Baumfolder BAUM 2018 Instruction Manual Download

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PAGE 1 TP10313

BAUM 2018

1ST STATION FOLDER W/PILE FEED

INSTRUCTION MANUAL

©Baumfolder Corp., 1999

Printed in U.S.A.

TP10313

BAUMFOLDER

Summary of Contents for BAUM 2018

Page 1: ...PAGE 1 TP10313 BAUM 2018 1ST STATION FOLDER W PILE FEED INSTRUCTION MANUAL Baumfolder Corp 1999 Printed in U S A TP10313 BAUMFOLDER ...

Page 2: ...vements in its products without imposing any obligation upon itself to install them on its previously manufactured products It is recommended that modifications to this equipment not be made without the advice and express written consent of Baumfolder Corporation 1999 BAUMFOLDER CORPORATION All Rights Reserved FOLDER IDENTIFICATION MODEL NO _______________________________ SERIAL NO _______________...

Page 3: ...ns for Selection Adjustments 12 2 0 RUN MODE FUNCTIONS 12 2 1 Machine Setup and Diagnostic Mode 12 2 2 Counter Setup Mode 16 2 3 Easy Mode and Continuous Cycle Mode 17 2 4 Learn Mode 17 2 5 Make Ready Mode 18 2 6 Network Job Mode 19 2 7 Production Mode 19 3 0 LOGIC BOARD STATUS INDICATORS 20 4 0 Process Variables Definitions 21 4 1 Total Input Count 21 4 2 Total Output Count 21 4 3 Batch Down Coun...

Page 4: ...ions 37 XVIII Accessories 37 XIX Troubleshooting 38 XX Operating Tips 40 XXI Principles of Mechanical Folding 42 XXII Folding Chart 43 XXIII Manual Usage 45 XXIV Typical Layout Sheet Orientation 46 XXV Impositions 47 1 4 PAGE 47 2 4 PAGE DOUBLE IMPOSITION 47 3 6 PAGE STANDARD 47 4 6 PAGE ACCORDION 47 5 8 PAGE PARALLEL IMPOSITION 47 6 8 PAGE RIGHT ANGLE 47 7 8 PAGE RIGHT ANGLE OBLONG 48 8 8 PAGE RI...

Page 5: ...e Usage Status Parameter List 16 Table 7 Output Type Animations 16 Table 8 Count Source Selection 17 Table 9 Learn Mode Status 17 Table 10 Suction Mode Symbols 18 Table 11 Suction Length Function 18 Table 12 Determining the Large Display Contents 19 Table 13 Reset mode Selection 19 Table 14 LED Status Indicators 20 Table 15 Output Delay and Duration 20 Table 16 Power Up Fault Messages 23 Table 17 ...

Page 6: ... power supply 8 Never use improper or defective tools 9 After making adjustments or after doing maintenance or repair work always make sure that all tools and other objects are removed from the machine Other wise they might fall into the machine causing severe damage or injuries 10 Make sure that all safety devices are in place before restarting the machine 11 Never clean moving parts of the machi...

Page 7: ...TS GUARDS MUST BE IN PLACE WHEN OPERATING FOLDER KEEP HANDS HAIR LOOSE ARTICLES AWAY FROM MOVING PARTS 50215 CAUTION HAZARDOUS MOVING PARTS DO NOT OPERATE MACHINE WITHOUT GUARD IN PLACE 40686 C A U T I O N HIGH VOLTAGE EXISTS WHEN DOOR IS OPEN REMOVE VOLTAGE AT POWER SOURCE BEFORE SERVICING 42877 39379 CHANGE SPEEDS ONLY WHEN FOLDER IS RUNNING ...

Page 8: ... sales representative To lift the folder from the skid place the fork lift rails under the lower rails as shown in Figure 2 Note that the fork lift must have at least a 1500 lb capacity Remove all rust protection coating after unpacking the folder Level the machine on the floor Place a spirit level on the 2 fold roller Figure 3 and on the feeder crossmembers SQUARING THE MACHINE It is essential th...

Page 9: ... should not be removed Figure 5 1 2 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 vo...

Page 10: ...restarted An error message StoP will appear on the readout The emergency stop buttons are found at the main operator control panel 8 1 and the delivery control 9 2 Figure 9 Figure 7 Figure 8 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...

Page 11: ...the feeder is in reverse mode Continuous Feeder or moving down Pile feeder h 0 1 2 3 4 5 6 7 8 9 10 BAUMFOLDER CORPORATION 9 13 11 16 26 27 22 23 4 5 7 6 15 3 18 19 20 21 34 35 1 29 30 31 32 33 25 28 24 2 8 12 10 14 17 36 06 Input Indicator The input indicator shows the status of the suction photo eye 07 Output Indicator The output indicator lights when the Batch Preset is reached and the user has...

Page 12: ...c parameters knife status parameters and machine usage parameters Parameter Selection within a Group If the large display 1 decimal points are moving this set of minus and plus buttons will select the machine parameters within each group see tables 1 6 Select Parameter Adjustment If the large display 1 decimal points are moving this set of minus and plus buttons will move through the set of values...

Page 13: ...enabled Time displayed in 01 Hours This information becomes part of the job record Parameter Function Type Variable Displayed P00 Input Factor Setup Variables Adjustable 1 24 P01 Output Factor Setup Variables Adjustable 1 to Input Factor P02 Tremat Setup Variables Adjustable 1 or 0 P03 Knife Setup Variables Adjustable 1 or 0 P02 Tremat This is an unavailable option P03 Knife This is an unavailable...

Page 14: ... English German Codes P22 Network Address Setup Variables Adjustable 0 255 P23 Pause Setup Variables Adjustable 1 or 0 P24 Network Setup Variables Adjustable 1 or 0 P25 Easy Setup Variables Adjustable 1 or 0 P26 Software Version Machine Configuration Fixed V X X X P27 Machine Type Machine Configuration Fixed Set at Factory P28 Serial Output Type Machine Configuration Fixed Off Display or Network P...

Page 15: ...P30 7 P30 8 Pile Motor Function Pile Down Pile Stop Pile Up Compress Compress Drive Start Energized Control K1 Button Button Button Stop Button Start Button Relay K3 P31 Status Input Port 2 P31 1 P31 2 P31 3 P31 4 P31 5 P31 6 P31 7 P31 8 Pile Sensor Double Pile Sheet Start Sheet Stop Thermal Wrong Sheet Emerg Stop Sheet Fault Bottom Button Button Fault Fault Drive Stop Button P32 Status Input Port...

Page 16: ...h display 3 is active Change Batching Type The minus and plus buttons move through a list of four output devices The chosen Type is then activated when the batch down count goes to zero Feed interruption stops the feeding of sheets for the batching time setting Function Type Variable Displayed P50 Power on time Machine Status Based on Inputs Time in 1 100 Hours P51 Machine run time Machine Status ...

Page 17: ... buttons will toggle between the EASY mode or cYcL mode Set EASY in the large display and press again Select Continuous Cycle Mode Pressing this button enables the selection of either the EASY mode or cYcL mode Pressing these buttons will toggle between the EASY mode or cYcL mode Set cYcL in the large display and press again Exit Run Mode Pressing any of these keys will cause the counter to change...

Page 18: ...rols the timing of the suction valve to maintain the user selected gap If the gap is less than 1 5 4 0 cm the right hand decimal point of the small display 2 will flash and the Leading edge control will be active If the gap is greater than or equal to 1 5 4 0 cm full Leading and Trailing edge control is maintained Refer to table 10 for suction mode symbol definitions Sheet Length Adjustment The sh...

Page 19: ...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 The range of adjustment is 5 to 50 of the current sheet length h h h h h h Output Count Batch Count Down Number of Batches Current Rate Input Count Waste Count Large Display Contents h h 0 This mode is only available if a STA NET adapter is installe...

Page 20: ... LED1 Tachometer Indicator Tracks the Tachometer input LED2 Not Used Turns on when MKE output is activated LED3 Suction Indicator Tracks the Suction output LED4 K1 Status of Relay K1 LED5 Pile Down Tracks the Pile down output LED6 Pile Up Tracks the Pile up output LED7 Pile Indicator Tracks the Pile outputs If one of the Pile outputs is on this LED will be on LED8 Logic 5VDC Supply Shows status of...

Page 21: ...t job will clear this process variable to zero Reset batch will clear this process variable to zero 4 5 Current Rate The Current Rate is based on the number of Input Count inputs received during the sample period The Current Rate is calculated every second The Current Rate is shown as rate per hour The Current Rate is rounded to the nearest hundreds Current Rate can range from 0 to 99 999 900 This...

Page 22: ...ection 5 5 Gap Length This parameter is accessible in Run mode and Learn mode and specifies the length of gap to use between sheets of paper that are fed into the machine Available range is 0 2 to 98 0 2 0 is the default selec tion 5 6 Suction Length This parameter is accessible in Run mode and Learn mode andspecifies the suction length used on a sheet of paper that is fed into the machine Availab...

Page 23: ...C System The Pile Safety Relay is stuck on or there is no power supply to the Error pile circuits Action Check the condition of Relay 1 K1 Fuses F1 and F2 and X18 Cycle Power If error persists call service Error 3 Error 3 Error 3 PLC System There is power in the Pile Drive when it is off Action Check the Error condition of Relay 1 K1 Fuses F1 and F2 and X18 Cycle Power If error persists call servi...

Page 24: ...l The Machine Tachometer is reading a velocity outside of the System range 10 230 meters per minute while the main drive should Error be running Action Check the electric If error persists call service Overload Uberlast Error11 Electrical A Thermal Overload has been tripped System Action Check the electric If error persists call service Error Pile Err Spg Uber Error12 Electrical The Pile Safety Re...

Page 25: ... the condition of the count photo eye Feeder Sensor Stop5 Machine Photo eye at suction valve is covered before Sheet Start is active Run Error Long Sht Bg Lang Stop6 Machine The count photo eye has been covered for more than 150 of Run Error the user set sheet length distance ACTION Check misfeed connector X14 and the condition of the count eye Knife 1 Schwert1 Stop7 Machine The knife input 1 has ...

Page 26: ...d guide 12 4 Slide the register guide 12 7 inward until the see through left hand guide 12 4 is approximately 1 16 away from the stack 1 2 Hold down Locations Set the sheet hold downs so the rubber bumpers rest on top of the sheet pile and prevent double sheets from being pulled in Using the rubber bumpers is dependent upon the stock being fed 1 3Air and Vacuum Settings Press the pile up button if...

Page 27: ...t is made at the pump Figure 16 using the valve 16 1 Vacuum adjustment requirements should be minimal Listen to the feeding at the vacuum wheel to determine if there is too much vacuum The vacuum valve 16 1 should be set as shown for most applications 1 4 Vacuum Wheel The vacuum flow is controlled by a solenoid valve Figure 11 4 17 1 This can be quickly and easily removed to clean the piston 17 2 ...

Page 28: ... unusual conditions The double sheet control Figure 20 is adjusted to the thickness of the paper being fed by pulling up the lever 20 1 and inserting two paper strips 20 2 of the sheets to be folded in the clip at the back of the lever The feeler segment remains inoperative when a single sheet is passing through When double sheets are being fed through the feeler segment is pulled against a micros...

Page 29: ...t being made by turning the knurled screw The numbers on the Baumset adjustment knobs corre spond to the buckle plate numbers into which the sheet is fed All upper buckle plates have odd numbers while the plates below are even The Baumset adjustment device is correctly zeroed at the factory If any adjustment is necessary strips of single paper thickness should be placed under every adjustment plat...

Page 30: ...be tightened for this adjustment For the fitting of a fold plate both sides of the stop 23 1 must have the fold plate symbol turned to the front so that the adjustment screw contacts the support rail Equal adjustments at both ends are needed to prevent oblique folds or perforations CAUTION If the buckle space is reduced be sure that the fold plate does not rub against the folding rollers If this o...

Page 31: ...s and one stationery deflector Figure 26 STACKER DELIVERY The motorized hang on stacker has the following unique features Independent speed adjustment by using the speed selector Figure 28 1 Telescoping delivery tray that is fixed in position using thumbscrews 28 2 below the tray Nosebar with brush 28 3 that prevents sheets from becoming trapped and eliminating a pinch point The stacker can be mou...

Page 32: ...before starting the machine Figure 30 1 1 Scoring The folder can be used to score a sheet and deliver it flat or to score a sheet after a fold or folds have been made To ensure accuracy in making right angle folds always score the sheet where the fold or folds are to be made This applies in all instances when a perforator cannot be used Various weights of stock with few or numerous folds require a...

Page 33: ...er shaft with the flat side of the blade just touching a side of the groove When doing book work perforator blades should be mounted with the bevel side of the blade toward the follow ing bank of fold rollers See Figure 34 When mounted in this manner there is slightly less tendency for the sections of the signature to come apart and less tendency for one section to pull out of line with another Th...

Page 34: ... loosely attached on the end of the shaft Then tighten securely to align both blade and collar and allowing free horizontal movement Place the blade on the upper shaft in the position where the cut is to be made Then move the blade on the lower shaft so that the two blades are pressed snugly together Too much space between the blades will produce a ragged cut Figure 36 1 shows a spacing washer mou...

Page 35: ...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 If a strip wider than one quarter of an inch is to be cut each blade is attached to an individual collar and any desired width may be cut To remove the trim place the appropri...

Page 36: ...ndwheel Lubricate bi annually with commercial grade lubricating oil Fold Rolls WARNING Never clean fold rolls while the machine is running With the folder turned off rub down the fold rolls with a cloth dampened with Surewash Never immerse fold rolls into the washing solvent After cleaning they should be rubbed down with a clean dry cloth Gear Drive The helical gear drive is lubricated by an autom...

Page 37: ...parallel folder Slitter shaft diameter 7 8 22mm Electrical 220 Volt 1 phase 60 Hz 23 Amperes See serial plate on folder ACCESSORIES In addition to the various folding slitting perforating and scoring functions the Baum 2018 can perform even more productive functions using the following accessories Jam Detectors Remote Control Static Eliminator Sound Guards Gluing Fold Plates Contact your local Bau...

Page 38: ...ding edge of the sheet Adjust holder tongue buckles on register or is being buckled the holder accordingly lower sheets are being tongue below the suction wheel pushed forward is too high if too low sheets are pushed forward Dirty valve piston sticking Clean Sheets fails to run into the Only at 1st buckle plate Fit sheet deflector to 1st buckle plate A curl in the sheet buckle and fold in 3rd can ...

Page 39: ...r across or angles to the folding rollers parallel Sheet drawn too sharply against Insert fewer balls or use the register guide causing a wave lighter ones to form Buckle plate feed stop not Correct buckle plate stop parallel to the incoming sheet setting edge Folding rollers set too tight Slacken roller setting Crooked perforation after Register guide and buckle Reset 1st fold plate stop not at r...

Page 40: ...r shaft accesso ries Mark up a dummy sheet with the scores perforations etc locations Roll through by hand and position your slitter shaft accessories accordingly Also keep all set TIPS FOR FOLDING The following section contains a number of hints drawn from practical experience for the setting up and adjustment of folding machines Roller Setting for Accordian and Letter Folding The rollers used fo...

Page 41: ...paper qualities and thicknesses vary greatly it is essential that buckle plates are properly adjusted With thin papers the lower buckle lip is brought slightly forward With thicker paper it must be set further back The buckle plate configuration is directly related to the thickness and stiffness of the paper being folded This relationship must be taken into account if a high quality fold is to be ...

Page 42: ...up by the rotating rollers and the fold is formed as the sheet passes through them It can be seen that in this case the folding process is not restricted to any cyclical movement and is thus capable of a very high output For each folding station it is possible to fit up to four buckle plates arranged alternately above and below Buckle plates that are not required for a particular folding operation...

Page 43: ...P10313 IMPOSITIONS 18 MOST POPULAR FOLDS 1 2 3 4 5 MAIN DRIVE F O L D P A N 1 F O L D P A N 3 F O L D P A N 2 F O L D P A N 4 DEFLECTOR OPEN DEFLECTOR CLOSED DEFLECTOR OPEN DEFLECTOR CLOSED SHEET STOP SHEET STOP ...

Page 44: ...bbed by the fold rollers and compressed into a fold Look at the figure below You can see that fold pans 1 and 3 are angled upwards Because of this and the configuration of the fold rollers sheets fed into the 1 and 3 fold pans will always be folded up i e so that the up surface of the sheet is folded into contact with itself Likewise because foldpans 2 and 4 are angled down sheets fed into them wi...

Page 45: ...ume any respon sibility for any errors that might inadvertently be contained in this manual When trying a new fold it is always advisible to set up a test run to check for potential problems 1 Refer to the diagram below Visualize the sheet to be folded lying flat on the register table The edge toward the fold rolls is called the LEADING EDGE The paper edge under the register guide will be referred...

Page 46: ... page 3rd STATION 32 page 1 UP 1 UP 2 DOWN 2 DOWN 3 UP 4 DOWN NOTES 1 When planning an imposition check your folded layout for proper page numbers and guide edges Verify that your folder is large enough to do the job that is that the fold pan depths are sufficient for the folds desired 2 If the desired imposition is unusual try the stock on the folder before printing make a trial folding run 3 Use...

Page 47: ...folded two or more up and cut apart Trim edge after folding 2 6 PAGE STANDARD Parallel 1 3 May be folded two or more up and cut apart 3 1 2 3 4 1 2 3 4 1 2 3 4 6 5 1 2 3 4 6 PAGE ACCORDION Parallel 1 2 May be folded two or more up and cut apart 4 8 PAGE PARALLEL IMPOSITION Parallel 1 2 May be folded two or more up and cut apart 5 8 PAGE RIGHT ANGLE Parallel 1 8 Page 1 6 ...

Page 48: ...WO RIGHT ANGLE OBLONG Parallel 1 8 Page 1 7 8 PAGE RIGHT ANGLE DOUBLE IMPOSITION Parallel 1 8 Page 1 2 3 8 8 PAGE PARALLEL OVER OVER Parallel 1 2 4 May be run two or more up and cut apart 9 12 PAGE BOOK SADDLE STITCH Parallel 1 2 8 Page 2 10 12 PAGE BOOK SADDLE STITCH Parallel 1 2 8 Page 1 11 12 PAGE LETTER FOLD HEADS OUT Parallel 1 8 Page 1 2 12 ...

Page 49: ... 3 4 6 5 1 2 B C B 11 12 9 10 B C C B C 14 13 15 16 12 PAGE LETTER FOLD HEADS IN Parallel 1 8 Page 1 3 13 12 PAGE LETTER FOLD ACCORDION Parallel 1 8 Page 1 2 14 16 PAGE THREE RIGHT ANGLE BOOK IMPOSITION Parallel 1 8 Page 1 16 Page 1 May be run two or more up and cut apart 15 12 PAGE FOLDER HEADS OUT Parallel 1 8 Page 1 2 16 24 PAGE BOOKLET Parallel 1 2 8 Page 1 2 17 32 PAGE BOOK Parallel 1 2 3 8 P...

Page 50: ...ree 1 800 543 6107 for parts or the number of your nearest authorized dealer BAUMFOLDER C O R P O R A T I O N 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 com ...

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