IFOLD SERVICE MANUAL TP10497
TABLE OF CONTENCE IFOLD ELECTRICAL INSTALATION……......................PAGE 3 IFOLD MACHINE CONFIGURATION….........................PAGE 12 IFOLD STARTUP PROCEDURES………................…...PAGE 17 IFOLD SHUTDOWN PROCEDURES…………..............PAGE 17 SCREEN MAINTAINENCE………………...................….PAGE 17 WARRANTY NOTE……………………………….............PAGE 17 MAIN SCREEN HELP…………………........................…PAGE 18 FOLD SELECT HELP………………………….................PAGE 21 PAPER SELECT HELP……………………................…..
TP10497 Page 1 of 45 Figure 1 COM 2 1 Power Switch Power Socket 3. Install I-fold display mount (See Assy. Drawing FK2001426) onto register frame as shown in I-fold display mounting location (See Page 33). Note: Before tightening the (4) socket head screws, locate display mount so that a gap between the top of the register frame and the display mount is at maximum clearance, so that the register guard can be re-installed. 2. Remove the back feeder, parallel & register guards. 1.
TP10497 Page 2 of 45 Figure 2 Communication Cable 2 Power Cable 9. Run both power and communication cable up into the hole of the enclosure mounting bracket and down through the goose neck mounting arm tube and pull cables out the bottom of the mounting block, as shown in Figure 3. 8.
TP10497 Page 3 of 45 3 10. Mount the 2 cable anchors, as shown in Figure 4. Mount cables with wire ties to the anchors as shown, run through the wire channel across the register. Remove two hole plugs in the back of the electrical enclosure and install two cable strain reliefs. Run the two cables through the strain reliefs. Install folder guarding and wire channel cover. Tighten the two strain relies to secure the cables.
TP10497 Page 4 of 45 Figure 4 Cable Anchor Wire Tie 4 Wire Channel Strain Reliefs
TP10497 Page 5 of 45 Din Rail Cable 5 Communication Board Terminal Block Ribbon Cable Communication Cable Orientation Stripe Figure 5 DCT500 Board 11. The communication board will sit on the right side of din rail that sits above the transformer, as shown in Figure 5. Run the communication cable to the top of the communication board and will wire into the two rows of terminals. Add an extra 2” to 3” of cable, and then cut cable to that length.
TP10497 Page 6 of 45 Green Yellow Gray Brown White Pink 2 3 4 9 10 1 Terminal Block DCT500 Orientation Stripe Ribbon Cable X27 6 13. Add new fuse blocks to the din rail to the right of the existing fuse blocks as shown in Figure 7, The fuse blocks must be tied together with a tie pin, this will insure that both fuse holders will open at the same time. Label fuse blocks as A-F1 and A-F2. NOTE: DO NOT INSTALL FUSES AT THIS TIME.
TP10497 Page 7 of 45 Fuse Block A-F1 4L1 Ground Lug A-F2 4L2 7 14. Take wire and cut into two equal lengths. Strip approximately 5/16” of wire insulation from each conductor at both ends. Label one conductor 4L1 and the other conductor 4L2 at both ends. Wire 4L1 to the top of fuse block A-F1, and wire 4L2 to the top of fuse block A-F2, as shown in Figure 7.
TP10497 Page 8 of 45 Figure 8 K2 8 15. Run wire 4L1 to K2-53 if folder is a 15” or 18” model or to K2-53 if folder is a 20” model. Run 4L2 toK2-83 if folder is a 15” or 18” model or to K2-63 if folder is a 20” model, as shown in Figure 8.
TP10497 Page 9 of 45 Figure 9 9 Software chip Orientation Stripe Run/Maintenance jumper DCT500 Board Ribbon Cable Notch end X27 Connector 17. Replace DCT500 software chip, shown in Figure 9. Carefully do this by using a small screw driver and lifting the chip at both ends and out of the U6 socket. Do not handle the chip by the legs, only by the sides of the chip. Note the orientation of the chip notch, the new chip must be installed in the same direction.
TP10497 Page 10 of 45 Figure 10 Button 1 10 Button 7 Button 3 Button 6 Display 2 Button 5 Button 2 Button 4 Display 1 21. Set Serial Port operating mode. Note display 1, Figure 10, this display needs to display “nEt”. To toggle between modes by pressing button 1, or button 2, until “nEt” is displayed. 20. Folder will wake up in maintenance mode. Both displays will light up with “8” in each segment. Then a diagnostic message will display in display 2.
TP10497 Page 11 of 45 BAUMFOLDER CORP. ATTN. MARK WALKER 1660 Campbell Road Sidney, Ohio 45365 11 29. Place the removed chip, from instruction 13 back into the box the new chip came in and please send it back to Baumfolder for reprogramming. 28. If I-fold computer is not up at this time check power switch on the computer, it must be switched on, see Figure 1. 27. Go into the machine setup mode by pressing button 3, see Figure 9. Use button 1, or button 2, to get “P20” to display in display 1.
TP10497 Page 12 of 45 For service technicians use only ifold machine configuration instructions
TP10497 Page 13 of 45 The first time ifold is powered up the Machine Configuration button will appear on the start up screen. Touch this button to configure for your machine.
TP10497 Page 14 of 45 This should be set from the factory. 0 = Autoset 1 = 2015 2 = 2020 pile 3 = 2020 continuous 4 = 1526 or 1530 Once you have completed the configuration touch this button to go to the main page. Touch this box to tell Ifold how many plates you have in the 16page unit. It will increment thru 0 2 3 4 6 each time you touch this box. If you do not have a 16page unit leave it set to 0 Touch this box to tell Ifold how many plates you have in the 8page unit.
TP10497 Page 15 of 45 Touch this box to shut down Ifold but not the computer. This should only be used when updating the program DO NOT TOUCH THIS BUTTON. This button is for factory use only. Touch this box to tell Ifold if you have the optional Presser Stacker. It will toggle between yes and no each time it is touched. Touch this box to tell Ifold if you are using the standard hang on stacker. It will toggle between yes and no each time it is touched. This is very important if this is an Autoset.
TP10497 Page 16 of 45 This will bring up a keypad asking you to enter the password. Enter the password 4921281 then touch the enter button. Once in the Maintenance screen touch the Machine Set-up button.
Start up procedures The I-Fold software should start-up automatically when the machine is turned on. If for any reason it does not start up properly cycle power to the machine. If the I-Fold software still will not start up contact your local dealer for support. Shut down procedures It is very important to shut down the I-Fold properly before turning off the machine. Before powering down the machine press the button to start the power down procedure.
TP10497 Page 18 of 45 Touch this button before turning off the machine. Once the screen says it is safe to turn off your computer then you can turn off the machine Touch this button for troubleshooting help with any problems you may be having Touch this button to see parts and operators manuals for your machine. Touch this button to recall a previously saved job Touch this button to setup a new job Touch this button to go to the summary screen for the current job.
TP10497 Page 19 of 45 Touch these buttons to see the current settings for the fold plates and Baumsets for the indicated fold section. You can also make changes to these settings if necessary. If you do not have an 8 page(2nd station) or a 16 page(3rd station) the buttons will not be displayed. When this box is red it indicates there is a maintenance item that needs your attention. You can touch this button anytime to see recommended maintenance items and how to do them.
TP10497 Page 20 of 45 If this is the first time you have logged on touch the NEW button then type your name and touch enter. It will ask for a password, if you do not enter a password at this time you will never be ask for one in the future. If you type a password and touch enter you will need to enter this password every time you log in. If you have logged in before just type in your initials and touch enter then type in a password and touch enter if necessary.
TP10497 Page 21 of 45 Paper orientation shows how to load the paper and how the address or label will come out on the stacker. Example: Load the address or label down and forward (toward the sucker wheel) and the label will come out face up on the stacker. Panels indicates the number of panels in a roll or accordion fold. If the stacker display shows none, the output on the stacker is difficult to determine for the selected fold. This box shows the selected fold.
TP10497 Page 22 of 45 A Touch these boxes to enter a custom paper size. When you touch a box a keypad will pop up. Using the keypad enter the paper custom paper size. Do this for both the width and length. This box shows how the paper is loaded (label or address face down and forward). You can change this from portrait (shown) to Landscape and back by touching the orientation button.
TP10497 Page 23 of 45 Touch this button to go back to the fold select screen. Touch this button to go to the summary screen. Touch this button to go to the main screen. Touch this button to go to the feeder setup screen. Touch this button to see the setup list. The setup list is explained on the next page. Touch this box once the desired paper size and orientation have been selected. The text will change from select this paper size and orientation to fold/paper setup completed.
TP10497 Page 24 of 45 This will come up on the left of any setup screen when the see setup list button is touched. This list shows all of the setup screens needed for the selected fold. You can go to any screen on the list just by touching the corresponding button. The done button shows a green checkmark when the page is completed and the press when setup complete button has been touched. This can help you keep track of where you are in the setup of the job.
TP10497 Page 25 of 45 This area shows the suggested scoring dies for each station to run the selected fold. This area shows the feeder settings. Where to set the non-operator side paper guide and the blow tube settings. Touch this button to see the setup list. The setup list is explained on page 4. These areas show the number of sheets that go under each gapset and the fold plate settings for every station required to do the selected fold.
TP10497 Page 26 of 45 In this area you can enter up to 4 notes with up to 55 characters per note to be saved with a fold job. These could contain information like what speed it ran best at if it needed a slit or a perf and what type of perf. To enter a note just touch one of the gray lines next to a note: and a keypad will pop up (see the next page).
TP10497 Page 27 of 45 Use the keypad to enter a note, the clear button will clear everything in the display, this is recommended if you are entering a new note. The Ins/Del button is used to control what happens when you touch the arrow buttons. If the button displays Ins you are in insert mode the < and > buttons will move the curser left or right then anything you type will be inserted where ever the curser is located.
TP10497 Page 28 of 45 This will come up on the left of any setup screen when the see setup list button is touched. This list shows all of the setup screens needed for the selected fold. You can go to any screen on the list just by touching the corresponding button. The done button shows a green checkmark when the page is completed and the press when setup complete button has been touched. This can help you keep track of where you are in the setup of the job.
TP10497 Page 29 of 45 These rows of boxes shows the number of sheets to be placed under the gapsets. In this example gapset 4 gets 2 sheets. To make a change to one of the settings just touch the box you wish to change and a keypad will pop up. This is shown and explained on page 3. 4 boxes show the settings for the fold plates. To make a change to one of the settings just touch the box you wish to change and a keypad will pop up. This is shown and explained on page 2.
TP10497 Page 30 of 45 This is the current setting (0 or blank = deflect). If a number is displayed touch the C to clear it then enter the desired number. The BK SP button will clear the last number entered. Touch done when you have finished.
TP10497 Page 31 of 45 This is the current setting touch the C to clear it then enter the desired number. Touch done when you have finished. This line indicates the gapset you are making a change to.
TP10497 Page 32 of 45 Touch one of these boxes to set the timer for the maintenance item to the right of that box. When you touch the box a keypad will pop up. Use the numbers to enter the time interval for the selected maintenance item then press done. Enter zero to turn off the selected timer. Click on any of these boxes to see how to perform a maintenance item Press this to return to the main screen After the maintenance is preformed touch the box to reset the timer.
TP10497 Page 33 of 45 This box displays how long it will take to run the entire job. Not including setup or any other down time. Touch here to change the folder speed display from meters per minute to inches per minute. This box displays the sheets per hour. Touch this box to enter the total job size. This box displays the sheets per minute. Touch this box to enter the folder speed you plan to run the job. The default is 60% of full speed.
TP10497 Page 34 of 45 CORPORATION BAUMFOLDER UNIT NAME: IFOLD DISPLAY MOUNTING LOCATION IFOLD DISPLAY DESCRIPTION: ASSEMBLY NUMBER: SHEET 1 OF 1 REV:
TP10497 Page 35 of 45 CORPORATION BAUMFOLDER UNIT NAME: IFOLD DISPLAY ADAPTOR KIT IFOLD DISPLAY DESCRIPTION: ASSEMBLY NUMBER: FK2001484 SHEET 1 OF 2 REV:
TP10497 Page 36 of 45 CORPORATION BAUMFOLDER UNIT NAME: IFOLD DISPLAY ADAPTOR KIT IFOLD DISPLAY DESCRIPTION: ASSEMBLY NUMBER: FK2001484 SHEET 2 OF 2 REV:
TP10497 Page 37 of 45 CORPORATION BAUMFOLDER UNIT NAME: IFOLD DISPLAY MOUNT IFOLD DISPLAY DESCRIPTION: ASSEMBLY NUMBER: FK2001485 SHEET 1 OF 2 REV:
TP10497 Page 38 of 45 CORPORATION BAUMFOLDER UNIT NAME: IFOLD DISPLAY MOUNT IFOLD DISPLAY DESCRIPTION: ASSEMBLY NUMBER: FK2001485 SHEET 2 OF 2 REV:
TP10497 Page 39 of 45 CORPORATION BAUMFOLDER UNIT NAME: DISPLAY-ENCLOSURE IFOLD DISPLAY DESCRIPTION: ASSEMBLY NUMBER: FK2001370 SHEET 1 OF 2 REV:
TP10497 Page 40 of 45 CORPORATION BAUMFOLDER UNIT NAME: DISPLAY-ENCLOSURE IFOLD DISPLAY DESCRIPTION: ASSEMBLY NUMBER: FK2001370 SHEET 2 OF 2 REV:
TP10497 Page 41 of 45 CORPORATION BAUMFOLDER UNIT NAME: IFOLD DISPLAY MOUNT IFOLD DISPLAY DESCRIPTION: ASSEMBLY NUMBER: FK2001426 SHEET 1 OF 2 REV:
TP10497 Page 42 of 45 CORPORATION BAUMFOLDER UNIT NAME: IFOLD DISPLAY MOUNT IFOLD DISPLAY DESCRIPTION: ASSEMBLY NUMBER: FK2001426 SHEET 2 OF 2 REV:
TP10497 Page 43 of 45 CORPORATION BAUMFOLDER UNIT NAME: CABLE ASSY.
TP10497 Page 44 of 45 CORPORATION BAUMFOLDER UNIT NAME: CABLE ASSY.
TP10497 Page 45 of 45 CORPORATION BAUMFOLDER UNIT NAME: SCHEMATIC-IFOLD IFOLD DISPLAY DESCRIPTION: ASSEMBLY NUMBER: FK7600179 SHEET 1 OF 1 REV: