trim Width - Short Edge ..............................................................191
5-2-3 Adjusting the Trim Length - Long Edge .............................................................192
5-2-4 Adjusting Individual Trim Positions ....................................................................193
5-3 Adjusting the Guide Positions ...........................................................................196
5-3-1 Adjusting the Register Guide for the 1st Regist Unit .........................................196
5-3-2 Adjusting the Ejecting Gates on the 2nd Process Unit ......................................198
5-3-3 Adjusting the Angle Adjusting Guides on the Merge Conveyor .........................199
5-3-4 Adjusting the Stopper on the Merge Stacker .....................................................200
5-3-5 Adjusting the Pressure of the Sheet Hold-Down Plates in the Merge Stacker ........201
5-3-6 Adjusting the Stopper on the B2 Stacker ...........................................................202
5-3-7 Adjusting the Pressure of the Sheet Hold-Down Plates in the B2 Stacker ..............203
5-4 Adjusting the Optional Scoring Unit ..................................................................204
5-4-1 Adjusting the Scoring Positions .........................................................................204
5-4-2 Adjust the Scoring Depth ...................................................................................205
6 Troubleshooting
6-1 If an Error Icon Appears ....................................................................................208
11SmartStacker User's Manual
6-2 If an Error Code Is Displayed on SmartStacker ................................................ 211
6-3 If a Warning Screen is Displayed on SmartStacker ..........................................345
6-4 If an Error Code Is Displayed on FLC ...............................................................349
6-5 If a Warning Message Is Displayed on FLC ......................................................354
6-6 Pole Lamp and Up/Down Buttons .....................................................................355
6-6-1 Pole Lamp .........................................................................................................355
6-6-2 Up/Down Buttons ...............................................................................................355
6-7 Problems with Cutting Quality ...........................................................................356
6-7-1 Cutting is Skewed in the 1st Process Unit .........................................................356
6-8 Problems with the Sheet Feeder .......................................................................357
6-8-1 Misfeeding .........................................................................................................357
6-8-2 Double Feeding .................................................................................................360
6-9 If a Jam Occurs .................................................................................................363
6-9-1 Clearing the sheets after a jam ..........................................................................363
6-9-2 Removing the jammed sheets ...........................................................................364
7 Maintenance
7-1 SmartStacker ....................................................................................................370
7-1-1 Cleaning the Sensors ........................................................................................370
7-1-2 Cleaning the Air Filter ........................................................................................375
7-1-3 Cleaning the Belts .............................................................................................377
7-1-4 Lubrication .........................................................................................................380
7-1-5 Checking the Sheet Guide .................................................................................382
7-1-6 Checking the Rollers .........................................................................................386
7-2 Optional Sheet Feeder ......................................................................................387
7-2-1 Cleaning the Vacuum Piston and Air Filter ........................................................387
7-2-2 Replacing the Separator and Suction Rubbers .................................................389
8 Appendix
8-1 Specications ....................................................................................................392
8-1-1 Specications of SmartStacker ..........................................................................392
8-1-2 Specication Requirement on PC for FLC .........................................................395
8-2 Accessories .......................................................................................................396
8-2-1 SmartStacker Accessories ................................................................................. 396
8-2-2 Optional Sheet Feeder Accessories ..................................................................401
8-2-3 Component parts for FLC-H ..............................................................................404
8-2-4 Optional B2 Stacker Accessories ......................................................................405
12 SmartStacker User's Manual
1 Machine Description
This chapter explains the main features on
the machine, the touch panel screen on
the SmartStacker and the screen on the
Finishing Line Controller.
1
1-1
123456789
10
11
Features of the Machine
1-1-1
SmartStacker Configuration
Here are the sections included in a typical production line, along with the abbreviations we will use in this
manual.
1 Sheet Feeder (SF) (Option)
2 1st Regist Unit (1Reg)
3 1st Process Unit (1Pro)
4 90-degree Turn Conveyor (TC)
5 2nd Regist Unit (2Reg)
6 2nd Process Unit (2Pro)
7 Merge Conveyor (MC)
8 Merge Stacker (MS)
9 Output Shift Conveyor
10
1m Conveyor
11
B2 Stacker (BS)
14 SmartStacker User's Manual
Features of the Machine
1-1-2
Delivery Side
Delivery
Side
Directions described in this manual
Infeed Side
Drive Side
Drive Side
Delivery
Operator Side
Operator Side
Drive Side
Delivery
Side
Side
Infeed
Infeed Side
Side
Operator SideOperator Side
Infeed Side
Operator SideOperator Side
Delivery Side
Operator Side
Operator Side
Drive Side
Infeed
Side
15SmartStacker User's Manual
Features of the Machine
1-1-3
To
To
Top Tray
Top Tray
11
Sheet Flow
GateGate
MergeMerge
24 23 22 2124 23 22 21
28 27 26 2528 27 26 25
Scoring Unit
(Optional)
16 15 14 1316 15 14 13
20 19 18 1720 19 18 17
Gate
Gate
2nd Process
(9 Cutters)
12 11 10 912 11 10 9
Gate
Gate
2nd Regist
8 7 6 58 7 6 5
33
4pc4pc
4 3 2 1
4 3 2 1
11
22
2pc2pc
3pc3pc
To B2
To B2
Stacker
Stacker
16 SmartStacker User's Manual
16 15 14 13
16 15 14 13
20 19 18 17
20 19 18 17
24 23 22 21
24 23 22 21
28 27 26 25
28 27 26 25
4 3 2 14 3 2 1
8 7 6 5
8 7 6 5
12 11 10 9
12 11 10 9
4pc4pc
Features of the Machine
1st Process
(14 Cutters)
4
4
8
8
3
15
15
18
18
21
21
11
11
14
14
17
17
3
7
7
2
2
6
6
1
10
10
13
13
1
5
5
9
9
4
4
8
8
3
28
28
24
24
27
27
20
20
23
23
26
26
16
16
19
19
22
22
25
25
12
12
15
15
18
18
21
21
11
11
14
14
17
17
3
7
7
10
10
13
13
28
28
6
6
9
9
24
24
27
27
2
2
1
1
5
5
16
16
20
20
19
19
23
23
26
26
1st Regist
4
4
8
8
12
12
7
7
11
11
15
15
10
10
14
14
18
18
13
13
22
22
17
17
21
21
25
25
28
28
3
3
6
6
24
24
9
9
27
27
2
2
20
20
5
5
23
23
26
26
Double Feed Detect
Ultrasonic Sensor
1
1
4
4
8
8
3
15
15
18
18
21
21
11
11
14
14
17
17
7
7
10
10
13
13
3
2
2
6
6
9
9
16
16
19
19
22
22
12
12
25
25
1
1
5
5
12
12
16
16
20
20
24
24
19
19
28
28
23
23
27
27
22
22
26
26
25
44
25
33
22
4pc
4pc
4pc4pc
11
2pc2pc
17SmartStacker User's Manual
Features of the Machine
10 mm
Offset Guide
GateGate
Stack
Stack
Gate
Gate
Gate
Gate
Eject
Eject
26030
10103C1
18 SmartStacker User's Manual
Features of the Machine
1-1-4
The processed stacks will be delivered to either of two destinations.
Delivery
When Using in the Near Line or Inline System
To Completed Conveyor
The stack goes to the complete
conveyor in case that the stack is
reached to the planned number of
sheets.
To Uncompleted Conveyor
A stack which is less than the
planned number of sheets goes to the
uncompleted box in all cases.
For Example of 3 stacks in job
• A jam on middle of the rst stack
Uncompleted Box
Completed Box
(Eoj = End of Job)
• A jam on middle of the last stack
• The job end on middle of the last stack
19SmartStacker User's Manual
Features of the Machine
• The job end on middle of the rst stack
• If the “Offset” or “None” is selected for the operations after job processing on the FLC screen, the
previous job is not delivered, and the Line Clear button is pressed
• The user changes starting sheet number (from the Press UI)
• The user changes starting sheet number after the jam
Uncompleted Box
Completed Box
• Break of a job with changeover
20 SmartStacker User's Manual
Features of the Machine
When using in the ofine system
To Completed Conveyor
The stack goes to the completed conveyor in case that the stack reaches the planned number of
sheets.
The block whose number of sheets reaches the planned number goes to the completed conveyor.
To Uncompleted Conveyor
A stack which is less than the planned number of sheets goes to the uncompleted box in all cases.
• The jam occurs at rst block of the second stack when the job is set in 3 stacks.
Fist Block
Uncompleted Box
Completed Box
Second and After Block
21SmartStacker User's Manual
Features of the Machine
1-1-5
Sheet Size
Uncut Size
Max.
762 mm
30.000”
Finished Size
Supported Jobs
530 mm
20.865”
Min.
When delivered to Merge Stacker
279.4 mm
11.000”
When delivered to B2 Stacker
380mm
14.965”
330 mm
12.995”
330mm
12.995”
Standard Size
ISO A Series: A2 / A3
ISO B Series: B2 / B3
Inch Series: 18” x 24” / 17” x 22” /
13” x 19”
Merge Stacker
Max.
381 mm
15.000”
Min.
100 mm
3.940”
When the optional scoring unit is
installed, the size is limited as follows.
With Scoring
Without Scoring
148 mm
5.83”
177.8
7”
through
(Min.)
105 mm
4.13”
530 mm
20.865”
105 mm 4.135”
through
265 mm
10.43”
Finished Size
B2 Stacker
Max.
762 mm
30.000”
530mm
20.865”
Min.
380 mm
14.965”
210 mm
8.270”
22 SmartStacker User's Manual
Number of Cuts
28-up (Max)
Features of the Machine
Feed
Direction
E
G
G
G
G
G
G
E
G G G
1234
5678
9101112
13141516
17181920
21222324
25262728
1 to 4 rows (8 cutters)
E E
: Edge Trim
E
(Bleed Trim)
: Gutter Trim
G
1 to 7 columns (14 cutters)
Slit Positions
Several blocks can be included in a job.
(The system can feed sheets with different numbers of pages.)
Attention
The maximum number of sheets which is capable in one job is as following:
• For near line operation: 100,000 sheets
• For inline operation: 50,000 sheets
23SmartStacker User's Manual
Features of the Machine
Limitations of offset and delivery
The offset function and delivery function can be set in parallel to the feeding direction. They cannot
be set in perpendicular.
OK NG
The ejection operation can be done after the last row and other one row.
No.1
23
45
OK NG
No.2
45
offset
1
eject
123
4567
eject
123
4567
No.1
123
123
No.2
23
45
eject
eject
1234
eject
34
51
offset
The ejecting operation
cannot be done twice
except after the last row.
4567
24 SmartStacker User's Manual
Limitation for blank page removal
Mechanism of Blank Page Removal
Features of the Machine
1. The gates slide to the
2. The gates open. 3. The blank pages which are
position where the blank
pages will pass.
OK NG
Feed direction Feed direction
The blank pages must be arranged
from the tail edge along the feeding
direction so that the several pages
can be removed at once.
Leading
edge
Tail
edge
Leading
edge
hit against the gates will be
ejected.
Printed page Blank page
The blank pages are arranged in the
leading edge.
The blank pages are not continued from the tail edge.
Tail
edge
Feed direction Feed direction
If there are at least one row
between the blank pages as this
drawing, the blank page can be
ejected.
Feed direction Feed direction
However, in case that the blank pages are continued against the feeding
direction of the 2nd process unit, if
all the pages on the next row is blank
pages, the removal is possible.
Feed direction Feed direction
If there are at least one row
between the blank pages as
this drawing, the blank page
can be ejected.
Next sheet
Next sheet
First
row
Last
row
In case that several rows which
have different separation position
are continued, the SmartStacker
cannot eject the blank pages.
In case of this drawing, the SmartStacker cannot eject the blank
pages. Because two rows which
have different separation position
are continued.
In case of this drawing, the
SmartStacker cannot eject
the blank pages. Because
First
row
Last
row
two rows which have different separation position are
continued.
Next sheet
Next sheet
25SmartStacker User's Manual
Features of the Machine
1-1-6
Functions Ofine Near line Inline
Sheet Cut and Stack Enable Enable Enable
Create a Job Enable Disable Disable
Fine Adjustment of
the Job Setting
JDF-based Operation Disable Enable Enable
Blank Page Rejection Disable Enable Enable
Operation Using the
Banner Sheet
Continuous Operation
of Multiple Jobs
Reprint Process
after an Error
Progress Report to the
Upstream System
Capability of Each Line
Enable
Disable Enable Enable
Disable
Disable
Disable Disable Enable
Enable
but ag is
necessary to set
Enable
using banner sheet
Enable
(You print the reprint
list and pass it to an
operator for press.)
Enable
but the ne-
adjustment should
be made before
printing is started
Enable
Enable
• Ofine and Near line can be switched just by pressing a button, but to use as the Inline system, the machine
should be installed again.
26 SmartStacker User's Manual
Features of the Machine
1-1-7
The Role of Panels of the SmartStacker and the FLC
The role of panels of the SmartStacker and the FLC, the procedure to create and start a job, and also to
make the ne adjustment are different depending on the conguration of line. The outline is shown below.
Near Line
Main Role
Saving the ne adjustment
•
values to the memory
beforehand
Recalling the saved adjustment
•
before running the job that was
set the ag
Main Role
Starting the job
•
Setting the ag on the
•
job
Creating the reprint list
•
Panel
FLC
FeederSmartStacker
Pallet
Creating the job
DFE
(UBM)
Press
Ofine
Saving the ne adjustment
•
values to the memory
beforehand
Recalling the saved job setting
•
Inline
Enter the values for the ne
•
adjustment before starting
the operation so that the
ne adjustment values are
carried over.
Panel
Panel
Creating the job
•
Starting the job
•
FLC
FeederSmartStacker
FLC
DFE
(UBM)
Press
Pallet
Creating the job
•
Starting the job
•
Creating and starting
the job for print
DFE
(UBM)
Press
SmartStacker
27SmartStacker User's Manual
1-2
SmartStacker Screen Descriptions
1-2-1
1
2
3
4
Run - Main Screen - Part 1
1 TEST
5
pieces/hr
6
Job Name
1
When you recall a job from the job memory in the
ofine system, the current job number and name are
displayed here.
Additional Information
1 TEST
If you change the settings or ne adjustment
settings after recalling the job from the memory
screen, the name of the job shown in the draw-
ing above will change to red. Save the modied
job with a different name if necessary.
Production Speed Indicator
2
The current operation speed (number of pages per
hour) is shown here.
Feed Counter for Uncut Sheets
3
The total number of fed uncut sheets is displayed
here. This number is saved even if the power is
turned off. If you are using this machine in the
ofine mode and want to change the job, press
(Clear) to reset the counter to zero.
Delivered Block Counter
4
This shows the number of blocks that have been
delivered. The number is saved even if the power is
turned off. Press
zero.
Counter for Delivered Pages (Pieces)
5
The total number of delivered pages is displayed
here. Every piece is counted. The number is saved
even if the power is turned off. Press
reset the counter to zero.
Preset Counter for the Number of Uncut
6
Sheets
If you are using the machine in the ofine mode, and
you press
sheets is displayed. The number of uncut sheets
which should be fed is calculated automatically using
the counter for the number of pages in each block
and the preset counter for the total number of blocks.
Number of sheets already fed
(Clear) to reset the counter to
(Stop), the preset number of uncut
0
10
Total number of sheets to be fed
(Clear) to
28 SmartStacker User's Manual
SmartStacker Screen Descriptions
1-2-2
1
2
3
4
Run - Main Screen - Part 2
pieces/hr
5
Counter for the Number of Blocks in Each Stack
1
When the machine is used in an ofine system and
is selected for the stack function, the number
of blocks stacked is displayed.
Number of blocks
already stacked
Number of Blocks in Each Stack
2
When the machine is used in an ofine system and
is selected for the stack function, enter the
number of blocks in each stack.
Stack Function On/Off
3
Use this to set how many blocks should be stacked in the
stacker before the blocks are delivered.
If you are using the machine in an inline system
or a near line system, the setting on the press is
displayed and this function cannot be set from this
screen. If you are using the machine in the ofine
mode, set this function on this screen.
Number of blocks in each stack
0 5
Press this button to
clear the number of
blocks which have
already been stacked.
This turns off the stack function. The machine will
continue feeding the uncut sheets until the pages
reach the upper limit of the Merge Stacker.
This turns on the stack function. The
machine will stop after feeding the number
of blocks in one stack.
Offset Function On/Off
4
Use this setting to set whether or not each block is
offset by the stacker.
If you are using the machine in an inline system or a near
line system, the setting on the press is displayed and this
function cannot be set from this screen. If you are using the
machine in the ofine mode, set this function on this screen.
The offset function is turned off (straight stacking).
All of the blocks of pages are stacked without any offset.
The offset function is turned on.
One block is offset to the right, and the next
block is offset to the left.
Number of Sheets for One Block
5
Enter the number of sheets for one block.
If you are using the machine in an inline system or a
near line system, the setting on the press is displayed
and this function cannot be set from this screen. If
you are using the machine in the ofine mode, set this
function on this screen.
29SmartStacker User's Manual
SmartStacker Screen Descriptions
1-2-3
1
Run - Main Screen - Part 3
pieces/hr
2
3
Counter for the Number of Pages
1
(Pieces) in Each Block
This indicates the number of pages included in one
block, and the number of pages already stacked.
Number of pages
already stacked
0 5
Press this button to clear the number of
pages which have already been stacked.
Preset Counter for the Total Number of Blocks
2
If you are using the machine in the ofine mode and select
(stop) for the preset function, enter the preset number of blocks.
Number of blocks
already delivered
0 50
Number of pages included
in one block
Total preset number of blocks
Press this button to clear the
number of blocks which have
already been delivered.
Total Preset Function On/Off
3
Use this setting to set how many blocks should be
delivered before the machine stops. If you are using the
machine in an inline system or a near line system, the
setting on the press is displayed and this function cannot
be set from this screen. If you are using the machine in the
ofine mode, set this function on this screen.
The preset function is turned off. The machine
continues feeding the uncut sheets until the
Stop button is pressed or the sheets run out.
The preset function is turned on. The machine
stops after feeding the number of blocks which
has been set on the preset counter.
All of the blocks are stacked without offsetting.
When the top of the stack reaches to the
upper limit of the Merge Stacker, the sets are
delivered.
30 SmartStacker User's Manual
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