BAUMFOLDER BAUM 2020 1ST STATION FOLDER W/PILE FEED INSTRUCTION MANUAL ©Baumfolder Corp., 1999 Printed in U.S.A.
© 1999 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.
DESCRIPTION I.) II.) III.) IV.) V.) VI.) VII.) VIII.) CONTENTS PAGE Safety ................................................................................................................................................................. 6 Warning Labels ................................................................................................................................................ 7 Introduction Overview ....................................................................................
DESCRIPTION IX.) X.) XI.) XII.) XIII.) XIV.) XV.) XVI.) XVII.) XVIII.) XIX.) XX.) XXI.) XXII.) XXIII.) XXIV.) XXV.) XXVI.) CONTENTS PAGE Pile Feeder Operation .................................................................................................................................... 1.0 .Loading .............................................................................................................................................. 1.1 .Hold-down Locations ................................
DESCRIPTION List of Tables PAGE Table 1. Machine Setup Parameter List "A" ...................................................................................................................... 14 Table 2. Machine Monitor Parameter List ......................................................................................................................... 14 Table 3. Machine Setup Parameter List "B"...........................................................................................................
10. Make sure that all safety devices are in place before restarting the machine. SAFETY FIRST Your new Baum paper folding machine has been designed in accordance with the latest safety specifications. The warning and caution labels on the machine must remain in place. Make sure all guarding provided is in place before starting up and running the machine.
WARNING LABELS WARNING WARNING GUARD MISSING DO NOT OPERATE GUARD MISSING DO NOT OPERATE 50944 50945 CAUTION – HAZARDOUS MOVING PARTS – GUARDS MUST BE IN PLACE WHEN OPERATING FOLDER – KEEP HANDS, HAIR & LOOSE ARTICLES AWAY FROM MOVING PARTS.
INTRODUCTION OVERVIEW The 1st station [parallel] folder with pile feeder contains the following main components (Figure 1): 1. Pile Feeder 2. Register 3. 1st Station Folder (Parallel) 4. Fold Roller Gapsets 5. Fold Plates 6. Slitter Shafts (not shown) 7. Delivery (Stacker) 8. Operator Controls 9. Double Sheet Detector (Caliper) 10. Vacuum Pump (not shown) 11. Handwheel Level the machine on the floor. Place a spirit level on the #2 fold roller (Figure 3) and on the feeder crossmembers.
ELECTRICAL CONNECTIONS 1.2 Other Connections Refer to the serial number plate for electrical requirements. The serial number plate notes the voltage, phase and hertz, minimum time delay fuse, total machine 1.0 Wiring the Pump (2020 / 3 phase) amperage, and minimum wire conductor size for the main Connect the pressure/vacuum pump at the pump junction box (Figure 5) using the attached cable. Follow the power connection.
1.3 Tapping the Transformer Pass the power cable through the strain relief and the hole provided in the control box. Connect the power cable to the open terminals on the main disconnect in the control box. The incoming ground wire should be attached to the ground stud located in the lower right-hand corner of the control box. To tap the transformer, read the incoming voltage at the main disconnect. Then move the wire numbered 11L1 on the transformer to the corresponding tap on the transformer.
INSTALLING FOLD PLATES & STACKER DELIVERY Install the fold plates into the folder. When installing the fold plates, take note of the symbol on the fold plate stop (Figure 7-1). The swing deflector may only be brought forward when the deflector symbol is also in the forward position. Lock the fold plates in position with the clamp levers (7-2). See "Fold Pan" section for fold plate setting procedure.
1.0 Control Panel BAN-5 17 8 12 10 14 24 2 25 28 1 29 + 5 4 30 32 33 + + 6 0 h 7 3 8 2 9 1 31 + 10 BAUMFOLDER CORPORATION 36 9 13 11 16 15 26 27 3 22 18 23 19 4 20 5 21 7 34 6 35 Figure 1. Control Panel. 1.1 Displays 01) Large Display Eight digit multi use display composed of 7segment LEDs. 02) Small Display Three digit multi use display composed of 7segment LEDs.
1.4 Keypad Buttons with Selection Indicators 18) 19) 20) 21) 22) 23) Show Output Count Show Batch Count and Number of Batches Show Current Rate Show Input Count Learn Mode Make Ready Mode Pushing this key puts the controller in machine setup mode. 1.5 Keypad Buttons for Selection Adjustment 24) 25) 26) 27) 28) 29) 30) 31) 32) 33) 34) 35) 36) 2.
2.1.1 Machine Setup Parameters Parameter P00 P01 P02 P03 Function Input Factor Output Factor Tremat Knife Type Setup Variables Setup Variables Setup Variables Setup Variables Adjustable Adjustable Adjustable Adjustable Variable Displayed 1-24 1 to Input Factor 1 or 0 1 or 0 Table 1.
2.1.3 Machine Setup Parameters # P20 P21 P22 P23 P24 P25 P26 P27 P28 Function Units of Measure Language Network Address Pause Network Easy Software Version Machine Type Serial Output Type Type Setup Variables Setup Variables Setup Variables Setup Variables Setup Variables Setup Variables Machine Configuration Machine Configuration Machine Configuration Table 3.
P28: Serial Output Type This selection, in maintenance mode, shows selected serial output type. 2.1.4 Diagnostic Parameters P30 P31 P32 P33 P34 P35 Status Input Port 1 P30.1 P30.2 Pile Motor Function Energized Control K1 Status Input Port 2 P31.1 P31.2 Pile Sensor Double Sheet Fault P30.3 Pile Down Button P30.4 Pile Stop Button P30.5 Pile Up Button P30.6 P30.7 P30.8 Compress. Compress. Drive Start Stop Button Start Button Relay K3 P31.3 Pile Bottom P31.4 Sheet Start Button P31.
2.1.6 Machine UsageStatus Parameters # P50 P51 P52 Function Power on time Machine run time Total Input Sheets Type Machine Status Machine Status Machine Status Table 6. Machine Usage Status Parameter List Based on Inputs Based on Inputs Based on Inputs The speed up-table output activates the marking table output for the batching time duration. P50: Power On Time This selection shows the time in 1/100 hour during the main switch of the machine is on. The MKE mode is an unavailable option.
Batching Time Adjustment + + The batching time adjustments allow the user to select the time duration associated with the currently selected output type. Two output types and times are available. 1. Feed interrupt has a range of 0.0 to 9.9 seconds. 2. Speed-up Table has a range of 0.00 to 5.00 seconds. Select Count Source The Output Count and Input Count keys select between count at delivery and feeder, respectively.
If P06 is set to 0 (no knife is active) and 10 cm /4.0 inches. If P06 is setting to 1, knifes are active. Gap Length Adjustment + The minus and plus keys adjust the gap length. The gap length range is 0.2 to 98.0 (0.5cm to 250cm). Suction Length Adjustment + This is the same as in run mode The suction length adjustment keys allow the user to change the amount of suction applied to the current sheet length. The display shows the percentage in 5% steps. All of the bars must be totaled to get the value.
2.7 Production Mode Exit Make Ready Mode Enter Run Mode and Select Large Display Content h 0 h Pressing any of these keys will cause the controller to change to a new mode. 2.6 Network Job Mode Pushing this key puts the counter in network job mode 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.
Reset Function 0 Pressing and holding this key will result in a reset function being activated after a 5-second countdown. The function is based on the current large display selection, see table 12. The large display (1) will show countdown to reset in this manner. When the button is pressed the message CLr In 5 will show on the large display (1).
The Current Rate is rounded to the nearest hundreds. Current Rate can range from 0 to 99,999,900. This process variable is not stored in memory. 4.0 Process Variables Definitions 4.1 Total Input Count Total Input Count increments by the factor setting each time an input is received at the Input Count input. Total Input Count can range from 0 to 99,999,999. This process variable is stored in memory in case of a power outage. Reset job will clear this process variable to zero. 4.
5.3 Batch Output Time This parameter, accessible in the Batch Setup mode, specifies the output duration or delay that will be used when the Batch Count Down reaches zero. Available ranges are determined by the Batch Output Type selected. The Table below shows the ranges for each output type. Output Delay Duration Type Min. Time Max. Time Min. Time Max. Time Feed Not applicable 0.0 Sec. 9.9 Sec. Table 0.000 Sec. 1.000 Sec. 100 ms Delivery 0.000 Sec. 1.000 Sec. 25 ms Speed Not applicable 0.00 Sec. 5.
6.0 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.
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 a technician or service. ENGLISH DCT X.X.X GERMAN DCT X.X.X CODES TYPE DCT 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 Wrng Sht Fehlerbg Stop2 Machine Run Error 2 Sheet Doppelbg Stop3 Machine Run Error No Feed Bog.Fehl Stop4 Machine Run Error Feeder Sensor Stop5 Long Sht Bg.
PILE FEEDER OPERATION 1.0 Loading the Pile Feeder Set the right hand side guide (Figure 11-1) to half the sheet using the scale (11-2). The vacuum wheel is in the center of the sheet. Lock the guide in place using the lever (11-3). Remove the left hand guide (Figure 12-4) from the feeder. Move the sheet drag guide block (12-5) on the righthand guide to the rear of the paper stock. Press the table down button (for controls, see page 8).
1.3 FRONT BLOW TUBE SETTINGS The front blow consists of two tubes (Figure 13-1 & 2 and Figure 15-1 & 2) instead of the traditional one tube. The numbers on the left hand side of the tubes correspond to the chart (Figure 15-3) found on the side of the main control enclosure. Setting Up 1.) Determine the width of the job to be run. 2.) Find the numbers on the right-hand side of chart that correspond with the sheet width. 3.
The fluted knob (19-6) provides microadjust-ment of the side guide (19-2). Knurled knobs (19-7) provide bias adjustment for the side guide for adjusting sheets that are not square or for other unusual conditions. The double sheet control (Figure 20) is adjusted to the thickness of the paper being fed by pulling up the lever (201) and inserting two paper strips (20-2) of the sheets to be folded in the clip at the back of the lever.
With single sheet thickness, the scanner remains untouched and sheets move freely. A double sheet strikes the scanner on the microswitch, interrupting the sheet flow-through. Figure 21 BAUMSET ADJUSTMENT 1.0 Adjustment of Folding Rollers Folding accuracy is determined largely by precise adjustment of the folding rollers. Using the Baumset precision adjustment device, the correct setting of the rollers can be made simply by inserting the appropriate paper thickness between the adjustment plates.
SETTING OF FOLD PLATES NOTE: Check the symbols on the fold plate stop (Figure 23-1) for installation of the fold plate swing deflectors (Figure 24-1) to avoid damaging the fold rollers. The deflector must only be brought forward when the stop (23-1) with the deflector symbol is in the forward position. Be sure that the adjustment screw (23-2) is in contact with the support rail on both sides. Clamp the fold plates with the clamping screw (Figure 23-3).
Check that the adjustment screws (26-4) are in contact with the support rail (26-5) on both sides. The basic position is marked by a notch (26-6) in the fold-plate frame. Setting Stationary Deflector (Separate sheet deflector) (Figure 27-1) The stationary sheet deflectors are installed and clamped in place in the same way as the fold plates. NOTE: The fold plates in an 8-page folder will work in the #4 fold plate position when four plates are desired.
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. 1.0 Slitter Shaft Accessories Removal To remove slitter shafts, remove knob (Figure 29-1).
1.3 Slitting (Cutting) Sheets Folders may be used to cut folded or flat sheets apart. Two or more cuts may be made if duplicate sets of slitters are used. Be careful when mounting slitter blades to collars in order to avoid ragged edges which can be caused by two conditions: 1) Nicks or burrs on the collars or blades. Remove carefully by filing or using a fine piece of emery cloth. 2) Incorrect mounting of blades.
1.5 Trimming a Strip from Center of Sheet Figure 34 shows the setup for taking a quarter inch trim out of the center of a sheet. Two or more trims may be made as long as duplicate sets of cutters and strippers are used and this setup adhered to. A strip three sixteenths of an inch wide is the minimum trim. This is the thickness of two of the cutting blades placed together and attached to a blade holder collar. Blades on the upper shaft, for all trims up to one-quarter inch, are attached to one collar.
LUBRICATION/MAINTENANCE Pile Feeder Vacuum Solenoid Valve Figure 35 The vacuum at the suction wheel is controlled by a solenoid valve (Figure 35). 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. See Figure 17. Gear Reducer Check fluid level annually. Check for wear. Refer to parts manual for part number. O-Rings (on vacuum wheel) See Figure 18.
TECHNICAL SPECIFICATIONS BAUM 2020 Maximum sheet size 20.5" x 31" [52 x 78.7cm] Minimum sheet size 4" x 6" [10.1 x 15.2cm] Maximum folder speed 8200 ipm [208m/min] Maximum pile height 25" [63.5cm] Minimum fold length 1.57" [40mm] Maximum fold length 20.5" [52cm] (parallel folder) Slitter shaft diameter 1 1/8" [28.
TROUBLESHOOTING PROBLEM CAUSE REMEDY Sheets stick together particularly along sides. Inadequate ink drying, cut with blunt guillotine blade. Fan out thoroughly when piling, increase blower air. Suction wheels 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 fails to re-emerge from buckle plate. Product too thick for folding. Consult Baum technical rep. Not enough roll pressures. Check Baumset settings. Sheet remains lying on the roller table of the 2nd station or fails to run into the 1st buckle plate of the 2nd folding station. Electrostatic charge in product caused by friction with rollers and deflectors and also relatively low humidity.
OPERATING TIPS screws for the slitter shaft accessories facing out, so you don't have to turn the shafts to get to the screws. Setup When setting up a job on your folder, watch so the sheet doesn't end up with either the RH or LH edge along the edge of a fold pan or register plate. This could kick it over causing inaccurate folding. Brass Tipped Screws When replacing screws in collars and various other assemblies, be sure to note if they are brass tipped screws.
Fixing Crooked Perforations If misaligned perforations appear after the parallel folding station, first check for correct squareness setting of the register guide relative to the buckle plate stop. If square, the sheet deflector following the last buckle plate must be set back slightly on the side on which the sheet is tending to advance. Adjustment can be made by inserting a card underlay of suitable thickness.
Principles of Mechanical Folding The buckle folding principle In buckle folding, each station consists of three rollers and a buckle plate. The first two rollers are arranged one vertically above the other and they carry the incoming sheet into the buckle plate until it reaches a feed guide stop that can be adjusted as required. The sheet is delivered into the buckle plate at a determined speed. The leading edge strikes the paper stop. Once against the stop the sheet continues to be driven.
FO LD DEFLECTOR OPEN PA N FO #1 LD N PA #3 SHEET STOP 1 2 MAIN DRIVE DEFLECTOR OPEN DEFLECTOR CLOSED 4 3 5 LD FO PA N DEFLECTOR CLOSED #2 LD FO N PA SHEET STOP #4 IMPOSITIONS 18 MOST POPULAR FOLDS PAGE 43 TP10243-1
On a buckle folder, the sheet is laid flat on a register table and then enters the fold pan assembly where it comes to a stop against the stationary fold plate stop. A series of buckles then forms throughout the sheet. The buckles whithin the fold pan are kept very small by the narrow channel design. The buckles at the end of the fold pan, however, will be larger.
MANUAL USAGE Use this manual when you need to know how to set-up your folder to end up with a particular folded piece or, if possible, when planning the layout before printing the job. In most cases, the page numbers and their orientations after the fold are included. Below is an explanation of how to read the diagrams in this manual. On the next page is a quick explanation of the basic theory of buckle folding.
TYPICAL LAYOUT AND SHEET ORIENTATION L E A D I N G Each numbered Imposition Block in this manual contains: A. Imposition Title B. Fold Pans Used C. Sheet Layout D. Folded Sample 2 7 6 3 1 8 5 4 E D G E SIDE GUIDE 2. Dashed lines represent folds. Page numbers or letters without circles are face up. Page numbers or letters with circles are on the underside of the sheet. When letters are used, folds are to be made A to A, B to B, etc. 3.
3 6-PAGE, STANDARD Parallel: 1, 3 May be folded two or more up and cut apart. 4 6 5 2 1 2 1 4 6 8-PAGE, RIGHT ANGLE Parallel: 1 8-Page: 1 1 2 4 5 8-PAGE, PARALLEL IMPOSITION Parallel: 1, 2 May be folded two or more up and cut apart. 3 2 1 3 2 1 3 3 4-PAGE, DOUBLE IMPOSITION Parallel: 1, 2, 3 May be folded two or more up and cut apart. Trim edge after folding. 4 2 4 4 6-PAGE, ACCORDION Parallel: 1, 2 May be folded two or more up and cut apart.
7 8 8-PAGE, TWO RIGHT ANGLE OBLONG Parallel: 1 8-Page: 1 9 8-PAGE, RIGHT ANGLE DOUBLE IMPOSITION Parallel: 1 8-Page: 1, 2, 3 8-PAGE, PARALLEL OVER & OVER Parallel: 1, 2, 4 May be run two or more up and cut apart.
3 4 11 21 12 3 30 19 3 22 15 21 PAGE 49 22 28 14 16 9 10 8 27 5 4 7 17 6 29 18 20 8 19 5 7 6 25 4 5 12 13 4 3 14 11 6 8 26 9 23 16 12 10 1 11 13 13 B B 7 14 24 20 C 10 23 32-PAGE BOOK Parallel: 1, 2, 3 8-Page: 1, 2 13 B 15 2 1 18 14 B 7 8 2 17 24-PAGE BOOKLET Parallel: 1, 2 8-Page: 1, 2 16 10 9 16 12-PAGE FOLDER, HEADS OUT Parallel: 1 8-Page: 1, 2 15 11 12 C 6 5 C C 2 1 15 16-PAGE, THREE RIGHT ANGLE BOOK IMPOSITION Paralle
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 Producing 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@brightnet.
