Baumfolder FLEXIFOLD 1st STATION User manual
FLEXIFOLD
1st STATION
INSTALLATION
&
OPERATION MANUAL
FOR INSTRUCTION MANUALS IN
GERMAN, SPANISH AND FRENCH
GO TO WWW.BAUMFOLDER.COM
TP10494
BAUM
TP10494A PAGE 2
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.
Baumfolder reserves the right to make changes in design or to make additions or improvements in
its products without imposing any obligation upon itself to install them on its products previously
manufactured. It is recommended that modifications to this equipment not be made without the
advice and express written consent of Baumfolder.
FOLDER IDENTIFICATION
MODEL NO: _______________________________ SERIAL NO: _____________________________
DEALER : __________________________________________________________________________
INSTALLED BY: ______________________________________________ DATE: ________________
PHONE NO: _________________________________________________________________________
© 2004 Baumfolder
All Rights Reserved
PAGE 3 TP10494A
TABLE OF CONTENTS
FUNDAMENTAL SAFETY INSTRUCTIONS .......................................................................... 5-20
(English,German,Spanish,French)
1.0 INTRODUCTION ......................................................................................................................21
2.0 SPECIFICATIONS .....................................................................................................................21
3.0 INSTALLATION ........................................................................................................................21
3.1 Unpacking & Inspection ..............................................................................................................21
4.0 ASSEMBLY .................................................................................................................................22
4.1 Main Unit .....................................................................................................................................22
4.2 Pump Electrical Connections .......................................................................................................22
4.3 Pump Hose Connections ..............................................................................................................22
4.4 Delivery Table ..............................................................................................................................22
4.5 Feed Table Assembly Installation (If applicable) ..........................................................................22
4.6 Fold Plate Installation ..................................................................................................................23
5.0 ELECTRICAL ACCESS ............................................................................................................23
6.0 FEED TABLE SETUP (If applicable) .......................................................................................24
6.1 Gap Adjustment .............................................................................................................................24
6.2 Feed Table Adjustment .................................................................................................................24
6.3 Air Blow Adjustment ....................................................................................................................24
7.0 OPERATION ...............................................................................................................................25
7.1 The Main Power/Reset Switch .....................................................................................................25
7.2 Loading of Feed Table ..................................................................................................................25
7.3 Starting the Production Job ..........................................................................................................25
7.4 Check Squareness of Fold ............................................................................................................25
7.5 Use Of Handwheel .......................................................................................................................26
8.0 OPERATOR PANEL ..................................................................................................................26
8.1 Button Identification (2nd Function) ............................................................................................26
9.0 START UP ....................................................................................................................................27
10.0 SETUP .........................................................................................................................................27
10.1 Setup for a Standard Fold ...................................................................................................... 27-28
10.2 Setting Up a Special Fold ............................................................................................................29
10.2.1 To Save a Non-Standard Fold in a Memory Location ..............................................................29
10.2.2 Recall a Fold Saved in Memory Location ................................................................................29
10.3 Starting the Production ................................................................................................................29
TP10494A PAGE 4
TABLE OF CONTENTS
11.0 COUNTER OPERATION .........................................................................................................30
11.1 Resetting the Total Count .............................................................................................................30
11.2 Programming the Batch Counter ..................................................................................................30
11.3 Resetting the Batch Couter ..........................................................................................................31
11.4 Rate ..............................................................................................................................................31
12.0 FOLDER OPERATION ............................................................................................................32
12.1 Time .............................................................................................................................................32
12.2 Start/Stop Button ..........................................................................................................................32
12.3 Pump Button ................................................................................................................................32
12.4 Speed ............................................................................................................................................33
12.5 Fold Plates ....................................................................................................................................33
12.6 Stacker Wheels .............................................................................................................................34
12.7 Paper Jams ...................................................................................................................................35
12.8 Shutting Off Jam Detectors .................................................................................................... 35-36
13.0 PERFORATING, SCORING & SLITTING ...........................................................................37
13.1 Perforating ....................................................................................................................................37
13.2 Scoring .........................................................................................................................................37
13.3 Slitting ..........................................................................................................................................38
14.0 MAINTENANCE .......................................................................................................................38
14.1 Maintenance and Care of your Flexifold .....................................................................................39
14.2 Cleaning of Fold Rolls .................................................................................................................39
14.3 Cleaning Filters ............................................................................................................................39
14.4 Photo Eyes ...................................................................................................................................39
14.5 Cleaning The Fold Stop Guides ...................................................................................................39
14.6 Replacement Parts ........................................................................................................................39
15.0 LANGUAGE SELECTION ......................................................................................................40
16.0 DISPLAY MESSAGES ..............................................................................................................41
17.0 BASIC THEORY OF BUCKLE FOLDING ...........................................................................42
PAGE 5 TP10494A
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.
TP10494A PAGE 6
FUNDAMENTAL SAFETY
INSTRUCTIONS!
These operating instructions are designed to familiarize
the user with the machine and its designated use.
The instruction manual contains important information on
how to operate the machine safely, properly and most efficiently.
Observing these instructions helps to avoid danger, to reduce
repair costs and downtimes and to increase the reliability and life
of the machine.
In addition to the operating instructions and to the mandatory
rules and regulations for accident prevention and environmental
protection in the country and place of use of the machine, the
generally recognized technical rules for safe and proper working
must also be observed.
The following signs and designations are used in the
manual to designate instructions of particular importance.
Important
(refers to special information on how to use the
machine/plant most efficiently)
Attention
(refers to special information and/or orders and
prohibitions directed towards preventing
damage)
Danger
(refers to orders and prohibitions designed pre-
vent injury or extensive damage)
1.0
Basic operation and designated use of the machine/
plant
1.0.1
The machine /plant has been built in accordance with
state-of-the art standards and the recognized safety rules.
Nevertheless, its use may constitute a risk to life and limb
of the user or of third parties, or cause damage to the
machine and to other material property.
1.0.2
The machine/plant must only be used in technically perfect
condition in accordance with its designated use and the
instructions set out in the operating manual, and only by
safety-conscious persons who are fully aware of the risks
involved in operating the machine/plant. Any functional
disorders, especially those affecting the safety of the
machine/plant, should therefore be rectified immediately.
1.0.3
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.
Operating the machine within the limits of its designated use also
involves observing the instructions set out in the operating manual
and complying with the inspection and maintenance directives.
The working temperature of the machine should range between 0°
and 55° C.
1.1 Organizational measures
1.1.1
The operating instructions must always be at hand at the place
of use of the machine/plant, e.g. by stowing them in the tool
compartment or tool-box provided for such purpose.
1.1.2
Personnel entrusted with work on the machine must have read
the operating instructions and in particular the chapter on safety
before beginning work. Reading the instructions after work has
begun is too late. This applies especially to persons working
only occasionally on the machine, e.g. during setting up or
maintenance.
1.1.3
For reasons of security, long hair must be tied back or otherwise
secured, garments must be close-fitting and no jewelry - such as
rings - may be worn. Injury may result from being caught up in the
machinery or from rings catching on moving parts.
1.1.4
Observe all safety instructions and warnings attached to the
machine/plant.
1.1.5
See to it that safety instructions and warnings attached to the
machine are always complete and perfectly legible.
1.1.6
In the event of safety-relevant modifications or changes in
the behaviour of the machine/plant during operation, stop the
machine/plant immediately and report the malfunction to the
competent authority/person.
1.1.7
Never make any modifications, additions or conversions which
might affect safety without the supplier’s approval. This also
applies to the installation and adjustment of safety devices and
valves as well as to welding work on load-bearing elements.
1.1.8
Spare parts must comply with the technical requirements specified
by the manufacturer. Spare parts from original equipment
manufacturers can be relied to do so.
PAGE 7 TP10494A
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.
1.2 Selection and qualification of personnel
- Basic responsibilities
1.2.1
Employ only trained or instructed staff and set out clearly the
individual responsibilities of the personnel for operation, set-up,
maintenance and repair.
1.2.2
Make sure that only authorized personnel works on or with the
machine.
1.2.3
Work on the electrical system and equipment of the machine/plant
must be carried out only by a skilled electrician or by instructed
persons under the supervision and guidance of a skilled electrician
and in accordance with electrical engineering rules and regulations.
1.2.4
Work on gas fueled equipment (gas consumers) may be carried out
by specially trained personnel only.
1.3 Safety instructions governing specific
operational phases
1.3.1 Standard operation
1.3.1.1
Avoid any operational mode that might be prejudicial to safety.
1.3.1.2
Take the necessary precautions to ensure that the machine is used
only when in a safe and reliable state. Operate the machine only if
all protective and safety-oriented devices, such as removable safety
devices, emergency shut-off equipment, sound-proofing elements
and exhausters, are in place and fully functional.
1.3.1.3
Check the machine/plant at least once per working shift for obvious
damage and defects. Report any changes (incl. changes in the
machine’s working behaviour) to the competent organization/person
immediately. If necessary, stop the machine immediately and lock it.
1.3.1.4
Before starting up or setting the machine/plant in motion, make sure
that nobody is at risk.
1.3.2
Special work in conjunction with utilization of the machine/plant
and maintenance and repairs during operation; disposal of parts and
consumables.
1.3.2.1
Always press the emergency (Not-Stop) button first, if you stop the
machine for adjustments or maintenance work which must not be
done while the machine is in operation.
1.3.2.2
For extensive maintenance or repair work, turn off the main power
supply.
1.3.2.3
After making adjustments or after doing maintenance or repair
work, always make sure that all tools or other objects are removed
from the machine. Otherwise they might fall into the machine,
causing severe damage or injuries.
1.3.2.4
Keep the floor around the entire machine clean. Immediately
clean any oil, grease or paint spills up off the floor. Remove tools,
cleaning cloths or paper scraps from all work areas.
1.3.2.5
Never operate a folding machine without buckle plates or deflectors
since these are protective as well.
1.3.2.6
Never clean moving parts of the machine (rollers, shafts) or remove
any test sheets, spoiled sheets or bits of paper in such areas.
1.3.2.7
Observe the adjusting, maintenance and inspection activities and
intervals set out in the operating instructions, including information
on the replacement of parts and equipment. These activities may be
executed by skilled personnel only.
1.3.2.8
Brief operating personnel before beginning special operations and
maintenance work, and appoint a person to supervise the activities.
1.3.2.9
If the machine/plant is completely shut down for maintenance and
repair work, it must be secured against inadvertent starting by:
– locking the principal control elements and
removing the ignition key and/or
– attaching a warning sign to the main switch.
1.4.1 Electric energy
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.
1.4.1.2
If provided for in the regulations, the power supply to parts of
machines and plants, on which inspection, maintenance and repair
work is to be carried out must be cut off. Before starting any work,
check the de-energized parts for the presence of power and ground
or short-circuit them in addition to insulating adjacent live parts and
elements.
TP10494A PAGE 8
1.4.1.3
The electrical equipment of machines/plants is to be inspected and
checked at regular intervals. Defects such as loose connections or
scorched cables must be rectified immediately.
1.4.1.4
Necessary work on live parts and elements must be carried out only
in the presence of a second person who can cut off the power supply
in case of danger by actuating the emergency shut-off or main
power switch. Secure the working area with a red-and-white safety
chain and a warning sign. Use insulated tools only.
1.4.1.5
Only unplug or plug electrical connectors if the main switch has
been disconnected.
1.4.1.6
Only connect the folding units and no machines of other brands to
the existing connectors. Any electrical connection of our folding
machines with other brands needs our express consent.
1.4.1.7
For electrical connection, observe the prescribed admissible voltage
and frequency. The minimum voltage protection required for this
folder is 25 Amps.
1.4.1.8
Keep switch cabinets closed.
1.4.1.9
The socket outlet shall be installed near the folder and shall be
easily accessible.
1.4.2
Oil, grease and other chemical substances
1.4.2.1
When handling oil, grease and other chemical substances,
observe the product-related safety regulations.
1.5 Description and definition of the safety
labels and pictographs on the machine
Replace damaged pictographs by new ones. The corre-sponding
reference numbers are indicated.
Warning!
Folding rollers rotate in opposite directions.
Keep hands away from rollers while the
machine is running!
Warning!
To avoid bruising, keep hands away when
operating moving machine parts!
Warning!
Do not reach into moving belts!
Warning!
Be careful! Height adjustment devices
might cause bruising!
Warning!
Only operate machine when covers are closed.
1.6 Explanation of the pictographs used
in the operating instructions
Warning!
You might risk bruising when
moving the machine.
Main Power
On/Off/Reset
Switch
Folder Drive
Motor
On/Off Switch
E-stop Switch
PAGE 9 TP10494A
GRUNDLEGENDE
SICHERHEITS-
HINWEISE!
Die in diesen Hinweisen verwendeten Diagramme und Beschreibungen gelten
nicht notwendigerweise für die gelieferte Maschine. Änderungen, die aus
technischen Gründen oder für einen verbesserten Betrieb durchgeführt wurden,
werden ohne Vorankündigung übernommen.
TP10494A PAGE 10
1.0.3
Die Maschine/Anlage wurde ausschließlich für die Verarbei-
tung von Bögen mit bestimmten Mindest- und Höchstformaten
konstruiert (siehe die entsprechende Bedienungsanleitung). Wird
die Maschine/Anlage für andere, als die zuvor aufgeführten
Zwecke verwendet, wird dies als im Gegensatz zum Einsatzzweck
stehend angesehen. Der Hersteller/Lieferant kann für Schäden oder
Verletzungen, die sich aus solch einem Missbrauch ergeben, nicht
haftbar gemacht werden. Das Risiko solch eines Missbrauchs trägt
allein der Anwender.
Ein Betrieb der Maschine innerhalb der Grenzen des Einsatz-
zwecks beinhaltet ebenfalls die Einhaltung der in der Bedienungs-
anleitung enthaltenen Anweisungen sowie der Inspektions- und
Wartungsrichtlinien. Die Betriebstemperatur der Maschine muss
zwischen 0 °C und 55 °C liegen.
1.1 Organisatorische Schutzmaßnahmen
1.1.1
Die Bedienungsanleitung muss am Aufstellungsort der Maschi-
ne/Anlage stets zur Hand sein, z.B. indem diese im Werkzeugfach
oder in dem für diesen Zweck vorgesehenen Werkzeugkasten
aufbewahrt wird.
1.1.2
Die mit der Arbeit an der Maschine beauftragten Personen müssen
die Bedienungsanleitung und insbesondere das Kapitel über Si-
cherheit vor Arbeitsbeginn durchgelesen haben. Wird die Anlei-
tung erst nach Arbeitsbeginn durchgelesen, ist dies zu spät. Dies
gilt besonders für Personen, die nur gelegentlich an der Maschine
arbeiten, wie z.B. während des Einrichtens oder während War-
tungsarbeiten.
1.1.3
Aus Sicherheitsgründen langes Haar hochbinden oder auf andere
Weise schützen, eng anliegende Kleidung und keinen Schmuck,
wie z.B. Ringe, tragen. Verfängt sich das Haar in der Maschine,
oder geraten Ringe in beweglichen Teilen, kann dies zu Verletzun-
gen führen.
1.1.4
Alle an der Maschine/Anlage angebrachten Sicherheitshinweise
und Warnungen beachten.
1.1.5
Darauf achten, dass an der Maschine angebrachte Sicherheitshin-
weise und Warnungen stets vollständig und gut lesbar sind.
1.1.6
Bei sicherheitsrelevanten Modifizierungen oder Änderungen im
Verhalten der Maschine/Anlage während des Betriebs, die Maschi-
ne/Anlage sofort anhalten und die Störung der hierfür zuständigen
Person melden.
1.1.7
Ohne Zustimmung des Lieferanten nie Modifizierungen, Zusätze
oder Umbauten vornehmen, welche die Sicherheit beeinflussen
könnten. Dies gilt ebenfalls für den Einbau und die Einstellung
von Sicherheitsvorrichtungen und Ventilen sowie für Schweißar-
beiten an lasttragenden Elementen.
GRUNDLEGENDE SICHER
- HEITSHIN-
WEISE!
Die vorliegende Bedienungsanleitung dient dazu, dass sich der An-
wender mit der Maschine und deren Einsatzzweck vertraut macht.
Die Bedienungsanleitung enthält wichtige Informationen über den
sicheren, bestimmungsgemäßen und wirkungsvollen Betrieb der
Maschine. Bei Beachtung dieser Anweisungen werden Gefahren
vermieden, Reparaturkosten und Stillstandszeiten verringert sowie
die Zuverlässigkeit und die Lebensdauer der Maschine erhöht.
Zusätzlich zur Bedienungsanleitung und den verbindlichen
Vorschriften und Bestimmungen zur Verhinderung von Unfällen
sowie im Hinblick auf den Umweltschutz in dem Land, in dem die
Maschine eingesetzt wird, sind ebenfalls die allgemein anerkann-
ten technischen Vorschriften für sicheres und korrektes Arbeiten zu
beachten.
Die folgenden Zeichen und Bezeichnungen werden im
Handbuch verwendet, um auf Anweisungen von besonderer Be-
deutung hinzuweisen.
Wichtig
(bezieht sich auf besondere Informationen
darüber, wie die Maschine/Anlage am
wirkungsvollsten eingesetzt wird)
Achtung
(bezieht sich auf besondere Informationen
bzw. Anweisungen und Verbote, mit denen
Schäden verhindert werden sollen)
Gefahr
(bezieht sich auf Anweisungen und Verbote,
mit denen Verletzungen oder größere
Schäden verhindert werden sollen)
1.0
Grundlegender Betrieb und Einsatzzweck der Ma-
schine/Anlage
1.0.1
Die Maschine/Anlage wurde in Übereinstimmung mit den neues-
ten Normen und anerkannten Sicherheitsvorschriften hergestellt.
Trotzdem kann ein Risiko für das Leben oder die Gliedmaßen des
Anwenders oder Dritter gegeben sein, oder eine Beschädigung der
Maschine und anderer Gegenstände verursacht werden.
1.0.2
Die Maschine/Anlage darf nur in technisch einwandfreiem
Zustand in Übereinstimmung mit dem Einsatzzweck und den
in der Bedienungsanleitung dargelegten Anweisungen und nur
durch Personen bedient werden, die sich der mit dem Betrieb der
Maschine/Anlage verbundenen Risiken bewusst sind. Jegliche
Funktionsstörungen, besonders diejenigen, welche die Sicherheit
der Maschine/Anlage betreffen sind daher sofort zu beheben.
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