3
Let's Star
t F
olding
Folding Standard Size Sheets................................. 4
Correcting Folding Problems .................................. 9
Let’s Start Folding
This section explains how to prepare the folder and perform some basic
operations.
Page 1: ......
Page 2: ...tomer unauthorized modification or misuse or operation outside of the environmental specifications for the product Horizon International Inc pursues a policy of continuing improvement in design and performance of the product Therefore the product design and specifications are subject to change without prior notice and without our legal obligation All rights are reserved No part of this manual may ...
Page 3: ...ted 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 ...
Page 4: ...per knob Otherwise the machine may be damaged If the stopper knob is heavy sheets may jam inside the buckle chute Do not rotate the stopper knob forcibly Otherwise the machine may be damaged Span that the stopper knob can turn smoothly is the movable range Do not turn the stopper knob by force Otherwise the machine may be damaged WARNING Be careful when plugging or unplugging the power cord Do not...
Page 5: ...bleshoot ing If an error code appears 22 Troubleshooting 23 Maintenance Removing Jammed Sheets Fold Roller Section 32 Removing Jammed Sheets Buckle Chute 34 Cleaning and Replacing the 35 Cleaning and Replacing the Fold Rollers 38 Cleaning the Sensors 41 Installation Installation 43 Appendix Specifications 46 Machine Description 47 Fold Mechanism 49 Accessories 50 Consumables Optional Parts 51 Inde...
Page 6: ...blem see page 9 If the sheet is folded correctly Start folding Power Switch ON Place the sheets Select job pattern and sheet size on the touch panel screen Raise the feed tray lever 2 5 4 1 3 7 6 23056 10101A1 S S L L Align the pointer for the stopper with the illuminated LED Pointer Stopper Knobs Quick Guide Copy this page and post it in a prominent place This will be helpful to the operators ...
Page 7: ...mber of folds H1 to H4 Delivery Roller Position Refer to page 6 E1 to E7 Error Code Refer to page 22 Fold Pattern Select Button This button selects the fold pattern Start Stop Button This button starts or stops the folding Test Button This button feeds one sheet for test folding Control Panel Selecting the Sheet Size and Fold Pattern 1 Fold location set by 1st stopper knob 2 Fold location set by 2...
Page 8: ...3 Let s Start Folding Folding Standard Size Sheets 4 Correcting Folding Problems 9 Let s Start Folding This section explains how to prepare the folder and perform some basic operations ...
Page 9: ...own by arrow 2 Plug the power cable into an outlet Turn on the power switch If the machine waits more than 3 minutes before being used it goes into power saving mode Lower the feed tray lever The feed table lowers so you can add sheets 23056 20101A1 Delivery Tray Support Table 23056 20101B1 Delivery Roller 1 2 23056 20101C1 Power Switch ON Be sure to connect the ground wire WARNING When plugging i...
Page 10: ...he end of the stack of sheets toward the feed roller and align the stack with the size marks on the support table Move the sheet guides against the sides of the stack Do not push the guides too hard against the stacked sheets and do not leave any gaps between the guides and the stacked sheets Set the support rollers Set the two outer rollers about 10 mm 0 39 inside the edges of the stacked sheets ...
Page 11: ...pattern and fold speed have been set the delivery roller position H1 to H4 will be displayed Move the delivery roller assembly to the position indicated on the display When the rollers are set in the indicated position heavier sheets may be bounced back by the rollers If this happens move the roller slightly to the left downstream 23056 20101I1 Select the fold pattern 23056 20101J1 Select the fold...
Page 12: ...ect refer to Correcting Folding Problems on page 9 After making an adjustment press the Test button again and check the fold If you select High speed set the stopper position 1 mm shorter than the normal stopper position This is because the faster feed speed causes the sheets to bend To set the stopper 1 mm shorter than the normal position align the stopper pointer with the left edge of the lamp 2...
Page 13: ... of sheets folded Be sure to keep track of the count for any jammed sheets To pause the machine Press the Start Stop button Lower the feed tray lever To resume folding Raise the feed tray lever Press the Start Stop button again When the folding job is complete Lower the feed tray lever then turn off the power switch Unplug the power cable 23056 20101Q1 Press the Clear button 23056 20101R1 Press th...
Page 14: ...23056 20201A1 Lengthen the part in the direction by turning toward S Shorten the part in the direction by turning toward L Lengthen the part in the direction by turning toward S Shorten the part in the direction by turning toward L Lengthen the part in the direction by turning toward S Shorten the part in the direction by turning toward L Lengthen the part in the direction by turning toward S Shor...
Page 15: ... guide using the fold skew correct lever In the default position the fold skew correct lever is aligned with the red dot on the feed table 23056 20201B1 23056 20201C1 Fold Skew Correct Lever Default Position 23056 20201D1 Delivery Direction If the fold is skewed like this 23056 20201E1 Delivery Direction If the fold is skewed like this ...
Page 16: ...tup 11 Folding Custom Size Sheets 12 Cross Fold 12 Page Letter Fold 14 Additional Adjustments for Smooth Folding 19 Advanced Setup This section includes set up instructions for custom sheet sizes and fold patterns ...
Page 17: ...e to Set the support rollers Select the fold pattern using the Fold Pattern Select button Set the stoppers Adjust the 1st stopper to match the 1st measured length and the 2nd stopper to match the 2nd measured length Complete the setup for the stoppers On page 7 follow the steps starting with Lift the feed tray lever 23056 30101A1 23056 30101B1 23056 30101C1 Select the fold pattern 23056 30101D1 S ...
Page 18: ...B C A B C A B C A B C 1 1 2 1 2 1 2 1 2 ABC 1 2 a Single Fold Appearance of delivered sheet Appearance of delivered sheet Appearance of delivered sheet Appearance of delivered sheet Appearance of delivered sheet Appearance of delivered sheet Front side down face down Parallel Fold Front side down face down Short Fold Front side up face up Letter Fold Front side down face down Accordion Fold Front ...
Page 19: ...n the folded sheet is opened the two fold lines will cross About the 12 page letter fold The single fold is made first Next the machine makes two second folds across the first fold Make a single fold Set the machine to make the single fold according to the instructions in Folding Standard Size Sheets Refer to pages 4 through 8 Press the folded edge of the sheet firmly If the folded edge is not pre...
Page 20: ... 185 mm 7 2 1 Set the front side feed guide 1 as far back as possible 2 Push the stack of sheets against the front side feed guide 1 3 Set the rear side feed guide 2 so that it just touches the stack If the width of the folded sheets is 185 mm 7 2 or more 1 Set the rear side feed guide 1 as far back as possible 2 Load the sheets against the rear side feed guide 1 3 Set the front side feed guide 2 ...
Page 21: ...ivery roller As soon as the sheet size fold pattern and fold speed are set the delivery roller position H1 to H4 will be displayed Move the delivery roller assembly to the position indicated on the display Set the stopper position Turn the 1st and 2nd stopper knobs to align the stopper pointers with the illuminated LEDs When folding custom size sheets refer to the note on page 13 and adjust the st...
Page 22: ...nd check the resulting fold Start the machine using the Start Stop button The machine will start folding To help the feeding action press lightly on the folded edge of the form with your finger You may also use the optional cross folding guide to do this Refer to page 18 for details Press the Start Stop button again to stop folding After the fold job is complete Be sure to lower the feed tray leve...
Page 23: ...e is used to hold the folded edges of the sheets while the machine is making the second folds Set the roller on the cross fold guide over the folded edge of the top sheet Set the cross fold guide beside the feed guide on the feed tray 23056 30201Q1 Roller Front Rear 23056 30201R1 Cross Fold Guide Roller ...
Page 24: ...fold roller pressure lever to Strong when folding sheets of 105 gsm or more 28 bond or 70 book Set the fold roller pressure lever to Normal when folding sheets of less than 105 gsm 28 bond or 70 book To reach the adjustment Remove the delivery roller Open the fold section cover Open the fold section cover slowly 23056 30301A1 Double Feed Stop Plate Pressure Adjusting Lever Pressure Normal Pressure...
Page 25: ...the fold roller pressure adjustment lever Close the clamp handle Hold the clamp and close the clamp handle in the direction shown by the arrow Close the fold section cover Attach the delivery roller assembly 23056 30301E1 Support Clamp Handle 23056 30201H1 Spring Hook Bar Fold Roller Pressure Adjustment Lever Fold Roller Pressure Increased Normal 23056 30301G1 Clamp Clamp Handle 23056 30301H1 Fold...
Page 26: ...s 25 If there are frequent misfeeds 26 If there are frequent sheet jams 27 If the sheets are wrinckled 28 If you hear an unusual noise 29 If the screen is blank 29 If the machine will not fold heavier sheets 29 If there are no lights on the display even though the power is turned on 30 If the delivered sheets are stained 30 Troubleshooting This section shows how to correct some simple problems ...
Page 27: ...error code E5 appears There is a problem inside the machine Turn off the power wait 10 seconds and turn it on again If this error code appears frequently contact your local dealer If error code E6 appears There is a problem inside the machine Turn off the power wait 10 seconds and turn it on again If this error code appears frequently contact your local dealer If error code E7 appears There is a m...
Page 28: ...s and Remedies Page The sheets being used are too thin or too thick Only use sheets which are within the specification Do not fold NCR paper heavy paper more than 127 gsm 34 bond or 85 book or coated paper 46 The sheets are sticking to each other because of static electricity Fan the sheets completely before loading them in the feed tray 5 Check whether the sheets are cut properly Use sheets which...
Page 29: ...correctly 39 Check Points Causes and Remedies Page Check whether the double feed stop plate is worn out Replace the double feed stop plate with a new one The part should be replaced after 15 to 30 million folds depending on the type of sheet If the folder is not used for a year the double feed stop plate may deteriorate Replace it with a new part 38 Check whether the feed roller is worn out Replac...
Page 30: ... plate pressure properly If the pressure is set to Weak change the setting to Normal 19 Check whether the feed table adjusting lever is properly set Check whether the feed table adjusting lever is properly set If the pressure is set to Strong change the setting to Normal 19 Check whether the double feed stop plate is stained with ink Clean the double feed stop plate using a cloth If the folder is ...
Page 31: ...aft are attached properly 37 Check whether the feed table adjusting lever is properly set The feed table pressure is too weak If the pressure is set to Normal change the setting to Strong 19 Set the double feed stop plate pressure properly Set the double feed stop plate pressure properly If the pressure is set to Normal change the setting to Weak 19 Check whether the feed roller is stained with in...
Page 32: ...ch other because of static electricity Fan the sheets completely and wait for a few minutes before loading them in the feed tray 5 Check the stopper positions Set the correct stopper positions using the stopper knobs 7 Check whether a sheet is jammed Remove any jammed sheets in the buckle chute 34 Check whether there is any paper chip along the paper path Open the fold section cover and remove any...
Page 33: ...olding thick or folded sheets select the High mode 6 The sheets being used are too damp Dry the sheets before using them Check whether the rollers are stained with ink Clean the rollers 38 Check whether the fold rollers are worn out If a fold roller is worn replace it with a new one 38 Check whether the feed table pressure is set to Strong Set the feed table pressure to Normal 19 Check whether the...
Page 34: ...s any button to go to the normal operating screen Check Points Causes and Remedies Page Check the fold speed Check the fold speed If the speed is set to Silent or Normal change the setting to High 6 Check whether the fold roller pressure is set properly Set the fold roller pressure properly If the pressure is set to Normal change the setting to Increased 19 Check whether the feed table pressure is...
Page 35: ...the circuit breaker for the stopper tripped the push button has popped out Turn off the power wait 10 seconds and push the button on the circuit breaker Next turn on the power switch If this problem appears frequently contact your local dealer Check Points Causes and Remedies Page Check whether the feed roller fold rollers or double feed stop plate are stained Clean the rollers See Cleaning or Rep...
Page 36: ...mmed Sheets Fold Roller Section 32 Removing Jammed Sheets Buckle Chute 34 Cleaning and Replacing the 35 Cleaning and Replacing the Fold Rollers 38 Cleaning the Sensors 41 Maintenance This section shows how to maintain the folder ...
Page 37: ...rt and open the clamp handle in the direction shown by the arrow Open the roller frame Hold the clamp and open the roller frame in the direction shown by the arrow Hold the roller frame firmly and open it slowly Remove any jammed sheets 23056 50101A1 Fold Section Cover Delivery Roller y 23056 50101B1 Support Clamp Handle 23056 50101C1 Clamp Roller Frame 23056 50101D1 RemovingJammedSheets FoldRolle...
Page 38: ...ler frame Hold the clamp and close the roller frame in the direction shown by the arrow Hook the clamp over the bar on the roller frame Close the clamp handle Hold the clamp and close the clamp handle in the direction shown by the arrow Close the fold section cover Attach the delivery roller 23056 50101E1 Grooves Yellow Arrows 23056 50101F1 Clamp Roller Frame 23056 50101G1 Clamp Clamp Handle 23056...
Page 39: ...emove any jammed sheets from the slot in the buckle chute or push the jammed sheets tin the direction shown by the arrow to remove them from the entrance of the buckle chute After removing any jammed sheets reverse the order of these instructions to replace the buckle chute 23056 50201A1 Buckle Chute Support Table 23056 50201B1 23056 50201C1 WARNING Be careful not to cut your finger on the edge of...
Page 40: ...roller shaft in the direction shown by arrow 1 and pull the feed roller shaft towards you 2 Remove the double feed stop plate Now you can pull up the double feed stop plate The part should be replaced after 15 to 30 million folds depending on the type of sheet If the folder is not used for a year the double feed stop plate may deteriorate Replace the double feed stop plate 23056 50301A1 Power Swit...
Page 41: ... direction shown by the arrow Push the new feed roller over the support Push in until the inner edge of the new feed roller is positioned inside the collar on the support Attach the double feed stop plate Be sure to install the double feed stop plate as shown in the drawing to the left 23056 50301D1 23056 50301E1 Feed Roller 23056 50301F1 Feed Roller Inside the collar 23056 50301G1 Double Feed Sto...
Page 42: ...ed roller assembly Insert both ends of the feed roller shaft as shown in the drawing Close the fold section cover Attach the delivery roller 23056 50301H1 Feed Roller Shaft 1 2 Snap Ring Push in this far Push in this far 23056 50101H1 Delivery Roller Fold Section Cover ...
Page 43: ...mp handle in the direction shown by the arrow Open the roller frame Hold the clamp and open the roller frame in the direction shown by the arrow Hold the roller frame firmly and open it slowly 23056 50301A1 Power Switch OFF WARNING Turn off the main power switch and unplug the power cable whenever you clean or replace the fold rollers 23056 50101A1 Fold Section Cover Delivery Roller y 23056 50101B...
Page 44: ...e groove of the roller holder at the location indicated by the yellow arrow If you need to replace one fold roller replace the other fold roller at the same time Close the roller frame Hold the clamp and close the roller frame in the direction shown by the arrow Hook the clamp over the roller link bar 23056 50401A1 23056 50401B1 23056 50401C1 Grooves Yellow Arrows 23056 50101F1 Clamp Roller Frame ...
Page 45: ...40 Close the clamp handle Hold the clamp and close the clamp handle in the direction shown by the arrow Close the fold section cover Attach the delivery roller 23056 50101G1 Clamp Clamp Handle 23056 50101H1 Delivery Roller Fold Section Cover ...
Page 46: ...oth the 1st and 2nd stoppers Move each sensor to make it easier to clean Turn the correct stopper knob to move the sensor you want to clean Clean the detecting area on the sensor Clean the detecting area on the sensor using a cotton tipped swab or something similar Do not lift the sensor 23056 50201A1 Buckle Chute Support Table 23056 50501A1 Sensor 23056 50501B1 1st Stopper 2nd Stopper Clean the s...
Page 47: ...42 This page is intentionally left blank ...
Page 48: ...43 Installation How to install the PF P3100 Folder 44 Installation These instructions should only be used by trained service technicians ...
Page 49: ...F P3100 Folder CAUTIONS Do not install the PF P3100 on an unstable floor surface The folder may fall over The frame of the machine may be twisted and this could affect the performance of the machine The PF P3100 weighs 37kg 396 lb Install the PF P3100 on a table which can support this weight This machine must be moved by at least two persons 23056 60101A1 23056 60101B1 Delivery Tray Support Table ...
Page 50: ...45 Appendix Specifications 46 Machine Description 47 Fold Mechanism 49 Accessories 50 Consumables Optional Parts 51 Index 52 Appendix This section includes some useful information ...
Page 51: ...30 mm gsm 1 15 Example 300 sheets 64 gsm 18 bond or 43 book Fold Patterns Single Fold Double Parallel Fold Short Fold Accordion Fold Letter Fold Open Gate Fold Production Speed High Speed Mode 240 sheets hr A4 Letter size Single Fold Normal Mode 140 sheets min A4 Letter size Single Fold Silent Mode 84 sheets min A4 Letter size Single Fold Other Function Total Counter Up to 9 999 Voltage Frequency ...
Page 52: ...nt damage to the machine The buckle chute is housed in this section If there is a sheet jam pull out this unit to remove any jammed sheets The folded sheets are held down by the delivery roller I ON OFF Delivery Belts Lower the feed tray lever to place the sheets on the feed tray Raise this lever to start feeding If the fold are skewed adjust the sheet feeding angle using this lever Refer to page ...
Page 53: ...quent misfeeds if you are feeding heavier sheets 82 gsm 22 bond or 55 book or more set the adjusting lever to the Increased position Refer to page 20 Set the fold roller pressure lever to Strong when thick sheets 105 gsm 28 bond 70 book or more are folded Set the fold roller pressure lever to Normal when thinner sheets less than 105 gsm 28 bond or 70 book are folded Refer to page 20 Display 0 1 2 ...
Page 54: ...er to the note on page 7 When folding heavier sheets the sheet is not bent as much Set the folding speed to High to create a larger bend in the sheet Refer to page 46 The sheet is folded The fold rollers nip the sheet bend and the fold edge is created Adjusting the stopper position changes the fold position 23056 70301A1 Feed Roller Double Feed Stop Plate Sheets 23056 70301B1 Feed Roller Fold Roll...
Page 55: ...50 Operation Manual 1 Power Cable 1 Delivery Roller 1 P F P 3 1 0 0 23056 70401B1 For 115V For 230V Either one of the two is attached 23056 70401E1 Support Table 1 23056 70401D1 Accessories ...
Page 56: ...onsumables Optional Parts Double Feed Stop Plate M014225 Feed Roller M001978 Fold Roller A941901 23056 70501B1 23056 70501C1 23056 70501D1 Cross Folding Guides 23056 70501E1 23056 70501F1 Consumables Optional Parts ...
Page 57: ... 25 F Feed Feed roller cleaning 36 Feed table pressure adjustment 19 Feed tray lever 4 7 Fold Fold pattern 6 Fold problem 9 Fold rollers cleaning 38 Fold speed 6 J Jammed sheets removing 32 M Misfeeding 26 N Non standard size sheets 12 P Power saving mode 4 R Removing jammed sheets 32 S Sheet jam correcting 27 Sheet size setting 5 Stoppers setting 7 Support rollers setting 5 T Test button 7 W Wrin...
