BAUM BAUM 26/BAUM 30 1ST STATION FOLDER W/CONTINUOUS FEED INSTRUCTION MANUAL ©Baumfolder Corp., 2004 PAGE 1 Printed in U.S.A.
© 2004 BAUMFOLDER CORPORATION All Rights Reserved WARNING • Do not operate this machine without all guarding in place. • Do not make adjustments or perform maintenance on this machine with power on. • Keep the machine and the work area clean and free of spills to prevent accidents. • Be sure to replace any safety decals that may have been detached for any reason.
CONTENTS DESCRIPTION I.) II.) III.) IV.) V.) VI.) VII.) VIII.) IX.) PAGE Safety .................................................................................................................................................................. 6 Warning Labels ................................................................................................................................................. 9 Introduction Overview ...............................................................................
CONTENTS DESCRIPTION X.) XI.) XII.) XIII.) XIV.) XV.) PAGE Setting Fold Plates ........................................................................................................................................... 38 Scoring/Slitting/Perforating ........................................................................................................................... 39 1.0 . Slitter Shaft Removal .......................................................................................................
List of Tables DESCRIPTION PAGE Table 1. Machine Setup Parameter List ................................................................................................................................ 20 Table 2. Statistics ................................................................................................................................................................. 21 Table 3. Machine Settings .................................................................................................
FUNDAMENTAL SAFETY INSTRUCTIONS! The diagrams and descriptions used in these instructions are not necessarily applicable to the specification of the machine supplied. Modifications, made for reasons of technical or operational improvement, are embodied without notice.
1.0.3 FUNDAMENTAL SAFETY INSTRUCTIONS! The machine/installation is designed exclusively for paper finishing of minimum and maximum sheet sizes (see corresponding operating instructions). Using the machine/ installation for purposes other than those mentioned above is considered contrary to its designated use. The manufacturer/supplier cannot be held liable for any damage or injury arising from such misuse. The risk of such misuse lies entirely with the user.
1.1.8 1.3.1.4 Spare parts must comply with the technical requirements specified by the manufacturer. Spare parts from original equipment manufacturers can be relied to do so. Before starting up or setting the machine/plant in motion, make sure that nobody is at risk. 1.3.2 1.1.9 Report any accident that occurs due to a malfunction of the machine though all prescribed safety precautions were observed directly to our agency or to the Heidelberg service department (VFKD).
1.4.1 Electric energy 1.5 Description and definition of the safety labels and pictographs on the machine 1.4.1.1 Use only original fuses with the specified current rating. Switch off the machine/plant immediately if trouble occurs in the electrical system. Replace damaged pictographs with new ones. The corresponding reference numbers are indicated. 1.4.1.2 Warning! Folding rollers rotate in opposite directions.
INTRODUCTION OVERVIEW 68" 265" (6.73m) 149" (3.78m) 2 (1.73m) 5 46" 11 (1.17m) The 1st station (parallel) folder with continuous feeder contains the following main components (Figure 1): 1. Continuous Feeder 2. Register 3. 1st Station Folder (Parallel) 4. Fold Roller Baumset settings 5. Fold Plates 6. Slitter Shafts (not shown) 7. Delivery (Stacker, not shown) 8. Operator Controls 9. Double Sheet Detector (not shown) 10. Vacuum Pump (not shown) 11. Handwheel 3 4 8 1 54.5" (1.38m) 77.5" (1.
ELECTRICAL CONNECTIONS 1.0 Wiring the Unit (3 phase) All repair or disassembly work must be performed by qualified personnel. Before inspecting the electrical system, always turn the main power switch OFF before opening the door of the circuit cabinet. Check that your power supply meets the requirements given in the machine specifications. Use an allen wrench to unlock the circuit cabinet door and open it. Feed the power supply cable from your distribution panel through the side of the circuit cabinet.
CONTINUOUS FEEDER OPERATION 1.0 Loading the Continuous Feeder Before loading the sheets, use the knobs (Figure 4-1) of the side guide to set the side for the correct folding format according to the scale on the feeder. Make certain that you always maintain the required 8-12 mm gap between the incoming sheets and the alignment ruler. The bottom table is equipped with a conveyor belt that is wide enough to stretch across all usable formats.
Stack feeding is stopped automatically if the tab of the switch is pushed beyond a preset point by the leading sheet edge (6-3). Make certain that the switch tab remains in a verticle position during the sheet feed operation and that it does not vibrate (flutter) with each passing sheet. The position of the switch tab is set at the factory. If necessary, it can be adjusted both horizontally and vertically by knobs located on the feeder side frame.
2 1 3 4 5 6 7 8 Figure 8 1.2 Sheet Separation and Suction Force The holddowns (9-1) on the two sides of the sucker wheel (9-2) should always be positioned slightly lower than the sucker wheel. This causes the sheet which is sucked against the wheel to arch up slightly allowing the top sheet to be peeled away from a second sheet which may be clinging to it. With stiff and heavy paper, the holddowns must be set so that the suction wheel can still pick up the sheet.
Adjust the front blowers in such a way that the sheet stack is fanned across the entire sheet width. Use less air for thin paper so that the sheets are not pushed back. The sheets must not arch because it may cause them to stick together. The lateral blowers (suction plate blowers figure 10) must be positioned so that the blowers rest on the sheet stack at a slight angle. The balance is adjusted at the rear counter weight. The swing span can be adjusted by restricting the lift range.
When a single sheet passes through, the scanner element (136) stays in the off-position. When a double sheet is fed, the scanner is activated and drawn into the microswitch (13-7) and the double is stopped. Only the sheet feed is switched off. To remove the double sheet, raise the arm. After fault removal, reset the "sheet-feed" start switch. For thin paper, loosen the knurled screw and reset the lever spring tension. Afterwards retighten the knurled screw.
INSTALLING FOLD PLATES OPERATOR CONTROLS Install the fold plates into the folder. Lock the fold plates in position with the clamping levers (15-1). See "Fold Pan" section for fold plate setting procedure. Plug the stacker power cable into the corresponding outlet on the main control enclosure on the continuous feeder. Pull the handwheel (Figure 1-11) to manually turn the fold rollers to be sure that they are operating smoothly.
1.DCT500 Control Panel BAN-5 17 8 12 10 14 24 2 25 28 1 29 + 4 5 6 31 32 33 + + 0 h 7 3 8 2 9 1 30 + 10 DCT 500 36 9 13 11 16 15 26 27 3 22 18 23 19 4 20 5 21 7 34 6 35 Figure 1. DCT500 Control Panel. Displays 01) Large Display Eight digit multi use display composed of 7-segment LED’s. 02) Small Display Three digit multi use display composed of 7-segment LED’s.
07) Output Indicator The output indicator lights when the Batch Preset PV is reached and the user has selected a batching option. The output indicator is lit during the time the batching option is active. Batching options are Feed interruption, Marking table, Speed up table or Kicker.
2. Run Mode Functions When the folder is started with the RUN/MAINT jumper in the RUN position, the system is enabled for the user to make machine setups and to fold paper. The counter will start up in production mode, the normal operating mode of the counter. In this mode, various job parameters can be displayed on the large display (1), and the small display (2) shows the gap length. The suction length display (3) is active in this mode and shows the suction length as a percentage of sheet length.
P00: Input Counter The number of sheets sensed by the sheet count sensor is multiplied by the factor number displayed, but does not effect the Batch Down Count, Number of Batches and the Rate. The Factor can range from 1 to 24. If the Input Factor is changed, it also changes the value of the Output Counter to the same setting. P01: Output Counter This number is added to the Total Output Count but does not effect the Batch Down Count, Number of Batches and the Rate.
P12: Production stoppage time Select this parameter to view the time during which the machine is not operating. The Pause function and Sheet feed are disabled. The time is shown in hours (decimals) and reset to zero for a new job. P13: Setup Time Select this parameter to view the Setup time in hours (decimals). The time indicator is reset to zero for a new job. P14: Pause Time Select this parameter to view the time during which the machine is held by the Pause function (P23 enabled). .
P23: Pause This function is used to activate/deactivate a Pause counter. Select this parameter to display the period of time for which the pause function was last engaged. It is not possible to feed in sheets when the Pause function is activated. P24: Network Network is only displayed when "Network" is selected and enabled in the Service menu. Not available in Software Version 100.300. P25:Easy Mode This function can only be used on machine types P-b20, C-b20, C-2020 and P-2020.
P30: Port 1 Inputs P30 indicates Port 1 input status. P31: Port 2 Inputs P31 indicates Port 2 input staus P32: Port 3 Inputs P32 indicates Port 3 input status P33: Port 4 Inputs P33 indicates Port 4 input status P34:Port 5 Inputs P34 indicates Port 5 input status P35: Port 1 Outputs P35 indicates Port 1 output status # P60 Function Drive start key delay Operation Adjustable with Key Combin. P61 K2 release time Adjustable mit RP2 Adjuster(large display) + Variable Displayed 0 - 13 secs.
P42: Folding station delivery Display of the time registered by the photoelectric barrier on the folding station delivery. P43:Counting input Display of the time registered by the photoelectric barrier on the counting input. Important: The counting input is not monitored when Kicker batching is selected. If the counting input is removed when the machine is activated, error message S-C 5 /B-C 5/STOP 13 is displayed once and the drive is shut down.
2.2 Counter Setup Mode Batching Time Adjustment + Pushing this key puts the counter in counter setup mode. Counter setup mode is used to prepare the controller to run a job. The large display (1) shows the batch preset on the left-hand side and the batching output time on the righthand side. The decimal points in the large display (1) will move from side to side to indicate that a parameter may be changed. The small display (2) shows the batching type. The suction length display (3) is active.
2.3 Learn Mode Select Suction Mode + This key places the counter in learn mode. Learn mode can only be activated if the folder is idle. The learn mode allows the user to setup the suction valve controller. Both manual and automatic setup is accomplished in this mode. The large display (1) shows two separate data items. On the left is the suction mode and the right shows sheet length. The small display (2) shows the current gap length. The suction length display is active.
Sheet Length Setting Greater than or equal to 30 cm. Less than 30 cm., and greater than or equal to 27 cm. Less than 27 cm., and greater than or equal to 24 cm. Less than 24 cm., and greater than or equal to 21 cm. Less than 21 cm. Table 12. Suction Length Function Resultant Suction Length Percentage. 30% of Sheet Length 25% of Sheet Length 20% of Sheet Length 15% of Sheet Length 10% of Sheet Length. Exit Learn Mode 0 h Pressing any of these keys will cause the controller to change to a new mode. 2.
2.6 Production Mode Suction Length Adjustment + Enter Run Mode and Select Large Display Content h These keys do not operate as mode select keys in counter setup. In all other modes, the keys both select the large display (1) contents and place the counter into run mode. Pushing one of the buttons will light the button’s associated LED and cause the parameter to be displayed. If both the input and output count keys are pressed simultaneously, then both LEDs go on and the waste count is displayed.
3. Controller Input Description 3.
3.3 24VDC Inputs Thermal The Thermal input indicates that a motor is overheating. If this fault occurs, the message “overload” will be displayed, sheet feeding will stop, the Drive and Pile outputs will be turned off. Once the fault has been cleared, the machine can start feeding sheets again by pressing the Drive Start switch followed by the Sheet Start switch. Wrong Sheet The Wrong Sheet switch is used to sense a jam in the output register.
Reference Designator LED1 LED2 LED3 LED4 LED5 LED6 LED7 LED8 LED9 LED10 LED11 LED12 Name Description Encoder Indicator Encoder input Batching Output Batching device pulse output activated. LED illuminated Suction cycle valve Suction cycle valve activated, LED illuminated K1 Illuminated when K1 relay is activated Pile Down Output Down activated. LED illuminated Pile Up Output Up activated. LED illuminated Pile Controller Pile outputs Up/Down or Forward/Reverse activated, LED illuminated.
4.8 Waste Count The Waste Count is the difference between the Total Input Count and the Total Output Count. Waste Count is accessible by pressing and holding the Total Count button followed by pressing the Total Output Count button. Waste Count can range from 0 to 99,999,999. This process variable is not stored in memory. Reset job will clear this process variable to zero. 5. Counter Setup Variables 5.1 Batch Preset This parameter is accessible only in Counter Setup mode for the DCT500.
6. System Messages and Run Messages 6.1 Power-Up Fault Messages Messages that are displayed during power on self-test. If PLC System Errors are shown in the display, call service. English 88888 German 88888 Codes 88888 TYPE Information DESCRIPTION The controller is performing its lamp test. MEM TEST MEM TEST MEM TEST Information The controller is performing its RAM test. all blank all blank all blank PLC System Error The display board is not functioning. Action: Cycle power.
6.2 Run Time Fault Messages Run time fault messages are only displayed when the unit is in Run mode. Fault errors can still occur, but the corresponding fault message will not be displayed until the unit is switched to Run mode. Run time fault messages are PLC System Errors or errors in the whole electric system. It is necessary to call an technician or service. English DCT X.X.X German DCT X.X.X Codes DCT X.X.X TYPE Information DESCRIPTION This is the Software-Version(X.X.
6.3 Machine Run Error Messages Machine Run Error Messages help the operator to indicate a production problem. English Stop German Stop1 Codes Stop1 TYPE Information DESCRIPTION One of the stop buttons is depressed. ACTION: Make sure all stop buttons are cleared and connectors X21, and X22 are seated. Jam Fehlerbg Stop2 Operating Error The Wrong Sheet Detector has been tripped. ACTION: Clear the fault.
Stop 12 Stop 12 Stop12 Operating Error External device error, e.g. Blind sheet monitor - Stop sheet S -C 5 B-C5 Stop13 Operating Error Delivery/Kicker sheet monitor activated. Folding problem. Check 1x 12 connector and light sensor. Stop 1-1 Stop 1-1 Stop 1-1 Machine Run Error Emergency Stop key on machine control panel activated. Stop 1-2 Stop 1-2 Stop 1-2 Machine Run Error Stop 1-3 Stop 1-3 Stop 1-3 Machine Run Error Emergency Stop key at next station activated.
SETTING OF FOLD PLATES Be sure that the adjustment screw (18-2) is in contact with the support rail on both sides. Clamp the fold plates with the clamping levers (18-3). The sheet-stop (18-4) should be moved to the desired fold length according to the scale (18-5) by loosening the clamping screw (18-6) and then turning the adjustment wheel (18-7). The sheet stop can be set at an angle for sheets that are not cut square by loosening the clamping screw (18-6) and turning the front adjustment wheel.
SCORING/SLITTING/PERFORATING 1.1 Scoring Your new folder is capable of many different applications that compliment the folding performance and provide for greater productivity. The folder is equipped with slitter shafts that are quickly set up for the required operation. These shafts accommodate the mounting of the standard and optional accessories available that perform scoring, slitting and perforating functions.
1.4 Trimming Edges of Booklets 1.6 Blade Installation Cutting blades and strippers for trimming edges of booklets or outer edges of circulars running two or more up, are attached to blade holder collars so that the bevel of the blades on the upper shaft are directed toward the strip being trimmed and the bevel of the blades on the lower shaft are directed away from the strip. Blades mounted in this manner tend to turn trimmed edges down which helps guide them to the floor.
Common Perforating, Scoring Setup Common Slitting (Cutting) Setup Common Edge Trimming Setup PAGE 41 TP10476-1
LUBRICATION/MAINTENANCE Feeder Vacuum Solenoid Valve The vacuum at the suction wheel is controlled by a solenoid valve. This can be quickly and easily removed to clean the piston by loosening the clamping springs. Be careful not to damage the piston and cylinder. O-Rings (on vacuum wheel) Vacuum Pump Loss of vacuum and blow can be caused by clogged filters. Check periodically. Check vanes for wear after 15,000 hours of service. Refer to parts manual for ordering parts.
TECHNICAL SPECIFICATIONS 1526 Maximum sheet size 26" x 44" [66 x 111.7cm] Minimum sheet size 5.5" x 7.25" [13.9 x 18.4cm] Maximum folder speed 9000 ipm [230m/min] Maximum stack height 3" [8cm] Minimum fold length 2.25" [5.7cm] Maximum fold length 27" [68.6cm] (parallel folder) Slitter shaft diameter 1.375" [3.49cm] Electrical See serial plate on folder 220 Volt, 3 phase, 60 Hz, 19 Amperes 1530 Maximum sheet size 30" x 50" [76.2 x 127cm] Minimum sheet size 5.5" x 7.25" [13.9 x 18.
TROUBLESHOOTING PROBLEM CAUSE REMEDY Sheets stick together particularly along sides. Inadequate ink drying, cut with blunt guillotine blade. Fan out thoroughly when piling. Increase air blow. Suction wheel picks up double sheets. Sheets stick together Excessive suction. Air blow improperly set Reduce vacuum setting. Increase air blow Double sheet stop reacts to single sheets. Set only to single paper thickness. Correct to double paper thickness. Tighten lock nut.
TROUBLESHOOTING - continued PROBLEM CAUSE REMEDY Sheets fail to re-emerge from buckle plate. Product too thick for folding. Consult Baumfolder Rep. Not enough roll pressure. Check gapset settings. Electrostatic charge in product caused by friction with rollers and deflectors and also relatively low humidity. Fit discharge unit at the exit to the 1st station or arrange for appropriate humidity on the premises. Damping rods and sheet holder set too low. Raise as necessary.
Baumfolder has authorized dealers located throughout the United States. Call toll free, 1-800/543-6107 for parts or the number of your nearest authorized dealer. BAUMFOLDER CORPORATION Quality Bindery Equipment Since 1917 1660 Campbell Road Sidney, Ohio 45365-0728 Phone: 937/492-1281 or 800/543-6107 Fax: 800/452-0947 Internet: www.baumfolder.com E-mail: baum@bright.
