service manual folding machine fk-4.400s … 4.400s-service manual.pdf · power consumption 1,8 kw...

FABRYKA

MASZYN

INTROLIGATORSKICH

[email protected] 90-019 Łódź, Poland, ul. Dowborczyków 12

www.introma.com.pl Adres do korespondencji i wjazd:

(Correspondence and delivery address:)

90-042 Łódź, ul. Targowa 11

Biuro handlowe – tel. 048-42-636-60-58

fax. 048-42-633-80-01

Serwis tel. 048-42-674-66-21

SERVICE MANUAL

FOLDING MACHINE FK-4.400S

WITH SUCTION FEEDER

Serial Number: ..........................

Year of Manufacture: ..........................

2

1. TRANSPORT AND STORAGE

1.1. Delivered condition

1.1.1. List of disassembled parts

1.1.2. List of equipment

1.1.3. Temporary protective layer

1.1.4. Conditions of storage

1.1.5. Packing

2. TECHNICAL DESCRIPTION

2.1. Application

2.2. Basic parameters

2.3. Folding principle

2.4. Folding methods

2.5. Folding capacity

3. ANALYSIS OF HAZARDS AND PROTECTION MEASURES APPLIED

3.1. Hazards

3.1.1. Mechanical hazards

3.1.2. Electrical hazards

3.2. Protective measures against mechanical hazards

3.3. Protective measures against electrical hazards

3.4. Conformity with safety standards

3.4.1. European standards

3.4.2. Polish standards

3.5. Principles of operating safety

4. PRE-ACTIVATION PREPARATIONS

4.1. Unpacking and assembly

4.2. Assembly of the folding machine

4.3. Checking the correctness of assembly

5. PRINCIPLES OF FOLDING MACHINE OPERATION

5.1. Mechanical part

5.2. Electrical part

5.3. Installation air

6. ADJUSTMENTS

6.1. Adjusting the selector mechanism

6.2. Setting the margins

3

6.3. Setting the blow-in nozzles

6.4. Setting the plates

6.5. Setting the gaps between rollers

6.6. Setting the paper clamp

6.7. Test manual folding

7. AUTOMATIC FOLDING

8. SCORING, PERFORATING, AND SLITTING

9. FOLDING DEFECTS, CAUSES, AND SOLUTIONS

10. MAINTENANCE

11. CONTROL PANEL

12. DRAWINGS

13. ELECTRICAL WIRING DIAGRAM

4

1. TRANSPORT AND STORAGE

1.1. Delivered condition

The FK-400S folding machine with suction feeder is delivered partly disassembled for transport.

The disassembled parts and equipment of the folding machine are as listed in points 1.1.1. and

1.1.2. below.

1.1.1. List of disassembled parts

Markings in accordance with Figure 2.

a) Feeding table (9)

b) Receiving conveyor (3)

c) Paper clamp (5)

d) Plate (7a),(7b), (8a) ,(8b)

e) Base of folding machine (1)

f) Compressor (21)

g) Compressor hose (15) (16) (17)

h) Delivering table mini (option)

1.1.2. List of equipment

a) Open ended spanner 6 / 7

b) Open ended spanner 8 / 10

c) Open ended spanner 13 / 17

d) Socket wrench 2

e) Socket wrench 3

f) Socket wrench 4

g) Socket wrench 6

h) Scoring unit

i) Perforating unit

j) Slitting unit

k) Service manual

l) Star-shaped screwdriver T20

m) Star-shaped screwdriver T25

1.1.3. Temporary protective layer

The folding machine is protected against corrosion for transport and storage. The durability of the

applied temporary protective layer is 3 months under specific conditions of storage.

1.1.4. Conditions of storage

The packed folding machine should be stored in a dry room, secured against atmospheric influ-

ences. During storage it is necessary to place the machine in accordance with the markings on the

packing and also avoid piling up pickings.

5

1.1.5. Packing

The packing of the folding machine consists of one cardboard boxes. These may be safely lifted

and moved using a fork-lift truck. During transportation of the boxes it is necessary to keep the

machine in an upright position, i.e. in accordance with the markings on the packing - the boxes

should not be turned, thrown, or dropped. The gross weight of the packed folding machine with

suction feeder equals 180 kg. The external dimensions of the cardboard boxes are 950 x 600 x

1000 mm each.

2. TECHNICAL DESCRIPTION

2.1. Application

The FK-4.400 folding machine with suction feeder is designed for folding sheets of paper by mak-

ing two folds. It may also be used for scoring, perforating and slitting sheets of paper.

2.2. Basic parameters

Folding capacity 30000 sheets/h

Maximum sheet size 37 x 70 cm

Minimum sheet size 9 x 9 cm

Maximum folding length 38 cm

Minimum folding length 4 cm

Minimal folding length for the special cassette* 2,5 cm

Paper basis weight* 60 - 180 g/m2

Compressor capacity 40m3/h

Positive/negative gauge pressure magnitude 0,5 bar

Supply voltage 230 V

Current frequency 50 Hz

Control voltage 24 V

Power consumption 1,8 kW

Weight of folding machine approximately 180 kg

External dimensions 150 x 130 x 60 cm

* Given parameters may vary depending on the type of fly and paperweight.

2.3. Folding principle

Description in accordance with Figure 1.

A separate sheet of paper is fed between feeding rollers 1,2 into cassette 1, until it reaches the

fender. Next, the sheet is bent in the room between the rollers and conveyed by the folding rollers

2,3. This is the first folding of the sheet. Rollers 2,3 feed the sheet with its folded edge into the cas-

sette until it reaches the fender. The sheer conveyed by the rollers is bent again in the room be-

tween the rollers and by the folding rollers 3,4. This is the second folding of the sheet. Similar op-

erations are performed using rollers 4,5 and 5,6. Folded sheet is received by the receiving rollers

6

7,8. These rollers can be equipped with scoring, perforating or cutting units. By adjusting fenders

inside the cassette it is possible to have various sorts of folding.

2.4. Folding methods

In order to have various sorts of folding, one needs to set the fenders in their proper places inside

the cassette, using the graduations marked on a cassette or to mount the stator. Table below

presents settings for various sorts of folding. In columns 1,2,3,4 the length of the fender in its cas-

sette is given. In columns A, B, C, D, E given the number of stripes of the folded paper, which

should be placed in proper slots which control the clearance between the rollers.

Types of folding 1 2 3 4 A B C D E

1/2

0

0

0

1

2

2

2

2

1/2

1/4

0

0

1

2

4

4

4

1/3

2/3

0

1/3

1/3

0

0

0

1

1

1

1

1

3

3

3

3

3

1/4

1/4

1/4

0

1

1

1

4

4

1/5

1/5

1/5

1/5

1

1

1

1

5

3/4

1/4

0

1/4

1

1

3

1

4

1/2

1/6

0

1/6

1

2

2

2

6

7

1/3

1/3

0

0

1

1

3

3

3

Table No. 1. Types of folding.

2.5. Folding capacity

The actual folding capacity is dependent above all on the format of the paper sheets, but also on

the basis weight and type of paper used. Capacity will also be influenced by the ambient humidity

and qualifications of operators and service personnel. The folding capacity given in point 2.2. is an

approximate value only.

3. ANALYSIS OF HAZARDS AND PROTECTION MEASURES APPLIED

3.1. Hazards

The potential hazards resulting from the construction and operation of the folding machine with

suction feeder are of a mechanical and electrical nature.

3.1.1. Mechanical hazards

Mechanical hazards may be caused by:

a) Sharp edges, corners and ends of elements, and also by their uneven and rough surfaces.

b) Moving parts of the drive and remaining mechanisms.

3.1.2. Electrical hazards

Coming into contact with active elements, i.e. with live elements constituting a threat of direct or

indirect electric shock.

3.2. Protective measures against mechanical hazards

a) The hazards referred to in point 3.1.1.a above have been eliminated by the rounding off or

smoothing of all accessible potentially hazardous edges and corners, and also by the appropri-

ate machining of surfaces in order to ensure their smoothness.

b) The hazards referred to in point 3.1.1.b above have been eliminated by the application of ap-

propriate guards.

3.3. Protective measures against electrical hazards

a) Application of a safe control voltage.

b) Location of control and supply equipment in casings.

8

3.4. Conformity with safety standards

The constructional solutions of elements and mechanisms applied in the folding machine, and also

the technical protective measures introduced to safeguard the operator against mechanical and

electrical hazards meet the requirements set forward in the standards referred to in points 3.4.1.

and 3.4.2. below.

3.4.1. European standards

- EN 292-1:1991 Safety of machinery - Part 1: Basic terminology, methodology

- EN 292-2: 1991 Safety of machinery - Part 2: Technical principles and specifications

- EN 294:1992 Safety of machinery - Safety distances to prevent danger zones being reached by

the upper limbs

- EN 953:1992 Safety of machinery. General requirements for the design and construction of

guards (fixed, movable)

- EN 60204-1:1992 Safety of machinery - Electrical equipment of machines. Part 1: General re-

quirements

3.4.2. Polish standards

- PN-83/M-08200 Work protection. Production machines and equipment. General safety require-

ments.

- PN-83/M-82001 Work protection. Mechanical guards for machines and equipment. General re-

quirements.

3.5. Principles of operating safety

During the execution of service-related operations, which include the use of the corner rounding

machine, the interchange of tools, maintenance, and repairs, it is necessary to observe the follow-

ing safety principles:

a) The operator of the folding machine and persons entrusted with its maintenance and repair

should be familiar with the construction, operation and technological potential of the machine.

b) Inspections, maintenance and repairs are to carried out solely by duly authorised persons hav-

ing the required qualifications.

c) All operations connected with the setting of the folding machine, interchanging tools, and carry-

ing out maintenance and repair-work may be carried out only after the power supply is

switched off.

d) The operator should start work only after having first checked whether all of the guards are in

place.

e) If any irregularities are observed in the functioning of the folding machine, the operator should

interrupt work and eliminate the defect (if he/she is duly qualified and authorised) or report the

irregularity.

f) Once work is finished, the power supply should be switched off.

9

4. PRE-ACTIVATION PREPARATIONS

4.1. Unpacking and assembly

The folding machine with suction feeder is delivered to the customer partly disassembled in card-

board boxes. The customer should take all of the elements of the machine out of these boxes, un-

wrap them from the protective foil sheets, and check the completeness of the delivery against the

list given in the service manual.

4.2. Assembly of the folding machine

The elements of the folding machine which have been disassembled for transport should be as-

sembled onto the folding machine in accordance with Figure 2. To this the end it is necessary to

carry out the following operations:

The components of the folding machine which have been uninstalled for transport should be reins-

talled as illustrated in Figure 2. Proceed as follows:

a) Place the base (1) of the folding machine on a level floor at the planned place of operation of

the machine.

b) Put the body (2) of the machine on the base (1). Fix it with four long screws M8 (22).

c) Install the conveyor (3) between the sidewalls of the body by placing the cutouts of the

conveyor on appropriate pins. Make sure that the conveyor dog (4) is properly engaged with

the drive cam.

d) Install the paper clamp.

e) Install the upper cassette (7) between the sidewalls of the body (2) by placing the cutouts of the

cassette on appropriate pins.

f) Install the lower cassette (8) in a similar way.

g) Install the feed table (9) between the sidewalls of the body (2) by placing the cutouts of the

table on appropriate pins. Make sure that the feed table gears are properly engaged with the

body gears.

h) Install two air-blast hoses (15) between the side margin stubs (12) and the distributor (19)

located below the feed table. Connect the suction hose (16) with the outflow stub (20) of the

valve, and the inflow stub of the valve with the suction cylinder stub (18).

i) Connect the electric cable of the compressor to the socket located on the wall below the

collector table.

4.3. Checking the correctness of assembly

In order to check whether the folding machine has been properly assembled, it is necessary to

carry out the following operations:

a) Turn the knob located on the right side of the folding machine. Turning should be smooth, light,

and jam-free. The flat belts of the feeding table should move uniformly, while the flat belts of

10

the receiving conveyor ought to execute a stepwise movement. The plate ends should not rub

against the folding rollers. The plates should be firmly placed upon the pivots and cannot have

any play.

b) Once the folding machine is connected to the supply network, switch on the compressor with

the switch-key (14). The four nozzles located on the feeding table should blow out air, while air

should be drawn in through the openings in the suction drum. If this is not the case, it is neces-

sary to change the hoses connecting the compressor with the feeding table.

5. PRINCIPLES OF FOLDING MACHINE OPERATION

5.1. Mechanical part

Description of principles of folding machine operation in accordance with Figure 3.

The stack of paper to be folded is placed between the margins (air strips) (2) on the feeding table

(1). This stack is then blown apart by the air issuing from the margins. The lowermost sheet is

sucked to the suction drum (4). The suction drum turns, takes this sheet, and passes it beneath the

lock (5) of the selector mechanism between the margins (6). In order to ensure the uniform single

collection of sheets, it is necessary to appropriately adjust the selector mechanism. The movable

flat belts in the front part of the feeding table move the sheet of paper between the folding rollers,

and then to the plates (9), where the folding process takes place. The plates are fitted with adjust-

able bumping blocks, which make it possible to choose one of a number of different folding meth-

ods. The folded sheet is transferred by the receiving rollers to the receiving conveyor (17).

The compressor, which generates positive gauge pressure in the side blow strips and the negative

gauge pressure in the suction cylinder, is mounted on the base (19). Mechanisms of the folding

machine are driven by an AC motor. The drive is transmitted from the motor to the mechanisms by

means of flat belts.

5.2. Electrical part

Description of principles of folding machine operation in accordance with Figure 4.

The main switch (1) supplies power to the machine. Pushbutton (3) starts the drive motor, while

pushbutton (2) stops it. See section 11.2 to adjust the drive motor speed, and therefore the operat-

ing speed. The machine is equipped with a sheet counter, which counts the number of folded

sheets, the number of sheets in a series, the time interval between series and displays the last

count of completed flies.

The counter cooperates with an optoelectronic sensor (8), which records the event of passing of a

sheet. If indications of the sensor are wrong, it needs to be programmed using the button on the

side wall of the sensor in the following way:

- First pressing and holding the button switches on the green, yellow and red diodes succes-sively, and then switches on all diodes.

- After second pressing, the green diode flashes for about 3 seconds and then it goes off. Now, the sensor is programmed.

11

5.3. Pneumatic system

Air is supplied to the system by compressor of capacity 40 m3/h. The blowing stub is connected to

the blow distributor mounted underneath the feed table with a hose. The air from the distributor is

delivered to the air strips through two hoses. On the strips there are valves that control the outflow

of air. The flowing-out air blows loose the paper sheet stack. The suction stub is connected to the

suction cylinder by an electric valve. Paper sheets are sucked to the cylinder and fed to the folding

rollers.

6. ADJUSTMENTS

6.1. Adjusting the selector mechanism

Description of selector mechanism adjustment in accordance with Figure 5.

The role of the selector mechanism is to collect one sheet of paper from the stack. In order to set

the selector mechanism, it is necessary to carry out the following operations:

a) Using the handwheel (1) set the lock relative to the suction drum (3). For thick paper the lock

should be located above the axis of the suction drum. For thin paper the lock should be moved

back by approximately 4 - 6 mm.

b) Using the handwheel (4), adjust the gap between the lock (2) and the suction drum (3). For

thick paper the gap should be adjusted to the thickness of the paper. For thin paper the gap

should be adjusted to 4-6 times the thickness of the paper.

c) Using the lever (5), set the suction nozzle located inside the suction drum to the appropriate

position. The nozzle should be directed towards the front edge of the lock (2).

6.2. Setting the margins

Description of setting in accordance with Figure 3.

The feed table of the folding machine (1) is equipped with two side margins (air strips). They are

used to set up the stack of paper sheets to be folded. The margins have to be set symmetrically to

the axis of the machine using knobs (3). The margins should be parallel to the axis of the machine.

The clearance between a sheet of paper and the margins should be less than 1 mm. But if it is too

small, collecting the sheets may be difficult. Incorrect setting of margins may be a possible reason

for the creasing being not perpendicular to the edge of a sheet. If this is the case, slightly adjust

the angular position of the margins making sure that they remain parallel. You can do it by turning

the knob (21) in a proper direction.

6.3 Setting the blow

Description below refers to Figure 3.

To facilitate collecting sheets from the bottom of a stack, the stack should be loosened by air blow-

ing from the margins (2). Depending on the size of a sheet to be folded, close the air outlets that

12

are beyond the stack using knobs (7). If the blowing is set up correctly, the stack of sheets will free-

ly float upon an air cushion.

6.4 Setting the plates


The folding machine is equipped with two plates (9). By appropriately setting the bumping blocks

(12) within the plates, it is possible to achieve the desired types of folding. For positioning of bump-

ing blocks, see Table No. 1. In order to move the bumping block within the plate, it is necessary to

loosen the knob (10) and slide the bumping block along the guide. The knob (14) serves to fine-

tune the setting of the bumping block. While moving the bumping block it is recommended to use

the scales located on the plate. Data given by the scales are general reference only, and their va-

lidity will be influenced by the basis weight of the folded paper. The sheet of paper which slides into

the plate should hit the bumping block along its entire width. It this is not the case, it is necessary

to adjust the setting angle of the bumping block by loosening the knob (11) and turning the nearby

knob (13). If a sheet of paper cannot enter the upper cassette while folding (a single creasing only

is to be made – see table 1), remove the cassette from the machine and insert a stator. Proceed in

a similar way with the lower cassette. Each time a cassette or a stator is replaced it is necessary to

check the cassettes for correct assembly by manually turning the machine with the hand-wheel.

The gap nozzle of the cassette may not abrade the folding rollers while turning the machine.

NOTE:

If the last folding is to be shorter than 4 cm., the last cassette should be equipped with a special

insert. The insert is inserted from the front side of the cassette into the slot for the paper and

mounted using special holds to its margins. The insert should be pressed against the bottom of the

slot with four screws tipped with balls.

6.5 Setting the gaps between rollers

Description refers to figure 1.

In order to assure the high quality of folding, the clearance between the rollers should be adjusted

properly. The rule of thumb is that the clearance should be equal to the width of the inserted paper,

taking into account folding between the rollers. To satisfy this condition, place stripes of paper into

clearance regulators, and then fold the desired amount of it. There should be equal number of

stripes at both sides of the machine in matching regulators.

The number of stripes that should be placed in regulators for different kinds of inserts is given in

table 1.

6.6 Setting the paper clamp


The role of the paper clamp (17) consists in ensuring the orderly arrangement of the folded sheets

of paper on the receiving conveyor. To achieve this it is necessary to loosen the knob (18) and

13

place the clamp at the appropriate distance from the receiving rollers. The folded sheets of paper

should fall out of the receiving rollers directly under the clamp wheels, and then be transported in

an orderly manner on the conveyor.

6.7 Test manual folding

Description of operations in accordance with Figure 3. Having carried out the initial settings in ac-

cordance with points 6.1, 6.2, 6.3, 6.4 and 6.5. above, it is necessary to proceed to test manual

folding. Place one sheet of paper of the type to be folded between the margins (2), pass it manu-

ally under the lock (5), and then execute a complete folding cycle by turning the handwheel. During

folding it is necessary to observe the sheet, its passage between the margins, and check whether

the edges of the sheet come into contact with the bumping blocks within the plates. After inspect-

ing the folded sheet, adjust settings if required.

Note:

The regulatory settings described in point 6 are general reference only. When activating and oper-

ating the machine, these should be adjusted depending on the type and humidity of the paper. The

quality of the end-product will also be influenced by the ambient humidity and temperature.

7. AUTOMATIC FOLDING


To start the automatic folding of paper sheets, proceed as follows:

a) Carry out all settings as described in section 6

b) Put a stack of paper in between the margins, after having it fanned and aerated, and press it

against the lock.

c) Start the compressor using switch (6)

d) Start the folding machine using the green pushbutton (3)

e) Feed in the control sheet of paper according to 11.4

f) Start the continuous operation of the machine according to 11.5

g) For emergency stop of the machine, use switch (7)

h) In case of any abnormal operation, stop the machine with pushbutton (2) and switch off the

compressor using pushbutton (4).

8. SCORING, PERFORATING, AND SLITTING

Apart from folding, the folding machine may be used to perform additional operations, such as

scoring, perforating, and slitting.

In order to carry out any one of the abovementioned operations, it is necessary to carry out the

following operations in accordance with Figure 6:

a) Remove the side guard on the knob side by unscrewing the four knobs which fasten the guard.

14

b) Using socket wrench 4 (delivered as standard machine equipment), unscrew the bearing

sleeves (1), (2).

c) Pull the receiving rollers (3), (4) out of the folding machine.

d) Using socket wrench 2 (delivered as standard machine equipment), loosen the three screws

which lock the sleeves (5), (6) in place, and slide these sleeves off the rollers.

e) Fit the receiving rollers with the appropriate elements in accordance with the drawing.

f) Install the sleeves (5), (6) onto the receiving rollers.

g) Reinstall the receiving rollers (3), (4), paying attention to the markings of rollers 1, 2.

h) Screw in the bearing sleeves (1), (2), paying attention to the markings of sleeves 1, 2 and the

markings on the housing (7). Before screwing in the sleeves, pour two drops of machine oil into

each of the bearing bushings.

i) Reinstall the side guard

9. FOLDING DEFECTS, CAUSES, AND SOLUTIONS

No. Symptoms Causes Solutions

1. Sheets of paper are

not collected from the

feeding table

- humid paper - dry the paper

- incorrect setting of blow-in noz-

zles

- set the nozzles in accor-

dance with point 6.3. above

- insufficient air blow-in - increase air blow-in in ac-

cordance with point 7 above

- stack of sheets of paper is too

high

- remove excess paper from

the stack

- incorrect setting of selector

mechanism

- set the selector mechanism

in accordance with point 6.1.

above

- high margins brought too close

together

- set the margins in accor-


2. Sheets are not folded

in parallel

- incorrect setting of low margins - set the margins in accor-


- incorrect setting of the angle of

the bumping block within the

plate

- set the bumping block within

the plate in accordance with

point 6.4. above

- badly-cut sheets of paper - adjust the cutting of paper

sheets

3. Folded sheets are

improperly arranged

on the receiving con-

veyor

- incorrect setting of paper clamp - set the clamp in accordance

with point 6.5. above

15

10. MAINTENANCE

No. Operations Agents Frequency

1. Cleaning and tidying the work station daily

2. Washing the folding and receiving roll-

ers

extraction naphtha daily

3. Greasing the bearing bushings of the

receiving rollers

machine oil weekly

4. Changing the compressor filters yearly

11. CONTROL PANEL

11.1. Control desktop


Having switched on the machine using the main switch, symbols ‘1111’, ‘2222’, ‘3333’, … , ‘9999’

will consecutively appear on the display (1), which means that the machine is testing its program in

the driver.

Next, you may see on a display:

- digit ‘0’, when the sheet counter had been reset before the machine was switched off, OR

- a number (e.g. ‘1234’), if the last count of flies had been stored in the memory

11.1.1 Saving the count of completed flies

In order to save the number of completed flies press and hold button (3) until the word ‘save’ ap-

pears on the display (1). It means that the last count of flies has been stored in the memory.

11.1.2 Resetting the sheet counter

In order to reset the sheet counter press and hold button (2) until you hear a sound and digit ‘0’

appears on the display.

11.2 Changing the machine operation settings

Descriptions below refer to Figure 7.

11.2.1 Changing the speed of folding rollers

In order to reduce the rotary speed of folding rollers:

- press button (4) to change the speed of folding rollers – it is signaled by switching the

button light on and displaying the note, e.g.:

F 5

16

Where:

F – denotes the speed mode

5 – last stored value of folding rollers speed, expressed as percent of the maximum speed (in this

example it is 5 % of maximum speed).

- reduce the speed of folding rollers by pressing button (2) (changes 5 units at once)

- save new settings by pressing button (4) again and hold it until the word ‘save’ appears on

the display (1).

In order to increase the rotary speed of folding rollers:

- press button (4) to change the speed of folding rollers – it is signaled by switching the

button light on and displaying the note, see above.

- increase the speed of folding rollers by pressing button (3) (changes 5 units at once)

- save new settings by pressing button (4) again and hold it until the word ‘save’ appears on

the display (1).

11.2.2. Changing values of air blow parameters

To turn the compressor ON press pushbutton (9). To turn it OFF, press pushbutton (10). You may

change the magnitude of air suction or blowing by turning appropriate knobs mounted on the com-

pressor.

11.2.3. Programming the length of a series

To program the numbers of sheets in the series:

- press button (6). You will see on the display

Where:

C – denotes the numbers of sheets in the series mode

0 – the actual numbers of sheets in the series

- change the number of sheets in the series by pressing buttons (2) or (3). Short pressing

causes the number to change by 5 units, while pressing and holding causes the numbers of

sheets in the series to change by 50 units.

- To save the set numbers of the sheets, press button (6), until the word ‘save’ appears on

the display.

11.3 Programming a time interval between series


In order to program the time interval between series:

C 0

17

- press button (5). You will see on the display

Where:

P – denotes the time interval mode

0 – the actual time interval

- change the time interval between series by pressing buttons (2) or (3). The minimum

interval is 1 s, the maximum interval is 30 s.

- To save the set time interval between series, press button (5), until the word ‘save’ appears

on the display.

11.4 Feeding a single control sheet


Each time a setting for a particular type of fly is made, it is necessary to check whether the ma-

chine produces the fly properly. The machine facilitates this task through an option of feeding a

single sheet. Proceed as follows:

- turn the compressor ON using button (9)

- shortly press button (7) so to feed a single sheet

Note:

The sheet is fed to the machine with a small delay.

11.5 Continuous operation mode

Having set all parameters of the machine and checked if the control fly is valid, start the machine

for operation in the continuous mode. Proceed as follows:

- turn the compressor ON using button (9) – it is signaled by displaying the note:

- press and hold button (7) – it is signaled by displaying the note

The machine starts the automatic feeding of paper after about 2 seconds

11.6 Stopping the machine

- To stop the machine, press button (8). You will see on the display:

- To turn the compressor OFF, press button (10). You will see on the display:

P 0

C o n

U o n

U o f f

18

11.7 Entering the number of folded sheets.

Description refers to figure 7.

In order to read from the display (1) how many thousands sheets have been folded, press simulta-

neously buttons (8) and (10) on the control panel. The readout lasts for 5 seconds.

C o F F

19

12. DRAWINGS

1

2 3

4 5

6

7

8

1

3

2

4

A

B

C

D

E F

Figure 1. Folding principle.

20

Figure 2. Assembly of the folding machine.

/ to be fo l lowed on the next page /

2

16

8

22

1

4

7

5

3

17

21

6

21

- +

15 12 9 14

18 19 20

22

Figure 3. Principles of folding machine operation - part 1.

9

18

16

17

20

19

1

22

9

3 5 4 3 2

6 21 7

23


10 11 12

15 14 13

24

- +


8 7 1

5

3

6

2

4

25

Figure 5. Selector mechanism adjustment.

26

Figure 6. Scoring, perforating, slitting.

1 2 7 3 4

5

6

27

- +

1 Display

2 Reduction of machine settings

3 Increase of machine settings

4 Change of folding rollers rotary speed

5 Set pause time between series

6 Set a long serie

7 Turning ON folding rollers

8 Turning OFF folding rollers

9 Turning ON the compressor

10 Turning OFF the compressor

F i g u r e 7

28

1 3 . E L E C T R I C A L W I R I N G D I A G R A M

SUCK TRIG

SYNC-

O1

MOC3020

R5 220

R91k

+12

12

JP6

R8 220

12

JP7

BLOW

SUCKR3

1k

MT- BLOW

MT- SUCK

GATE SUCK

GATE BLOW

R6 220

R7 220

BLOW TRIG

O2

MOC3020

R111k

+12

R4

1k

COMPR. ON/OFF

12

JP5

CO

MP

RE

SS

OR

SUCK TRIG

SYNC-

SYNC+BLOW TRIG

COMPRESSOR

R1

100k R2

1k

+12

COMPRESSOR

D61N4148

COMPRESSOR

11

22

33

44

55

K2

RELAY-SPDT

+12

123

JP10

+CE1

220uF/25VC5100n

11

22

33

44

TR2

TMD2 220/9V

C1

10n (Y)

C2

10n (Y)

C4

100nF (X2)

Class Y

Class X2

RV1S14K275EARTH

D7

1N4148D9

1N4148

D8

1N4148D11

1N4148

N

L

COMPRESSOR

COMPRESSOR ON/OFFT2

BC557

COMPRESSOR

R10

100k

R13

1k

T1BC847

C3

100n

+12

R12100k

COMPRESSOR

F16,3A D1

1N4148

1234567

JP8

HEADER 7

T3BTA140-800

O3

MOC3021

R15

22012

JP1

N

L_F

R16220

R14

150/1W

C6

100n/250V (Y)

VCC R18

1k

R20

330

R17

10k/0.5W

RV2S14K300

VALVE ON/OFF

L_F

D21N4148

29

VC

C

+

C11

1uT

SY

NC

SY

NC

SU

CK

BLO

W

C3

100n

C4

100n

GN

DG

ND

BU

Z2

CFG

06

EA

/VP

31

X1

19

X2

18

RE

SE

T9

P3.

7/R

D17

P3.

6/W

R16

P3.

2/IN

T0

12P

3.3/

INT

113

P3.

4/T

014

P3.

5/T

115

P10

1

P11

2

P12

3

P13

4

P14

5

P15

6

P16

7

P17

8

AD

0/P

0039

AD

1/P

0138

AD

2/P

0237

AD

3/P

0336

AD

4/P

0435

AD

5/P

0534

AD

6P06

33

AD

7/P

0732

A8/

P20

21

A9/

P21

22

A10

/P22

23

A11

/P23

24

A12

/P24

25

A13

/P25

26

A14

/P26

27

A15

/P27

28

PS

EN

29A

LE/P

30P

3.1/

TxD

11P

3.0/

RxD

10

U7

AT

89C

2452

X2

24M

Hz

C9

33p

C10

33p

GN

D

GN

D

VC

C

1 2 3

JP5

Photo det.

R44

10k

T6

BC

557 R91

10k

R67

100k

VC

C

GN

D

VC

C1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

J2 CO

N15

RO

W1

RO

W2

RO

W3

CO

L1C

OL2

LED

2

CO

L3

ab c

def

g

h

ED

WA1CH

GFWA2AB

LED

1a

b cd

efg

h

ED

WA1CH

GFWA2AB

LED

3

T7

BC

557

T9

BC

557

T11

BC

557

R82

10k

R81

10k

R80

10k

8x22

0R

R68

100k

R69

100k

R70

100k

ab c

def

g

h

ED

WA1CH

GFWA2AB

LED

2

VC

C

R93 R94

R95

R96

R97

R98

R99

R10

7

AN

OD

A0

AN

OD

A1

AN

OD

A2

LED

_A

LED

_B

LED

_C

LED

_D

LED

_E

LED

_F

LED

_G

LED

_H

ab c

def

g

h

ED

WA1CH

GFWA2AB

LED

8

T12

BC

557

R83

10k

R71

100k

AN

OD

A3

LED

1

GN

D

T4

BC

557

GN

D

+24V

IN

R53

100k

R90

10k

R89

10k

VC

C

PR

E1

M/W

C7

E1

2

E2

3

SC

L6

SD

A5

U8

ST

24C

02

EE

_CLK

EE

_DA

TA

VC

C

VC

CV

CC

C2

100n G

ND

VC

C

+C

T3

1uTV

CC

GN

D

GN

D

CO

MP

5T

CA

P3

IPK

7

IDC

8

ISW

C1

ISW

E2

VCC6

GND4

U11

MC

3406

3AD

D4

1N58

19

GN

D

L2

220u

H

R11

6

2R2

+C

E6

100u

/35V

C15

330p

GN

D

+C

T410

0uT/

10V G

ND

GN

D

R11

5

2R2

+C

T510

0uT/

10V

C14

100n

GN

DG

ND

VC

CR

118

3k3

R11

71k

1

GN

D

D6

BZX8

4/C

5V1

GN

D

R86

10k

R76

10k

R63

100k

R66

100k

GN

D

VS

DO

N/O

FF

PH

OT

O IM

P S

EP

BU

ZZE

R

R87

10kV

CC

PH

OT

O IM

P

1 2456

N11

CN

Y17

-4

R79

330

GN

DR

65 100k

CO

MP

RE

SS

OR

CO

MP

RE

SS

OR

GN

D

1 2456

N13

CN

Y17

-4

R85

330

GN

D

COMPRESSOR

R72 10

0k

CO

MP

RE

SS

OR

CO

MP

RE

SS

OR

SU

CK

TR

IG

R49

560

1 2456

N12

CN

Y17

-4

R50

560

R11

41k

R73

100k

GN

DG

ND

SY

NC

-S

YN

C+

R92

10k

VC

C

BLO

W T

RIG

VS

D S

PE

ED

CO

MP

RE

SS

OR

R75

10k

VSD

R52 1k

R54

100k

VS

D S

PE

ED

sep

1 2 3 4 5 6

JP4

VS

DC

OM

GN

D

GN

D

+5V

SD

+C

E5

4u7

+C

E4

4u7

VS

DC

OM

VS

DC

OMR51

1k

R74

100k

+5V

SD

OC

1C

LK11

1D2

2D3

3D4

4D5

5D6

6D7

7D8

8D9

1Q19

2Q18

3Q17

4Q16

5Q15

6Q14

7Q13

8Q12

U9

74H

C57

4

OC

1C

LK11

1D2

2D3

3D4

4D5

5D6

6D7

7D8

8D9

1Q19

2Q18

3Q17

4Q16

5Q15

6Q14

7Q13

8Q12

U10

74H

C57

4

7x33

0RR

100

R10

1R

102

R10

3R

104

R10

5R

106

GN

D

DA

TA

0D

AT

A1

DA

TA

2D

AT

A3

DA

TA

4D

AT

A5

DA

TA

6D

AT

A7

DA

TA

0D

AT

A1

DA

TA

2D

AT

A3

DA

TA

4D

AT

A5

DA

TA

6D

AT

A7

CLK

1C

LK2

CLK

2

RO

W1

RO

W2

RO

W3

CO

L1C

OL2

CO

L3

LED

3LE

D4

LED

5LE

D6

LED

7

CLK

1

VS

D S

PE

ED

VS

D O

N/O

FF

GN

D

+24V

IN

C13

100n

D1

1.5K

E27A

1 2456

N10

CN

Y17

-4

R78

560

VC

C

CO

MP

RE

SS

OR

CO

MP

R64

100kR88

10k

CO

MP

R. O

N/O

FF

R77

1k

R84

1k

SU

CK

BLO

W

VS

D O

N/O

FF

+24V

CO

MP

RE

SS

OR

R10

8R

109

R11

0R

111

R11

2R

113

GN

D

+24V

+C

T1

1uT

C1

100nV

CC

VC

C

GN

DG

ND

6x68

0R

R1

10k

C7

100nV

CC

GN

D

C6

100nV

CC

GN

D

C5

100nV

CC

GN

D

R7

10k

T3

BC

557

R4

100k

VC

C

R6

10k

T2

BC

557

R3

100k

VC

C

R5

10k

T1

BC

557

R2

100k

VC

C

C8

100nV

CC

GN

D

D2 1N

4148

D3

1N41

48

T5

BC

557

C12

10n

VS

DC

OM

VS

DC

OM

T8

BC

547

T13

BC

547

GN

D

C16

10n

GN

D

R8

330

T10

BC

547

D5

1N40

07

+24V

1 2 3 4 5 6 7

JP6

D7

BZX8

4/C

3V3

R9

1k

VC

C

R10

1k

VA

LVE

12

J1 JUM

PER

GN

D

1 2456

N1

CN

Y17

-4

R13

560

VC

C

CO

MP

RE

SS

OR

R12

100kR11

1k

CO

MP

RE

SS

OR

VA

LVE

VA

LVE

ON

/OFF

VA

LVE

ON

/OFF

service manual folding machine fk-4.400s … 4.400s-service manual.pdf · power consumption 1,8 kw...

Documents