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Horizon Fitness SmartStacker User Manual

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Sheet Cutter
SmartStacker
User's Manual

Important Information

- This manual is designed to help you to operate and maintain the Smart-
Stacker. Please read and understand this manual, and keep it in a safe and
convenient place.
- Do not operate the SmartStacker until you read and understand the in-
structions in this manual.
- Horizon International Inc. shall not be liable for incidental consequential
damages resulting from: improper or inadequate maintenance by the cus-
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 be photocopied, repro-
duced or translated to another language without the prior written consent
of Horizon International Inc.
170107/HN,CF,AT,RN/IDCS5.5/ICS5/PXI
UM206030-10(000)

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Table of Contents
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Summary of Contents for Horizon Fitness SmartStacker

  • Page 1: Important Information

    Stacker. Please read and understand this manual, and keep it in a safe and convenient place. - Do not operate the SmartStacker until you read and understand the in- structions in this manual. - Horizon International Inc. shall not be liable for incidental consequential...

  • Page 2: Safety Precautions

    Do not operate the machine when any covers are removed. Some of the drawings in this manual show the machine with the covers removed to help in explaining the details inside the machine. SmartStacker User's Manual...

  • Page 3: Glossary

    Glossary The drawing below shows the terms we will use in this manual. Page / Piece Page Block Sheet 26030 10101A1 Stack SmartStacker User's Manual...

  • Page 4: Basic Safety Precautions

    *1 This laser meets the IEC standards, 60825-1: 2007,class 1 LASER product. • Use of controls or adjustments or performance of procedures other than these specified here in may result in hazardous radiation exposure. Sheet Edge Indicator SmartStacker User's Manual...
  • Page 5 If a jam occurs, remove all the jammed sheets before you start the operation again. Other- wise the machine may be damaged. Do not use the machine for any improper purpose. Otherwise, the performance of the ma- chine cannot be guaranteed. SmartStacker User's Manual...

  • Page 6: Warning Label Locations And Meanings

    Do not approach your hands and fingers to the suction head while the feed table is moving. Otherwise your hands and fingers may be caught by the suction head. There are electric parts inside. Take care when opening the cover. Otherwise, high voltage can cause severe personal injury. SmartStacker User's Manual...
  • Page 7 There are electric parts inside. Take care when opening the cover. Otherwise, high voltage can cause severe personal injury. Keep your hands and fingers away from the belts and rollers while the belts are moving. Otherwise your hands and fingers may be caught by these parts. SmartStacker User's Manual...

  • Page 8: Table Of Contents

    Supported Jobs ....................22 1-1-6 Capability of Each Line ..................26 1-1-7 The Role of Panels of the SmartStacker and the FLC ........27 SmartStacker Screen Descriptions ..............28 1-2-1 Run - Main Screen - Part 1 .................. 28 1-2-2 Run - Main Screen - Part 2 ..................
  • Page 9 Setting - Job List Screen ................... 101 1-3-23 Setting - Line Screen ..................102 1-3-24 Setting - Banner Screen Part 1 ................103 1-3-25 Setting - Banner Screen Part 2 ................104 1-3-26 Setting - About the FLC Screen ................. 105 SmartStacker User's Manual...
  • Page 10 Setting the Control Panel - When using the B2 Stacker ......... 156 3-2-1 Setting the Job ....................156 3-2-2 Setting the Delivery Action ................. 159 3-2-3 Starting a Job ....................162 Saving, Loading, and Deleting Jobs ..............163 3-3-1 Saving a Job ...................... 163 SmartStacker User's Manual...
  • Page 11 Adjusting the Pressure of the Sheet Hold-Down Plates in the B2 Stacker ....203 Adjusting the Optional Scoring Unit ..............204 5-4-1 Adjusting the Scoring Positions ................. 204 5-4-2 Adjust the Scoring Depth ................... 205 Troubleshooting If an Error Icon Appears ..................208 SmartStacker User's Manual...
  • Page 12 If an Error Code Is Displayed on SmartStacker ..........211 If a Warning Screen is Displayed on SmartStacker .......... 345 If an Error Code Is Displayed on FLC ............... 349 If a Warning Message Is Displayed on FLC ............354 Pole Lamp and Up/Down Buttons ..............

  • Page 13: Machine Description

    1 Machine Description This chapter explains the main features on the machine, the touch panel screen on the SmartStacker and the screen on the Finishing Line Controller.

  • Page 14: Features Of The Machine

    Sheet Feeder (SF) (Option) 2nd Process Unit (2Pro) 1st Regist Unit (1Reg) Merge Conveyor (MC) 1st Process Unit (1Pro) Merge Stacker (MS) 90-degree Turn Conveyor (TC) Output Shift Conveyor 2nd Regist Unit (2Reg) 1m Conveyor B2 Stacker (BS) SmartStacker User's Manual...

  • Page 15: Directions Described In This Manual

    Drive Side Drive Side Drive Side Delivery Delivery Operator Side Operator Side Infeed Side Side Side Operator Side Operator Side Operator Side Operator Side Infeed Infeed Side Infeed Side Side Drive Side Operator Side Operator Side Delivery Side SmartStacker User's Manual...

  • Page 16: Sheet Flow

    (Optional) Top Tray Top Tray Gate Gate 2 p c 2 p c Merge Merge Gate Gate 3 p c 3 p c 4 p c 4 p c Gate Gate To B2 To B2 Stacker Stacker SmartStacker User's Manual...
  • Page 17 Features of the Machine 1st Process (14 Cutters) 1st Regist Double Feed Detect Ultrasonic Sensor 4 p c 4 p c 4 p c 4 p c 4 p c 4 p c 2 p c 2 p c SmartStacker User's Manual...
  • Page 18 Features of the Machine Offset Guide 10 mm Gate Gate Gate Gate Gate Gate Stack Stack 26030 10103C1 Eject Eject SmartStacker User's Manual...

  • Page 19: Delivery

    • A jam on middle of the first stack Uncompleted Box Completed Box (Eoj = End of Job) • A jam on middle of the last stack • The job end on middle of the last stack SmartStacker User's Manual...
  • Page 20 Line Clear button is pressed • The user changes starting sheet number (from the Press UI) • The user changes starting sheet number after the jam • Break of a job with changeover SmartStacker User's Manual...
  • Page 21 A stack which is less than the planned number of sheets goes to the uncompleted box in all cases. • The jam occurs at first block of the second stack when the job is set in 3 stacks. Fist Block Uncompleted Box Completed Box Second and After Block SmartStacker User's Manual...

  • Page 22: Supported Jobs

    762 mm 30.000” With Scoring 177.8 through 265 mm 7” through 10.43” 530mm 20.865” (Min.) Without Scoring Min. 105 mm 380 mm 148 mm 4.13” 14.965” 5.83” 210 mm 8.270” SmartStacker User's Manual...
  • Page 23 (The system can feed sheets with different numbers of pages.) Attention The maximum number of sheets which is capable in one job is as following: • For near line operation: 100,000 sheets • For inline operation: 50,000 sheets SmartStacker User's Manual...
  • Page 24 No.1 No.2 No.1 No.2 offset offset The ejection operation can be done after the last row and other one row. eject eject eject The ejecting operation eject eject cannot be done twice except after the last row. SmartStacker User's Manual...
  • Page 25 If there are at least one row In case that several rows which between the blank pages as this have different separation position drawing, the blank page can be are continued, the SmartStacker ejected. cannot eject the blank pages. Feed direction Feed direction...

  • Page 26: Capability Of Each Line

    Progress Report to the Disable Disable Enable Upstream System • Offline and Near line can be switched just by pressing a button, but to use as the Inline system, the machine should be installed again. SmartStacker User's Manual...

  • Page 27: The Role Of Panels Of The Smartstacker And The Flc

    The Role of Panels of the SmartStacker and the FLC The role of panels of the SmartStacker and the FLC, the procedure to create and start a job, and also to make the fine adjustment are different depending on the configuration of line. The outline is shown below.

  • Page 28: Smartstacker Screen Descriptions

    SmartStacker Screen Descriptions 1-2-1 Run - Main Screen - Part 1 TEST pieces/hr Job Name Delivered Block Counter When you recall a job from the job memory in the This shows the number of blocks that have been offline system, the current job number and name are delivered.

  • Page 29: Run - Main Screen - Part 2

    SmartStacker Screen Descriptions 1-2-2 Run - Main Screen - Part 2 pieces/hr Counter for the Number of Blocks in Each Stack This turns off the stack function. The machine will continue feeding the uncut sheets until the pages When the machine is used in an offline system and reach the upper limit of the Merge Stacker.

  • Page 30: Run - Main Screen - Part 3

    SmartStacker Screen Descriptions 1-2-3 Run - Main Screen - Part 3 pieces/hr Counter for the Number of Pages Total Preset Function On/Off (Pieces) in Each Block Use this setting to set how many blocks should be delivered before the machine stops. If you are using the...

  • Page 31: Run - Main Screen - Part 4

    SmartStacker Screen Descriptions 1-2-4 Run - Main Screen - Part 4 pieces/hr Help Button External Network Communication Error Icon Press this button to see explanations of each of the The icon is displayed if there is a problem with the icons on the screen.

  • Page 32: Run - Main Screen - Part 5 (For Merge Stacker)

    SmartStacker Screen Descriptions 1-2-5 Run - Main Screen - Part 5 (for Merge Stacker) pieces/hr Power Saving Mode Stop Button When this button is pressed, the machine goes into If the machine is used in an offline system or a power saving mode.

  • Page 33: Run - Main Screen - Part 6 (For B2 Stacker)

    SmartStacker Screen Descriptions 1-2-6 Run - Main Screen - Part 6 (for B2 Stacker) pieces/hr page 28. page 31. page 29. page 30. See page 32. SmartStacker User's Manual...

  • Page 34: Run - Setting Screen - Part 1

    SmartStacker Screen Descriptions 1-2-7 Run - Setting Screen - Part 1 Feed Speed Amount of Downward Vacuum of the Transport Roller Section This sets the number of uncut sheets to be processed per hour. This sets the amount of vacuum provided by the fans below the transport rollers in the Merge Conveyor.

  • Page 35: Run - Setting Screen - Part 2 (For Merge Stacker)

    SmartStacker Screen Descriptions 1-2-8 Run - Setting Screen - Part 2 (for Merge Stacker) Supporting Air Jogging Motion On/Off When the vacuum belts are transporting a sheet This turns the jogging motion in the Merge Stacker to the top of the stack in the Merge Stacker, air is on or off.

  • Page 36: Run - Setting Screen - Part 3 (For B2 Stacker)

    SmartStacker Screen Descriptions 1-2-9 Run - Setting Screen - Part 3 (for B2 Stacker) Supporting Air Amount of Downward Vacuum of the Register Guide Section When the vacuum belts are transporting a sheet to the top of the stack in the B2 Stacker, air is supplied This sets the amount of vacuum provided by the fans to support sheet.

  • Page 37: Run - Setting Screen - Part 4 (For B2 Stacker)

    SmartStacker Screen Descriptions 1-2-10 Run - Setting Screen - Part 4 (for B2 Stacker) Bypass for the B2 Stacker This turns the jogging motion in the B2 Stacker on or off. Sheets are stacked on the B2 stacker. Normally, select this button.

  • Page 38: Run - Fine Adjustment Screen - Part 1

    SmartStacker Screen Descriptions 1-2-11 Run - Fine Adjustment Screen - Part 1 The sheet feeder is optional. Option Sheet Feeder Table Guide Position Merge Conveyor Upper Stopper and Angle Adjusting Guide Position The table guide position can be adjusted here. The...

  • Page 39: Run - Fine Adjustment Screen - Part 2

    SmartStacker Screen Descriptions 1-2-12 Run - Fine Adjustment Screen - Part 2 The sheet feeder is optional. Option Merge Stacker Stopper Position The stopper position can be adjusted here. The head of the stack is held by this stopper while the pages are stacked.

  • Page 40: Run - Fine Adjustment Screen - Part 3 (For B2 Stacker)

    SmartStacker Screen Descriptions 1-2-13 Run - Fine Adjustment Screen - Part 3 (for B2 Stacker) The sheet feeder is optional. Option Option B2 Stacker Stopper Position The stopper position can be adjusted here. The head of the stack is held by this stopper while the pages are stacked.

  • Page 41: Run - Page Size Fine Adjustment Screen - Part 1 (For Merge Stacker)

    SmartStacker Screen Descriptions 1-2-14 Run - Page Size Fine Adjustment Screen - Part 1 (for Merge Stacker) Page Length Bleed Trim Width The page length can be adjusted. If the cut sheets If the bleed and gutter trim position of all of the pages are longer or shorter equally than the desired is shifted up or down, adjust the width here.

  • Page 42: Run - Page Size Fine Adjustment Screen - Part 2 (For B2 Stacker)

    SmartStacker Screen Descriptions 1-2-15 Run - Page Size Fine Adjustment Screen - Part 2 (for B2 Stacker) Page Length Bleed Trim Width The page length can be adjusted. If the cut sheets If the bleed trim position is shifted up or down, adjust are longer or shorter equally than the desired the width here.

  • Page 43: Run - Cutter Position Fine Adjustment - 1St Process Unit Fine Adjustment Screen

    SmartStacker Screen Descriptions 1-2-16 Run - Cutter Position Fine Adjustment - 1st Process Unit Fine Adjustment Screen Simultaneous Adjustment Button Cutter Position Indication Separately Adjustment: This indicates which cutter positions are adjustable, depending on the selected job. The cutters are adjusted individually.

  • Page 44: Run - Cutter Position Fine Adjustment - 2Nd Process Unit Fine Adjustment Screen

    SmartStacker Screen Descriptions 1-2-17 Run - Cutter Position Fine Adjustment - 2nd Process Unit Fine Adjustment Screen Simultaneous Adjustment Button Cutter Position Indication Separately Adjustment: This indicates which cutter positions are adjustable, depending on the selected job. The cutters are adjusted individually.

  • Page 45: Run - Scoring Position Fine Adjustment Screen (Optional)

    SmartStacker Screen Descriptions 1-2-18 Run - Scoring Position Fine Adjustment Screen (Optional) Fine Adjustment of the Scoring Fine Adjustment of the Scoring Position Position - Far Side - Operator Side Each sheet is cut into two parts in the 2nd Process Unit.

  • Page 46: Setting - Size Setting Screen - Only For Offline System- Part 1

    SmartStacker Screen Descriptions 1-2-19 Setting - Size Setting Screen - Only for Offline System- Part 1 Sheet Width Gutter Trim On/Off - Long Side Enter the width of the sheet. This is used to set whether to trim the gutter of the long side.

  • Page 47: Setting - Size Setting Screen - Only For Offline System - Part 2

    SmartStacker Screen Descriptions 1-2-20 Setting - Size Setting Screen - Only for Offline System - Part 2 Long Edge Trim On/Off Short Edge Trim On/Off This sets the trim function when the long edge of This sets the trim function when the short edge of sheet is cut.

  • Page 48: Setting - Size Setting Screen - Only For Offline System - Part 3

    SmartStacker Screen Descriptions 1-2-21 Setting - Size Setting Screen - Only for Offline System - Part 3 Gutter Trim Width - Short Side Fine Adjustment Carry Over Select this to carry over the fine If you have turned on the gutter trim function, this is used to set the gutter trim width.

  • Page 49: Setting - Size Setting Screen - Only For Offline System - Part 4 (For B2 Stacker)

    SmartStacker Screen Descriptions 1-2-22 Setting - Size Setting Screen - Only for Offline System - Part 4 (for B2 Stacker) See page 47. See page 46. See page 48. SmartStacker User's Manual...

  • Page 50: Trim Guide Setting Screen

    SmartStacker Screen Descriptions 1-2-23 Trim Guide Setting Screen If you turn the gutter trim function On or Off, the Trim Guide Setting screen will be displayed when you do the changeover. It’s also possible to display this screen from the Run screen.

  • Page 51: Memory - Main Screen - Part 1

    SmartStacker Screen Descriptions 1-2-24 Memory - Main Screen - Part 1 Press these icons to sort the jobs by job number, job name, or date. Job Number Scroll Buttons The top job displayed on the screen is The information for each saved job is based on a job number.

  • Page 52: Memory - Main Screen - Part 2

    SmartStacker Screen Descriptions 1-2-25 Memory - Main Screen - Part 2 Importing Fine Adjustment Values Save the Job If you are using the machine with a near line system Press here to save the settings for a job. or an inline system, if you press this button after The settings listed below are saved.

  • Page 53: Information - Main Screen - Part 1

    If the machine is used in a near line or offline system, the total number of uncut sheets fed from the optional sheet feeder to the SmartStacker is displayed here. Total Counter for Sheets at 1st Regist Unit This is the total number of uncut sheets which have passed the entrance of the 1st Regist Unit.

  • Page 54: Information - Main Screen - Part 2

    SmartStacker Screen Descriptions 1-2-27 Information - Main Screen - Part 2 Input Monitor Error History The Information - Monitor screen is displayed. See The Information - Error History screen is displayed. page 55 for details. See page 66 for details.

  • Page 55: Information - Input Monitor Screen - Part 1

    SmartStacker Screen Descriptions 1-2-28 Information - Input Monitor Screen - Part 1 Unit Selection Press the correct button to go to the Input Monitor screen for the selected unit. B912 B910 On/Off Indicators for Sensors and Switches This part of the screen is used to monitor the signals from the sensors and switches.

  • Page 56: Information - Input Monitor Screen - Part 2

    SmartStacker Screen Descriptions 1-2-29 Information - Input Monitor Screen - Part 2 B140 B141 B120 B110 B150 Reflector Reflector B151 SmartStacker User's Manual...

  • Page 57: Information - Input Monitor Screen - Part 3

    SmartStacker Screen Descriptions 1-2-30 Information - Input Monitor Screen - Part 3 Reflector B211 B220 B231 B212 B232 B253 B251 B260 Reflector B252 SmartStacker User's Manual...

  • Page 58: Information - Input Monitor Screen - Part 4

    SmartStacker Screen Descriptions 1-2-31 Information - Input Monitor Screen - Part 4 B340 B322 B320 B310 B330 B332 B590 B593 B594 10606610230A1 B595 Sheet Shift Amount If the edge of delivered sheet just touches the edge of vacuum belt, a jam may occur. In such condition, the delivery position of sheet is automatically shifts and the shifted amount is displayed here.

  • Page 59: Information - Input Monitor Screen - Part 5

    SmartStacker Screen Descriptions 1-2-32 Information - Input Monitor Screen - Part 5 B462 B410 B450 B461 B446 B448 B420 SmartStacker User's Manual...

  • Page 60: Information - Input Monitor Screen - Part 6 (For B2 Stacker)

    SmartStacker Screen Descriptions 1-2-33 Information - Input Monitor Screen - Part 6 (for B2 Stacker) B525 B550 B526 B524 B521 B523 B520 B522 Reflectors Reflectors B510 B512 10606610238A1 Sheet Shift Amount If the edge of delivered sheet just touches the edge of vacuum belt, a jam may occur. In such condition, the delivery position of sheet is automatically shifts and the shifted amount is displayed here.

  • Page 61: Information - Signal I/O Monitor Screen

    SmartStacker Screen Descriptions 1-2-34 Information - Signal I/O Monitor Screen Signal On/Off Indicators This screen is used to monitor the I/O signals. (Green): The signal between the machines is on (White): The signal between the machines is Go to the Information - Main screen...

  • Page 62: Information - Single Operation Screen - Part 1

    SmartStacker Screen Descriptions 1-2-35 Information - Single Operation Screen - Part 1 Unit Selection The rollers turn slowly in the normal direction. Press the correct button to go to the Single Operation screen for the selected unit. The table moves to the upper limit.

  • Page 63: Information - Single Operation Screen - Part 2

    SmartStacker Screen Descriptions 1-2-36 Information - Single Operation Screen - Part 2 SmartStacker User's Manual...

  • Page 64: Information - Single Operation Screen - Part 3

    SmartStacker Screen Descriptions 1-2-37 Information - Single Operation Screen - Part 3 SmartStacker User's Manual...

  • Page 65: Information - Single Operation Screen - Part 4

    SmartStacker Screen Descriptions 1-2-38 Information - Single Operation Screen - Part 4 SmartStacker User's Manual...

  • Page 66: Information - Error History Screen

    SmartStacker Screen Descriptions 1-2-39 Information - Error History Screen This screen is used to list any errors. Date Normal Error Button This indicates the date when the error occurred. This displays the history for error codes with numbers 1 through 999.

  • Page 67: Information - Administrator - Main Screen

    SmartStacker Screen Descriptions 1-2-40 Information - Administrator - Main Screen This screen is only used by the administrator. Administrator Settings Motor Enable Setting This displays the Administrator Settings screen. This displays the Motor Enable Settings screen. See See page 68 for details.

  • Page 68: Information - Administrator - Administrator Setting Screen - Part 1

    SmartStacker Screen Descriptions 1-2-41 Information - Administrator - Administrator Setting Screen - Part 1 Power Saving Mode When the stacker is full, the feeding operation is stopped, and the divided This is used to activate or deactivate the automatic blocks are delivered. Then, the power saving mode.

  • Page 69: Information - Administrator - Administrator Setting Screen - Part 2

    SmartStacker Screen Descriptions 1-2-42 Information - Administrator - Administrator Setting Screen - Part 2 Filter Cleaning Alarm Cutter Replacement Alarm An alarm can be set to indicate when it is time to An alarm can be set to indicate when it is time to clean the air filter for the electronics box.

  • Page 70: Information - Administrator - Input Signal Enable Settings Screen - Part 1

    SmartStacker Screen Descriptions 1-2-43 Information - Administrator - Input Signal Enable Settings Screen - Part 1 Unit Selection Attention Press the correct button to go to the Input Signal Enable Settings screen for the selected unit. If any devices are disabled (Off), the Input...

  • Page 71: Information - Administrator - Input Signal Enable Settings Screen - Part 2

    SmartStacker Screen Descriptions 1-2-44 Information - Administrator - Input Signal Enable Settings Screen - Part 2 SmartStacker User's Manual...

  • Page 72: Information - Administrator - Input Signal Enable Settings Screen - Part 3

    SmartStacker Screen Descriptions 1-2-45 Information - Administrator - Input Signal Enable Settings Screen - Part 3 SmartStacker User's Manual...

  • Page 73: Information - Administrator - Motor Enable Settings Screen - Part 1

    SmartStacker Screen Descriptions 1-2-46 Information - Administrator - Motor Enable Settings Screen - Part 1 Unit Selection Attention To the Motor Enable Settings screen of the selected unit. If any devices are disabled (Off), the Motor Enable Settings screen will be displayed Enable Setting Button every time you turn on the power.

  • Page 74: Information - Administrator - Motor Enable Settings Screen - Part 2

    SmartStacker Screen Descriptions 1-2-47 Information - Administrator - Motor Enable Settings Screen - Part 2 SmartStacker User's Manual...

  • Page 75: Information - Administrator - Motor Enable Settings Screen - Part 3

    SmartStacker Screen Descriptions 1-2-48 Information - Administrator - Motor Enable Settings Screen - Part 3 SmartStacker User's Manual...

  • Page 76: Information - Administrator - Adjustment Mode Screen

    SmartStacker Screen Descriptions 1-2-49 Information - Administrator - Adjustment Mode Screen Individual Unit Adjusting Mode 34: The MC/MS production speed is not changed even if the sheet gap is changed. (However, it Use this mode if you want to stop a sheet inside the...

  • Page 77: Information - Administrator - Network Configuration Screen

    SmartStacker Screen Descriptions 1-2-50 Information - Administrator - Network Configuration Screen IP Address Enter the IP address for the machine. Subnet Mask Default Gateway Port Number Go to the Information - Administrator - Main screen SmartStacker User's Manual...

  • Page 78: Error - Main Screen

    SmartStacker Screen Descriptions 1-2-51 Error - Main Screen Unit Selection Jog Button If a unit experiences a problem, a warning icon will While this button is pressed, the sheets move be displayed for that unit. The Error screen for that forward at a at low speed.

  • Page 79: Error - Unit Screen

    SmartStacker Screen Descriptions 1-2-52 Error - Unit Screen About Font License The IPA Font is used in the control panel. See the URL below for the detail of the IPA FONT Agreement. http://ipafont.ipa.go.jp/ipa_font_license_v1.html#LicenceEng SmartStacker User's Manual...

  • Page 80: Finishing Line Controller Screen Descriptions

    Changeover: The machine is doing a setup line are displayed here. On the screen shown above, just the change (changeover). SmartStacker is being used. See page 102 for details. Pause: A job has started but sheet is not If the machine image is shown in light colors, the machine fed yet.

  • Page 81: Run - Main Screen - Part 2

    Stop button when the machine is used in a Process Counter Near Line system. If a SmartStacker is connected, this counts the Immediately : The machine stops imemdiately. sheets that have been fed. If another kind of End of Block : The machine stops when the currently machine is connected, this can count sheets, processing job comes to an end.

  • Page 82: Run - Main Screen - Part 3

    Number of Jobs in a Stack Enter the maximum number of jobs delivered before the stack is delivered or offset. SmartStacker User's Manual...

  • Page 83: Run - Main Screen - Part 4

    If a job has been left in this list for seven days, it will Running: The machines are running a be deleted. This period can be changed on the FLC job. Setting screen. See page 99 for details. Ready: The machines are ready to receive a job. (Green) SmartStacker User's Manual...

  • Page 84: Run - Main Screen - Part 5

    Help Button If you press this button once, the screen enters the hint mode. Press an icon on the screen to see explanations. If you press the Help button again, the screen goes out of the hint mode. SmartStacker User's Manual...

  • Page 85: Run - Main Screen - Part 6

    If you click the + icon, information on the reprint job will be displayed below. job (see page 117 for details) on the job memory screen of SmartStacker. And press start button to run Select All Jobs the job after fine-adjustment.

  • Page 86: Run - Main Screen - Part 7

    This job is ready for running. If a job stops due to an error, mark appears (Green) here. This means that the job must be reprinted. This job is complete. Percentage Complete The progress of the job is displayed here. SmartStacker User's Manual...

  • Page 87: Run - Main Screen - Part 8

    Click this button to set a flag on the selected job. See page 85 and 117 for details. The fine adjustment values can be stored in the panel of SmartStacker for the repeat job. (See page 163 for details.) Holding Job Click this button to hold the selected job.

  • Page 88: Run - Main Screen - Part 9

    “Current sheet: 1” This moves the selected job to the list of Held jobs. Memo This displays the content of any memo for the selected job. Imposition The imposition image for the selected job is shown here. SmartStacker User's Manual...

  • Page 89: Run - Main Screen - Part 10

    This indicates the order that the sheets are printed assuming there is no other finishing device between the press and the SmartStacker. In an inline system, sheets are printed and fed in the same order. In a near line system, sheets are fed in the reverse order of printed order.

  • Page 90: Run - Main Screen - Part 11

    General screen. Stop button on the machine. The machine Cancel will resume the job when you press the Click this button to cancel any changes made to the Start button. settings and close the reprint list. SmartStacker User's Manual...

  • Page 91: Run - Main Screen - Part 12

    See page 95 for details. sheets which are in-process to the uncompleted Diagnostic Tool Start Button conveyor. If a jam occurs in the SmartStacker, the job is resumed after the jammed sheets See page 94 for details. are removed. In this case, the remained sheets...

  • Page 92: Run - Main Screen - Part 13

    Stacker The block after sheet • If you press the Block Delivery button on the cutting is complete Run-Main screen of SmartStacker is good, however, it is delivered to the • If you do a changeover with home positioning uncompleted box.

  • Page 93: Run - Job Details Screen

    This screen can change depending on the machine you are using. The screen shown above is the screen for the SmartStacker. Job Delivery Setting Indication This indicates the banner sheet setting and the offset setting. These settings cannot be changed using this screen.

  • Page 94: Run - Diagnostic Tool Screen

    Exit the diagnostic tool and return to the FLC Run - The logs of the date are selected to be output. Main screen. Additional Information The buttons that are not explained on this page are used only by service technician. SmartStacker User's Manual...

  • Page 95: Setting - General(1) Screen - Part 1

    Near Line system. By unchecking this box, the communication with DEF can be turned off even if the machine is used in a Near Line system. (Uncheck the box when only the hot holder is used.) SmartStacker User's Manual...

  • Page 96: Setting - General(1) Screen - Part 2

    Default is “1111”. sheet in the third block jams, the system will reprint the whole stack containing the first two blocks that were successfully stacked and also the last two blocks that have not been fed yet. SmartStacker User's Manual...

  • Page 97: Setting - General(1) Screen - Part 3

    If you click here when the hot folder Mark here to make is enabled. the Selection screen of the hot folder hot folder will be displayed. enabled. SmartStacker User's Manual...

  • Page 98: Setting - General(1) Screen - Part 4

    Example: BBBCCCDDD Job ID Number of sheets Sheet Number Number of Digits to be Digits to Start Read Number of Reading the Num- Digits to Start Reading Digits to ber of Sheets the Sheet Number Read SmartStacker User's Manual...

  • Page 99: Setting - General(2) Screen - Part 1

    If you want to select the reprinted sheets, click “Cancel” and edit the reprint list (See page 89.) If “Show this dialogue ...” is not selected, this confirmation dialogue will not be displayed. SmartStacker User's Manual...

  • Page 100: Setting - General(2) Screen - Part 2

    • This is used to recognize the sheet as the end of the job if the machine is used in a near line system. • A cover page including the barcode which is used in the post-process will be placed on the top of the stack. SmartStacker User's Manual...

  • Page 101: Setting - Job List Screen

    The selections are reset to the defaults. Allowable Range: -7, -6, ... -1, - (default), +0, ... +5 In case that the default speed is set on the Setting screen, the setting of the Run - Main screen will be used. SmartStacker User's Manual...

  • Page 102: Setting - Line Screen

    When you include a new machine in the finishing Click this button to delete the selected one from the line, enter the necessary information or settings: right area. Device ID IP address Port number Model number Informal name SmartStacker User's Manual...

  • Page 103: Setting - Banner Screen Part 1

    Feed a banner sheet If you want to feed the banner sheet with a barcode to the SmartStacker, select this. The banner sheet will be cut and ejected as waste. If you want to remove the banner sheet yourself before processing the sheets, leave the check-box empty.

  • Page 104: Setting - Banner Screen Part 2

    SmartStacker User's Manual...

  • Page 105: Setting - About The Flc Screen

    Finishing Line Controller Screen Descriptions 1-3-26 Setting - About the FLC Screen FLC Software Version This lists the software version of the FLC. SmartStacker User's Manual...
  • Page 106 This page is intentionally left blank.

  • Page 107: Procedures For Near Line Operation

    2 Procedures for Near Line Operation This chapter explains the procedures for sheet cutting operations when running the machine in a Near Line system.

  • Page 108: Daily Safety Check

    If an error icon is not displayed. while the feed table is • There is a problem with the safety circuit. Stop rising or lowering. using the machine and call a service technician. SmartStacker User's Manual...
  • Page 109 • Clear the Error screen. Open all of the safety covers and press all of the Emergency Stop buttons shown and press the Feed table Up button again. Check that the correct error icons appear on the screen. SmartStacker User's Manual...
  • Page 110 Daily Safety Check Lift the cover, pressing the hooks. Hooks SmartStacker User's Manual...
  • Page 111 Daily Safety Check Close all the covers, release all the Emergency Stop buttons, and press ➡ The Error screen is cleared. Emergency Stop Button Release Press 2307310101C1 SmartStacker User's Manual...

  • Page 112: Changeover

    Example of Use of Flag for Loading Fine Adjustment If the SmartStacker is in a Near Line system, it saves the details of fine adjustment that has ever been done. If you run several jobs of sheets of same size, you can load the sheets for several jobs together on the feeder and run the jobs continuously by using a banner sheet for each job and selecting automatic run.
  • Page 113 This sets the actual timing to stop the machine when you click the Stop button. The machine stops when the currently pro- The machine stops cessing jobs comes to an end. immediately. The machine stops after finish processing the currently processing job. SmartStacker User's Manual...

  • Page 114: Starting The Changeover

    • The feed table pauses at about 120 mm / 4.72” above the floor. (This prevents the table from catching your feet.) To move it down the rest of the way, keep pressing the Feed Table Down button. The feed table lowers to the lower limit and stops there. SmartStacker User's Manual...
  • Page 115 Run - Main screen of the FLC. 2. On the screen of FLC Select the job on the screen of FLC. Press to start the changeover. ➡ The machine starts the changeover for the selected job. SmartStacker User's Manual...

  • Page 116: Setting The Trim Guides For The Gutter Trim

    Tighten the two The trim guide for 3-MF cutter should be locking screws. installed only when the sheet is divided into six sheets at the first process unit. Press the changeover icon. The machine resumes the changeover. SmartStacker User's Manual...

  • Page 117: Recalling Fine Adjustment Values

    Setting screen, and do the changeover. The fine adjustment values saved for the selected job will be imported. • If you press , the display returns to the Memory - Main screen. The fine adjustment values will not be recalled. SmartStacker User's Manual...

  • Page 118: Loading The Sheets On The Sheet Feeder

    (This is necessary if you have not checked “Feed a banner sheet” on the Set- ting - Banner screen. See page 103.) SmartStacker User's Manual...
  • Page 119 Loosen the locking knob and move the feed guide to the operator side. This is to prevent the feed guide from hitting against the sheets when the feed table is lifted in later step. SmartStacker User's Manual...
  • Page 120 26030 20201A1 the feed table stops. Down Set Register Pin Check that the suction head is positioned so that the set register pin just touches the tail edge of the stack of sheets. SmartStacker User's Manual...
  • Page 121 Align the feed guide with the operator side of sheets. Locking Knob Fit the guide on the sheet edge. Adjust the separator, blower air and side air if necessary. (See Chapter 5 for details.) SmartStacker User's Manual...

  • Page 122: Starting A Job

    Setting - Banner screen of the FLC (Finishing Line Controller), the machine will read the barcode for the next job that is loaded on the pallet, do a changeover, and start processing automatically. SmartStacker User's Manual...

  • Page 123: Pausing And Resuming A Job

    Click the Pause button on the Run - Main screen of the FLC. ➡ The machine stops feeding. Any sheets which have already been fed will continue to be pro- cessed. When you want to resume feeding, click the Start button. SmartStacker User's Manual...

  • Page 124: Holding And Resuming A Job Using The Flc

    (Hold) button. ➡ The selected job moves to the Held job tab. Press the (Memo) button. ➡ The Keyboard screen will be displayed. Note the reason why the job is being held, and click the OK button. SmartStacker User's Manual...
  • Page 125 Pausing and Resuming a Job When you want to resume the job, click the (Release) button. ➡ The selected job returns to the Pending job tab. SmartStacker User's Manual...

  • Page 126: Removing Any Blank Pages

    Merge Stacker At the end of the operation, check for any blank pages of incomplete stacks and remove them. First Process Unit Second Process Unit Merge Stacker SmartStacker User's Manual...

  • Page 127: Reprint - When Using The Merge Stacker

    The system will display in the reprint list only the sheet that jammed. To do this, the reprint list must be edited. No.1 No.2 No.3 No.4 No.5 No.6 No.7 Stack 1 Stack 2 Stack 1 Stack 2 One sheet will be displayed in reprint list SmartStacker User's Manual...

  • Page 128: Deciding How To Handle Reprinting

    You do not have to worry about this setting. (Either one is OK.) 2. Reprint only the bad stack Select “Stack.” 3. Reprint only the bad block Select “Block.” 4. Reprint only the bad sheet Select “Sheet.” Save the setting. SmartStacker User's Manual...

  • Page 129: How The Stack Is Delivered If A Jam Occurs

    No.1 No.2 No.3 No.4 No.5 No.6 No.7 No.8 Jam here Completed conveyor The 2nd Process Unit stops immediately. The feeder stops feeding. Delivered to the eject tray Delivered to the of the 1st Process Unit. uncompleted conveyor. SmartStacker User's Manual...
  • Page 130 Jam here immediately. Completed conveyor The feeder stops feeding. Delivered to the eject tray Delivered to the eject tray of the Merge Stacker. of the 1st Process Unit. Delivered to the eject tray of the 2nd Process Unit. SmartStacker User's Manual...

  • Page 131: Reprinting The Whole Job From The Beginning

    • Also remove the sheets remaining on the Sheet Feeder. • See page 363 for instructions on removing the jammed sheets. Press the OK button on the Error screen. Select the job and click ➡ The reprint list is displayed. SmartStacker User's Manual...
  • Page 132 If you use the All Reprint function for a job, that job will move to the list of Held jobs. At that point the SmartStacker will not be able to process the remaining part of the job. Once the job is reprinted, the SmartStacker will be able to process the whole job.

  • Page 133: Reprinting Only The Bad Stack

    • Also, you can resume the job by clicking the Start icon on the screen of the FLC. ➡ The remaining sheets (No. 7 and 8 in this example) are processed and delivered to the complet- ed conveyor. SmartStacker User's Manual...
  • Page 134 ➡ The reprint list is printed by the desktop printer that has been selected by the FLC. ➡ Once the selected sheets (No. 4, 5 and 6 in this example) have been reprinted by the press, the job is returned to the list of Pending jobs. SmartStacker User's Manual...
  • Page 135 No. 7 and 8.) • Keep these sheets. They will be used later. Press the OK button on the Error screen. ➡ The job is stopped. You can run another job while you are waiting for the reprint. SmartStacker User's Manual...
  • Page 136 First Job Job for Reprinted Sheets Select the first job and run it again. ➡ The sheets No. 7 and 8 are processed and delivered to the completed conveyor. Run the job for the reprinted sheet. ➡ SmartStacker User's Manual...

  • Page 137: Reprinting Only The Bad Block

    You will use these If you are using a stack taken from the although the stack has uncompleted conveyor, be sure to check it been delivered to the carefully. uncompleted conveyor. Remove Use the stack on the completed conveyor. SmartStacker User's Manual...
  • Page 138 No. 7 and 8). ➡ A confirmation message on displayed in the screen of the FLC. Click the OK button. Important Before doing this step, tell the system to reprint the whole block. See page 96 for details. SmartStacker User's Manual...
  • Page 139 Select the job for the reprinted sheets and run it. This means that there is a job for the reprinted sheets First Job Job for Reprinted Sheets Remove the unnecessary pages from the delivered stack. No.1 No.2 No.3 No.4 No.5 No.6 No.7 No.8 Remove SmartStacker User's Manual...

  • Page 140: Reprinting Only The Bad Sheet

    Press the OK button on the Error screen, and then press the Start button. • The sheets No. 6, 7 and 8 are processed and delivered to the completed conveyor. Additional Information If you want to hold the job, see page 135. SmartStacker User's Manual...
  • Page 141 If the box for "Show this dialogue each time ..." on the Setting - General screen has not been checked, this screen will not be displayed. Select the job and click ➡ The Reprint List screen is displayed. SmartStacker User's Manual...
  • Page 142 ➡ When the sheet (No. 5 in this example) is reprinted by the press, the job is moved to the list of Pending jobs again. Set the reprinted sheet (No. 5 in this example) in the Sheet Feeder. Select the job which includes the reprinted sheets and run it. First Job Job for Reprinted Sheets SmartStacker User's Manual...

  • Page 143: Error Recovery - When Using The B2 Stacker

    If a jam occurs, the sheets will be delivered as shown below: 10606620708A1 The feeder Delivered to the container. stops feeding. Delivered to the eject The B2 Stacker tray of the 2nd Process stops immediately. Unit. Delivered to the eject tray of the 1st Process Unit. SmartStacker User's Manual...

  • Page 144: Resuming The Job

    • The counter on the Run - Main screen will be calculated by the number of removed sheets. Resume the operation by pressing the Motor/Feed Start button. Important See pages 131 through 136 for reprint- ing the sheets. SmartStacker User's Manual...

  • Page 145: Changing The Setting Of Handy Scanner For Flc

    Scan the barcodes below in order. The settings of the barcode scanner will be reset to the default settings. If you return to the default settings, the beep sound will be large and the automatic scan mode will be turned on. Return to default setting. Set the barcode font: Code39 Full Ascii SmartStacker User's Manual...
  • Page 146 This page is intentionally left blank.

  • Page 147: Procedures For Offline Operation

    3 Procedures for Offline Operation This chapter explains the procedure for doing sheet cutting when running the SmartStacker without using the FLC.

  • Page 148: Setting The Control Panel - When Using The Merge Stacker

    • Number of pages in off-set stacking needs attention. 3-1-1 Setting the Job When the FLC is powered on, disconnect the connection with the SmartStacker. Press the icon of the SmartStacker Additional Information on the Run - Main screen for more If you are using the mouse, right click the than three seconds.
  • Page 149 6 to 15 mm or 0.24” to 0.6” Enter the gutter trim width for the long side 6 to 15 mm or 0.24” to 0.6” If the gutter trim function is off No entries for gutter trim width SmartStacker User's Manual...
  • Page 150 Page Width If you enter a value which is out of range, the value will be displayed in red. If the optional scoring mechanism is installed, turn it on or off. Enter the sheet thickness (measured in µm). SmartStacker User's Manual...
  • Page 151 Select whether the fine-adjustment settings will be carried over or deleted. Any previously entered fine-ad- justment settings will be carried over to the current settings. All the previously entered fine-ad- justment settings will be deleted. SmartStacker User's Manual...
  • Page 152 Setting the Control Panel - When using the Merge Stacker Start the changeover. This screen is displayed if the gut- ter trim function is changed. See page 116. SmartStacker User's Manual...

  • Page 153: Setting The Delivery Action

    • The preset counter is not used. • All of the blocks are stacked without offsetting. When the top of the stack reaches the upper limit of the Merge Stacker, the blocks are delivered. The stack may include part of a block. SmartStacker User's Manual...
  • Page 154 Press this button to clear the number of Enter the number of sheets for one block. Number of pages pages which have already been stacked. already stacked Decide whether the blocks should be offset during stacking. Straight Stacking Offset Stacking SmartStacker User's Manual...

  • Page 155: Starting A Job

    ➡ The cut sheets are stacked and delivered according to the delivery setting. Press the Motor/Feed Stop button to stop the sheet cutting operation. Before you turn the power off after finishing the operation, lower the feed table to the floor. SmartStacker User's Manual...

  • Page 156: Setting The Control Panel - When Using The B2 Stacker

    • Number of pages in off-set stacking needs attention. 3-2-1 Setting the Job When the FLC is powered on, disconnect the connection with the SmartStacker. • See page 148 for details. Set the sheet size and the division numbers using the Setting - Size Setting screen.
  • Page 157 Page Length Page Width Enter the sheet thickness (measured in µm). Check the following before beginning the changeover. Loosen the locking screw on the sheet hold-down bar, and move it towards the feed rotor. SmartStacker User's Manual...
  • Page 158 Select whether the fine-adjustment settings will be carried over or deleted. Any previously entered fine-ad- justment settings will be carried over to the current settings. All the previously entered fine-ad- justment settings will be deleted. Start the changeover. pieces/hr SmartStacker User's Manual...

  • Page 159: Setting The Delivery Action

    • The preset counter is not used. • All of the blocks are stacked without offsetting. When the top of the stack reaches the upper limit of the B2 Stacker, the blocks are delivered. The stack may include part of a block. SmartStacker User's Manual...
  • Page 160 Enter the number of sheets Press this button to clear the number of Number of pages for one block. pages which have already been stacked. already stacked Decide whether the blocks should be offset during stacking. Straight Stacking Offset Stacking SmartStacker User's Manual...
  • Page 161 Four pages in one block When stacking posters All of the blocks are stacked without offsetting. When the top of the stack pieces/hr reaches the upper limit, the stack is delivered. No entry for the number of pages in each block. SmartStacker User's Manual...

  • Page 162: Starting A Job

    Press the Motor/Feed Stop button to stop the sheet cutting operation. Before you turn the power off after finishing the operation, lower the feed table and the pallet to B2 Stacker Control Panel the floor. Remove the stack from the B2 Stacker. SmartStacker User's Manual...

  • Page 163: Saving, Loading, And Deleting Jobs

    • If you want to overwrite the old job information, press • If you do not want to overwrite the job information, press ➡ The Memory screen is displayed. Select another job number and repeat from step 2. SmartStacker User's Manual...

  • Page 164: Loading A Job

    Setting screen, and do the changeover. (When you recall a job, the machine does not do a changeover automatically.) • Press to go back to the Memory screen. The job will not be loaded. SmartStacker User's Manual...

  • Page 165: Deleting A Job

    Numeric Keypad screen, press here. Delete Confirmation Screen Press ➡ The Delete Confirmation screen is displayed. • Press to delete the job. • Press to go back to the Memory screen. The job will not be deleted. SmartStacker User's Manual...

  • Page 166: Protecting The Job Data

    ➡ The Job Protected icon is displayed on the left side of the job number. 001 A4 BOOK 2013/01/20 If you want to unlock the job data, press again. ➡ The Job Protected icon will disappear. 26030 30204C1 SmartStacker User's Manual...

  • Page 167: Exporting The Job Data

    You can copy all the job data saved in the SmartStacker to a USB thumb drive. If you have more than one SmartStacker, you can export the job data from one SmartStacker and import it to the other SmartStacker. This allows you to use the same settings on the second machine.

  • Page 168: Recalling Exported Jobs

    Saving, Loading, and Deleting Jobs 3-3-6 Recalling Exported Jobs You can import job data from the USB thumb drive to a SmartStacker. All the job data can be imported, or just the data for a selected job. Important • If the SmartStacker already has job information...
  • Page 169 When the data has been imported, the screen returns to the Memory - Main screen. • If you do not want to overwrite the job information, press ➡ The Memory - Main screen is displayed. SmartStacker User's Manual...
  • Page 170 This page is intentionally left blank.

  • Page 171: Procedures For Inline Operation

    4 Procedures for Inline Operation This chapter explains the procedures for sheet cutting operations when running the machine in a Inline system.

  • Page 172: Daily Safety Check

    Check that the changeover does not start, and the correct icon is displayed on the screen. If an error icon is not displayed. • There is a problem with the safety circuit. Stop using the machine and call a service technician. SmartStacker User's Manual...
  • Page 173 Check the other safety functions. • Clear the Error screen. Open all of the safety covers and press all of the Emergency Stop buttons shown and press again. Check that the correct error icons appear on the screen. SmartStacker User's Manual...
  • Page 174 Daily Safety Check Close all the covers, release all the Emergency Stop buttons, and press The Error screen is cleared. Emergency Stop Button Release Press 2307310101C1 SmartStacker User's Manual...

  • Page 175: Changeover

    Tighten the two Additional Information locking screws. The trim guide for 3-MF cutter should be installed only when the sheet is divided into six sheets at the first process unit. Press the changeover button. The machine resumes the changeover. SmartStacker User's Manual...

  • Page 176: Reprint - When Using The Merge Stacker

    Stacker stops Jam here immediately Completed conveyor Printing stops Delivered to the eject tray Delivered to the eject tray of the Merge Stacker. of the 1st Process Unit. Delivered to the eject tray of the 2nd Process Unit. SmartStacker User's Manual...

  • Page 177: Restarting The Operation

    Pay attention not to mix the unnecessary sheets. Press the OK button on the Error screen. Restart the printing. Attention An uncompleted stack is delivered to the uncompleted conveyor. Check that the uncompleted pages and reprinted pages are in the correct order. SmartStacker User's Manual...

  • Page 178: Post Processing

    Merge Stacker. At the end of the operation, check for any blank pages of incomplete stacks and remove them. Second Process Unit First Process Unit Merge Stacker SmartStacker User's Manual...

  • Page 179: Fine Adjustments

    5 Fine Adjustments This chapter explains how to make some small adjustments which may be necessary. The sheet feeder that is described in the text is an optional device.

  • Page 180: Adjusting The Sheet Feeder

    The table guide is vertical. The rear edge of the stack should line up with the table guide. This adjustment can only be made if the feed table is positioned higher than the guide block. Guide Block SmartStacker User's Manual...

  • Page 181: Setting The Suction Head

    (Turn the knob in the 4 mm / 0.16" direction shown by arrow • Loosen the locking screw and increase the separator angle using the separator angle adjusting knob. (Turn the knob in the direction shown by arrow SmartStacker User's Manual...
  • Page 182 Front / Side Air Vacuum Gauge Pressure Gauge 23073 10401A6 Adjust so that the vacuum gauge is set Adjust so that the pressure gauge is set to -0.035 MPa (8.0 to 8.7 psi). between +0.055 and 0.06 MPa (-5.0 psi). SmartStacker User's Manual...
  • Page 183 Sheets correct the imbalance using the blower pressure levers. If the blower pressure is too strong, this can cause double feeding. 23073 10401A7 Separator Blower Position Adjusting Knob 23073 30101A2 Blower Pressure Levers SmartStacker User's Manual...
  • Page 184 This type of nozzle has four outlets. The air blows straight under the feed rotor from the two outlets in the middle and outward from the two outlets at either end of the nozzle. Air Flow 23073 10401B2 SmartStacker User's Manual...

  • Page 185: Setting The Side Air

    • Adjust the side air so that about five or six sheets at the top of the stack are separated. Strong Strong Side Air Adjusting Knob (Drive Side) Side Air Adjusting Knob (Operator Side) SmartStacker User's Manual...
  • Page 186 Adjusting the Sheet Feeder For smaller sheets with a width of 330 mm / 12.9” or less, use the smaller feed guides. Smaller Feed Guide Stop the vacuum pump. Information - Single Operation Screen SmartStacker User's Manual...

  • Page 187: Adjusting The Table Guide And The Rear Guide

    Adjusting the Sheet Feeder 5-1-5 Adjusting the Table Guide and the Rear Guide Rear Guide Table Guide • If the sheet hits the rear guide and causes a jam, increase the clearance at the rear guide. SmartStacker User's Manual...

  • Page 188: Feed Rotor Adjustments

    • Adjust the space using the feed table sensor adjusting knob. • Normally this space should be about 8 mm (0.31") when the feed table is at the upper 26030 30102B1 limit point. About 8 mm / 0.31" SmartStacker User's Manual...
  • Page 189 Move the suction point 2 to 3 mm (0.08” to 0.12”) forward (direction B). This will feed the front edge so that it prevents the sheet from hitting the entrance of the register guide. Loosen the locking knob to adjust the position of the suction point. Locking Knob 26030 30102E1 SmartStacker User's Manual...

  • Page 190: Adjusting The Cutting Positions

    If all of the pages are too wide If all of the pages are too long Adjustment or too narrow, adjust the width or too short, adjust the length here. here. Value after Fine Adjustment Run - Page Size Fine Adjustment Screen SmartStacker User's Manual...

  • Page 191: Adjusting The Trim Width - Short Edge

    ➡ The sheet is processed through the First Process Unit and stopped at the stopper in the 90-degree Turn Conveyor. Check whether the sheet has been cut correctly. If the quality is OK, enter "0" to return to the normal mode. SmartStacker User's Manual...

  • Page 192: Adjusting The Trim Length - Long Edge

    ➡ The sheet is processed through the Second Process Unit and stopped at the stopper in the Merge Conveyor. Check whether the sheet has been cut correctly. If the quality is OK, enter "0" to return to the normal mode. SmartStacker User's Manual...

  • Page 193: Adjusting Individual Trim Positions

    Adjust the cutter position cutter needs to be adjusted. as needed. Run - Cutter Position Fine Adjustment - Second Process Example: Changing two of the cutting Unit Fine Adjustment Screen positions in the Second Process Unit. Feed Direction 3-MF SmartStacker User's Manual...
  • Page 194 Adjusting the Cutting Positions Imposition Examples for Cutter Positions with Gutter Trim SmartStacker User's Manual...
  • Page 195 Adjusting the Cutting Positions Imposition Examples for Cutter Positions without Gutter Trim SmartStacker User's Manual...

  • Page 196: Adjusting The Guide Positions

    • If a sheet is not aligned with the register guide and causes skewed cutting, first of all, check if the piled sheets are fit with the table guide. If the sheets are OK, decrease the value for register guide. SmartStacker User's Manual...
  • Page 197 Check whether the sheet is aligned with the register guide correctly 1st Process Unit Check if the sheet is fully aligned with the register guide by viewing through the gap between the cov- ers. 1st Regist Unit SmartStacker User's Manual...

  • Page 198: Adjusting The Ejecting Gates On The 2Nd Process Unit

    (The guides and frames have been left out of this drawing.) In the example shown here, the sheet closest to the front is hitting one of the gates. • In the example shown here, the sheet that should move down is stopped, causing a jam. Reduce the value for the ejecting gates. SmartStacker User's Manual...

  • Page 199: Adjusting The Angle Adjusting Guides On The Merge Conveyor

    If the fine adjustment value of the side which is misaligned to the operator side is “0”, you cannot set the value to minus any more. In that case, adjust it by moving the side which is misaligned to drive side to the operator side( SmartStacker User's Manual...

  • Page 200: Adjusting The Stopper On The Merge Stacker

    Reduce the value for the stopper setting. If a sheet jams or the tail edge of the stack is scratched by the stack regis- ter guide when the stack is lowered - Increase the value for the stopper setting. SmartStacker User's Manual...

  • Page 201: Adjusting The Pressure Of The Sheet Hold-Down Plates In The Merge Stacker

    Run - Fine Adjustment Screen Sheet Hold-Down Plates If the sheet stops before it reaches the stopper, decrease the pressure. Sheet Stacked in the Merge Stacker If the stacked sheets are misaligned side- to-side, increase the pressure. SmartStacker User's Manual...

  • Page 202: Adjusting The Stopper On The B2 Stacker

    Reduce the value for the stopper set- ting. If a sheet jams or the tail edge of the stack is scratched by the stack regis- ter guide when the stack is lowered - Increase the value for the stopper setting. SmartStacker User's Manual...

  • Page 203: Adjusting The Pressure Of The Sheet Hold-Down Plates In The B2 Stacker

    Run - Fine Adjustment Screen Sheet Hold-Down Plates If the sheet stops before it reaches the stopper, decrease the pressure. Sheet Stacked in the B2 Stacker If the stacked sheets are misaligned side- to-side, increase the pressure. SmartStacker User's Manual...

  • Page 204: Adjusting The Optional Scoring Unit

    If the score line on the far side of the page is incorrect, adjust the position here: Run - Scoring Position Fine Adjustment Screen Feed Direction If the score line on the operator side of the page is incorrect, adjust the position here: SmartStacker User's Manual...

  • Page 205: Adjust The Scoring Depth

    If necessary, you can adjust the scoring depth to match the type and thickness of the sheet. Turn the scoring depth adjusting dials so that the scoring depth becomes even. Drive Side Scoring Depth Operator Side Scoring Depth Adjustment Dial Adjustment Dial Shallow Deep SmartStacker User's Manual...
  • Page 206 This page is intentionally left blank.

  • Page 207: Troubleshooting

    6 Troubleshooting This chapter explains some possible problems, and suggests some solutions.

  • Page 208: If An Error Icon Appears

    (Error Code 100) Cover Open (Error Codes 101,102,103,104) Sheet Jam (Error Codes 108 through 150) 1st Process Cutter Cassette Not Installed (Error Codes 161 through 164) Trim Full (Error Code 172) Waste Full (Error Code 171) SmartStacker User's Manual SmartStacker User's Manual...
  • Page 209 Cover Open (Error Codes 301 through 308) Sheet Jam (Error Codes 309 through 363) Icon Description Merge Stacker Emergency Stop (Error Code 400) Cover Open (Error Codes 401 through 403) Sheet Jam (Error Codes 409 through 452) SmartStacker User's Manual...
  • Page 210 If an Error Icon Appears Icon Description B2 Stacker Emergency Stop (Error Code 500) Cover Open (Error Codes 501 to 505) Sheet Jam (Error Codes 509 through 543) Pallet Setting Error (Error Codes 590) Slope Folding Error (Error Code 592) SmartStacker User's Manual...

  • Page 211: If An Error Code Is Displayed On Smartstacker

    If an Error Code Is Displayed on SmartStacker If an error occurs, an error code will appear on the Error screen. See the tables below and correct the cause of the error. The Error screen will be cleared when the OK button is pressed.
  • Page 212 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Sheet remains at 1st process unit entrance Remove the sheet jammed at the 1st process sensor unit. If this error code appeared even though the sheet is not jammed, check the B120 sensor The B120 has remained on for longer than the is not dirty.
  • Page 213 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Remove the full waste sheets. If this error Waste full error code appeared even though the waste sheets are not full, check the B150 sensor and mirror The light from B150 was blocked for longer than are not dirty.
  • Page 214 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Remove the sheet jammed at 90-degrees turn Sheet remains at gripper timing sensor conveyor. If this error code appeared even though the sheet is not jammed, check the either B211 or B212 has remained on for longer than of B211 sensor or B212 sensor is not dirty.
  • Page 215 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Remove the sheet which is jammed. Check the sensor LED. The LED is unstable if it is Sheet has not arrived at gate timing sensor blinking, Check that there is not any object on the sheet path. If...
  • Page 216 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Scoring unit not installed The connector for scoring unit was unplugged Install the scoring unit correctly. while the machine was running, or the machine was started while the connector for scoring unit was unplugged.
  • Page 217 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Sheet remains at 2nd process unit exit sensor or signal wiring disconnected Remove the sheet jammed at the 2nd process unit. If this error code appeared even though...
  • Page 218 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Sheet Stops at Merge Conveyor in Adjusting Mode This is normal behavior in the adjusting mode. The sheet stops at the stopper in the Merge Conveyor. Because the machine runs in the adjusting mode.
  • Page 219 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Check if the sheet thickness on the size setting screen is correct. If it is wrong; In case of Near line or Inline Sheet delay in upper transport section It should be corrected in the DFE.
  • Page 220 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Check if the sheet thickness on the size setting screen is correct. If it is wrong; Sheet delay in lower transport section In case of Near line or Inline It should be corrected in the DFE.
  • Page 221 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Too many sheets passed register section entrance sheet pass sensor Remove the sheets which are jammed. Also, check the B590 is not dirty. (See page 372 for B590 detected the sheet that had not pass B310.
  • Page 222 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Sheet jam during parallel stacking operation Check whether the sheets are not jammed. There was a difference longer than specified time on the detection of B595 and B594.
  • Page 223 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Too many sheets passed stack section entrance sheet pass sensor Check the B420 sensor is not dirty. (See page 373 for the cleaning instruction.) The number of the sheets detected by B420 exceeded the expected number of fed sheets.
  • Page 224 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Sheet remains at stack table foreign object Remove the sheet on the stack table. If this detecting sensor error code appeared even though the sheet is not jammed, check the B448 and the reflector The B448 stack table foreign object detecting are not dirty.
  • Page 225 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Sheet has not arrived at slope section sheet pass sensor Remove the sheet which is jammed. The B512 was not turned on within the specified time. Sheet remains at slope section sheet pass Remove the sheet which is jammed.
  • Page 226 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Sheet remains at stack section entrance sheet Remove the sheet which is jammed. If this error pass rear sensor code appeared even though the sheet is not jammed, check the B520 sensor is not dirty.
  • Page 227 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Too many sheets passed bypass exit sheet pass sensor Remove the sheets which are jammed. Also, check the B550 is not dirty. (See page 374 for B550 detected the sheet that had not pass B512.
  • Page 228 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions System Error: 1000-1999 Check the following in order: Deposition of K101 interlock contactor 1 - All the covers are properly closed. - The Emergency Stop button is not pressed.
  • Page 229 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions K104 Emergency Stop contactor 2 function error Though the interlock circuit is closed (=all the 1109 Emergency Stop buttons are not pressed), the contact points for terminals 21 and 22 on K104 are open.
  • Page 230 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Check the following in order: - All the covers are properly closed. 2nd regist unit transport motor alarm - The Emergency Stop button is not pressed. 1210 An alarm was input from the A231 2nd regist unit transport motor driver.
  • Page 231 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Check the following in order: - All the covers are properly closed. Upper fan motor failure - The Emergency Stop button is not pressed. 1340 Any of the upper fan motors M322 through M328 for the Merge Conveyor is defective.
  • Page 232 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions K401 interlock contactor 1 function error 1405 Though the interlock circuit is closed (=all the Check the following in order: covers close), the contact points for terminals 21 - The Emergency stop button is not pressed.
  • Page 233 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Stack table full error 1430 Decrease the stack amount. While the machine is running, the height of the stack table became 5 mm / 0.20” or lower.
  • Page 234 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Deposition of K503 Emergency Stop Contactor 1 Check the following in order: - The Emergency Stop button is not pressed. 1503 Even though the S500 Emergency Stop button is If this error occurs frequently, call your local pressed, the contact points of K503 are closed.
  • Page 235 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Vacuum Blower Motors M521 through M523 Failure 1540 The error signal from the M521 through M523 vacuum motors is received by the control board. Separation Air Motor M529 Failure...
  • Page 236 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Error Related to Changeover: 2000-2999 Register guide motor M111 home positioning error 2100 The M111 motor did not return to the home position within the specified time after the start of the home positioning.
  • Page 237 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions [1Pro] Cutter 3MF adjusting motor M128 home positioning error 2108 The M128 motor did not return to the home position within the specified time after the start of the home positioning.
  • Page 238 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions [2Pro] Cutter 1R adjusting motor M242 home positioning error 2202 The M242 motor did not return to the home position within the specified time after the start of the home positioning.
  • Page 239 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Scoring R adjusting motor M272 home positioning error 2210 The M272 motor did not return to the home position within the specified time after the start of the home positioning.
  • Page 240 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Fork up/down motor M431 home positioning error 2402 The M431 motor did not return to the home position within the specified time after the start of the home positioning.
  • Page 241 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions B2 Stacker Stack Sheet Center Pusher Home Positioning Error 2507 The M534 motor did not return to the home position within the specified time after the start of the home positioning.
  • Page 242 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Overcurrent during constant speed (Inverter display: E.OC2) 3111 During constant-speed operation, the output current of the inverter became double the rated current. Inverter alarm Overcurrent during acceleration (Inverter display: E.OC1)
  • Page 243 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Motor overload shut-off (Inverter display: E.THM) If this error occurs frequently, call your local 3131 The electronic thermal alarm built into the dealer. inverter has detected an overload of the motor of overheating in the motor due to poor cooling, and has stopped the output from the inverter.
  • Page 244 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Current leakage protection (Inverter display: E.GF) 3180 A ground fault has occurred in the power supply circuit of the motor, and the inverter stopped the output.
  • Page 245 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Overcurrent during constant speed (Inverter display: E.OC2) 3211 During constant-speed operation, the output current of the inverter became double the rated current. Inverter alarm Overcurrent during acceleration (Inverter display: E.OC1)
  • Page 246 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Fin overheat (Inverter display: E.FIN) Turn off the power. Wait about 30 minutes and 3240 turn on the power again. If this error occurs The cooling fins on the inverter have overheated, frequently, call your local dealer.
  • Page 247 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions No error code for inverter (Inverter display: N/A) If this error occurs frequently, call your local 3299 An error which does not correspond to any of dealer.
  • Page 248 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Circuit trouble (Amplifier display: ct) Turn off the power. Wait about 30 minutes and 3308 turn on the power again. If this error occurs There is a fault in the supply power voltage inside frequently, call your local dealer.
  • Page 249 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Close all the covers and make sure the Main power undervoltage Emergency Stop button is released. (Amplifier display: LvP) Additional Information 3321 The power supplied to the servo amplifier falls This error may be occurred even you open/close below the minimum specification voltage limit.
  • Page 250 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Absolute data lost 2. (Amplifier display: dL2) If this error occurs frequently, call your local 3329 dealer. The absolute data of the encoder is lost. (Multi- turn data fault in encoder) Absolute data lost 3.
  • Page 251 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions No error codes (Amplifier display: N/A) If this error occurs frequently, call your local 3350 An unexpected error occurs on the servo dealer. amplifier. (An error which does not correspond to any of the errors 3301 through 3349 has occurred.)
  • Page 252 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Overvoltage during constant speed (Inverter display: E.OV2) If this error occurs frequently, call your local 3421 dealer. During constant-speed operation, regenerative energy has caused the main circuit DC voltage in the inverter to exceed the specified value.
  • Page 253 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Stall prevention (Inverter display: E.OLT) If this error occurs frequently, call your local 3460 dealer. The operating frequency has been dropped to “0” by the stall preventer function.
  • Page 254 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Overcurrent 2 (Amplifier display: oc2) If this error occurs frequently, call your local 3502 The output current of the servo amplifier exceeds dealer. the rated value. Indirect detection with software of...
  • Page 255 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Motor combination error (Amplifier display: cE) If this error occurs frequently, call your local 3511 dealer. The combination of the servo amplifier and the motor is not correct.
  • Page 256 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Braking transistor error (Amplifier display: rH3) Turn off the power. Wait about 30 minutes and 3524 turn on the power again. If this error occurs The regeneration handling transistor built in the frequently, call your local dealer.
  • Page 257 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Braking transistor error (Amplifier display: rH3) The frequency of the command pulse inside the If this error occurs frequently, call your local 3533 servo amplifier is high.
  • Page 258 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Control power undervoltage (Amplifier display: Lvc) If this error occurs frequently, call your local 3604 dealer. The power supplied to the servo amplifier falls below the minimum specification voltage limit.
  • Page 259 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Encoder communication error (Amplifier display: Ec) If this error occurs frequently, call your local 3613 dealer. Communications with the internal encoder of the servo motor fails. CONT (control signal) error...
  • Page 260 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Amplifier overheat (Amplifier display: AH) If this error occurs frequently, call your local 3626 dealer. The temperature of the servo amplifier has exceeded the allowable limit. Encoder overheat...
  • Page 261 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter no response (Inverter display: N/A) 3640 The communication connection between the Check if Q221 breaker is not tripped. servo amplifier and the control board P109512 (QPM-290) for the 2nd regist unit has not been established.
  • Page 262 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Overvoltage (Amplifier display: Hv) If this error occurs frequently, call your local 3705 dealer. The DC voltage inside the servo amplifier exceeds the upper limit. Encoder trouble 1...
  • Page 263 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions CONT (control signal) error (Amplifier display: ctE) If this error occurs frequently, call your local 3714 dealer. The parameter stored in the servo amplifier is incorrect. Overload 1...
  • Page 264 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Encoder overheat (Amplifier display: EH) If this error occurs frequently, call your local 3727 dealer. The encoder inside the servo motor may be overheated. Absolute data lost 1.
  • Page 265 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Servo amplifier communication failure (Amplifier display: N/A) 3741 Check if Q230 breaker is not tripped. The communication is not stable. A communications data error occurred. Drive power undervoltage...
  • Page 266 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Overcurrent during acceleration (Inverter display: E.OC1) 3812 During deceleration, the output current of the inverter became double the rated current. Inverter alarm Overvoltage during acceleration (Inverter display: E.OV1)
  • Page 267 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Input phase failure (Inverter display: E.ILF) 3852 A phase failure has occurred in one of the three input phases (R, S and T) to the inverter, or there...
  • Page 268 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions A250 Gate Sliding Servo Amplifier: 3900-3999 Overcurrent 1 (Amplifier display: oc1) 3901 The output current of the servo amplifier exceeds the rated value. Direct detection by internal...
  • Page 269 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Memory error (Amplifier display: dE) Turn off the power. Wait about 30 minutes and 3909 turn on the power again. If this error occurs The parameter stored in the servo amplifier is frequently, call your local dealer.
  • Page 270 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Internal braking resistor overheat (Amplifier display: rH1) 3922 The power consumption of the braking resistor built in the servo amplifier exceeds the upper If this error occurs frequently, call your local limit.
  • Page 271 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Absolute data lost 2. (Amplifier display: dL2) 3929 The absolute data of the encoder is lost. (Multi- turn data fault in encoder) Absolute data lost 3. (Amplifier display: dL3)
  • Page 272 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions No error codes (Amplifier display: N/A) If this error occurs frequently, call your local 3950 An unexpected error occurs on the servo dealer. amplifier. (An error which does not correspond to any of the errors 3901 through 3949 has occurred.)
  • Page 273 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Overvoltage during constant speed (Inverter display: E.OV2) 4121 During constant-speed operation, regenerative energy has caused the main circuit DC voltage in the inverter to exceed the specified value.
  • Page 274 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Stall prevention (Inverter display: E.OLT) If this error occurs frequently, call your local 4160 dealer. The operating frequency has been dropped to “0” by the stall preventer function.
  • Page 275 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter communication error (Inverter display: N/A) 4201 The control board P109512 (QPM-290) for the Merge Conveyor received NAK several times from the inverter. Inverter alarm Overcurrent during acceleration (Inverter display: E.OC1)
  • Page 276 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Inverter overload shut-off (Inverter display: E.THT) 4230 The output current of the inverter has been more than 150% of the rated current. Because the output current is less than 200%, overcurrent cutoff has not occurred.
  • Page 277 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Current leakage protection (Inverter display: E.GF) If this error occurs frequently, call your local 4280 dealer. A ground fault has occurred in the power supply circuit of the motor, and the inverter stopped the output.
  • Page 278 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Overvoltage (Amplifier display: Hv) 4305 The DC voltage inside the servo amplifier exceeds the upper limit. Encoder trouble 1 (Amplifier display: Et1) 4306 If this error occurs frequently, call your local There is a fault in the encoder built in the servo dealer.
  • Page 279 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions CONT (control signal) error (Amplifier display: ctE) If this error occurs frequently, call your local 4314 dealer. The parameter stored in the servo amplifier is incorrect. Overload 1...
  • Page 280 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Encoder overheat (Amplifier display: EH) 4327 The encoder inside the servo motor may be overheated. Absolute data lost 1. (Amplifier display: dL1) 4328 The absolute data of the encoder is lost. (The voltage for data storage is dropped, or the encoder cable is broken.)
  • Page 281 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Servo amplifier communication failure (Amplifier display: N/A) 4341 Check if Q320 breaker is not tripped. The communication is not stable. A communications data error occurred. Drive power undervoltage...
  • Page 282 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Encoder trouble 1 (Amplifier display: Et1) 4406 There is a fault in the encoder built in the servo motor. (Single revolution position detection fault of encoder) If this error occurs frequently, call your local dealer.
  • Page 283 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Overload 1 Check that nothing is preventing the Merge (Amplifier display: oL1) Conveyor lower speed reduction roller from 4415 moving. If this error occurs frequently, call your The servo motor is mechanically locked.
  • Page 284 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Absolute data lost 1. (Amplifier display: dL1) 4428 The absolute data of the encoder is lost. (The voltage for data storage is dropped, or the encoder cable is broken.) Absolute data lost 2.
  • Page 285 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Drive power undervoltage (Amplifier display: N/A) 4442 The voltage of the power supplied to the servo amplifier is insufficient. If this error occurs frequently, call your local No error codes dealer.
  • Page 286 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm 4520 Overvoltage during acceleration (Inverter display: E.OV1) Inverter alarm Overvoltage during constant speed (Inverter display: E.OV2) 4521 During constant-speed operation, regenerative energy has caused the main circuit DC voltage in the inverter to exceed the specified value.
  • Page 287 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Input phase failure (Inverter display: E.ILF) 4552 A phase failure has occurred in one of the three input phases (R, S and T) to the inverter, or there...
  • Page 288 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions A410 Inverter for Entrance Transport Motor: 4600-4699 Inverter no response (Inverter display: N/A) The communication connection between the Close all the covers and make sure the 4600 inverter, the short circuit board P109111 (QPW- Emergency Stop button is released.
  • Page 289 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Overvoltage during deceleration (Inverter display: E.OV3) 4622 During deceleration, regenerative energy has caused the main circuit DC voltage in the inverter to exceed the specified value.
  • Page 290 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Brake circuit problem (Inverter display: E.BE) Turn off the power. Wait about 30 minutes and 4670 turn on the power again. If this error occurs The brake transistor has failed due to excessive frequently, call your local dealer.
  • Page 291 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Overcurrent during acceleration (Inverter display: E.OC1) 4710 During acceleration, the output current of the inverter became double the rated current. Inverter alarm Overcurrent during constant speed (Inverter display: E.OC2)
  • Page 292 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Motor overload shut-off (Inverter display: E.THM) If this error occurs frequently, call your local 4734 The electronic thermal alarm built into the dealer. inverter has detected an overload of the motor of overheating in the motor due to poor cooling, and has stopped the output from the inverter.
  • Page 293 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter alarm Output phase failure protection (Inverter display: E.LF) 4781 A phase failure has occurred in one of the three output phases (U, V and W) from the inverter. The output from the inverter has been stopped.
  • Page 294 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Encoder trouble 1 (Amplifier display: Et1) 4806 There is a fault in the encoder built in the servo motor. (Single revolution position detection fault of encoder) If this error occurs frequently, call your local dealer.
  • Page 295 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Overload 1 Check that nothing is preventing the fork from (Amplifier display: oL1) 4815 moving at the Merge Stacker. If this error occurs frequently, call your local dealer.
  • Page 296 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Absolute data lost 1. (Amplifier display: dL1) 4828 The absolute data of the encoder is lost. (The voltage for data storage is dropped, or the encoder cable is broken.) Absolute data lost 2.
  • Page 297 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Drive power undervoltage (Amplifier display: N/A) 4842 The voltage of the power supplied to the servo amplifier is insufficient. If this error occurs frequently, call your local No error codes dealer.
  • Page 298 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Encoder trouble 2 (Amplifier display: Et2) If this error occurs frequently, call your local 4907 There is a fault in the encoder built in the servo dealer.
  • Page 299 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Overload 2 Check that nothing is preventing the stack table (Amplifier display: oL2) 4916 of Merge Stacker from moving. If this error occurs frequently, call your local dealer.
  • Page 300 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Absolute data lost 1. (Amplifier display: dL1) 4928 The absolute data of the encoder is lost. (The voltage for data storage is dropped, or the If this error occurs frequently, call your local encoder cable is broken.)
  • Page 301 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Drive power undervoltage (Amplifier display: N/A) 4942 The voltage of the power supplied to the servo amplifier is insufficient. If this error occurs frequently, call your local No error codes dealer.
  • Page 302 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Overvoltage during constant speed (Inverter display: E.OV2) 5021 During constant-speed operation, regenerative energy has caused the main circuit DC voltage in the inverter to exceed the specified value.
  • Page 303 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Brake circuit problem (Inverter display: E.BE) Turn off the power. Wait about 30 minutes and 5070 turn on the power again. If this error occurs The brake transistor has failed due to excessive frequently, call your local dealer.
  • Page 304 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter communication error (Inverter display: N/A) 5101 The control board P109512 (QPM-290) for the Merge Stacker P109512 (QPM-290) received NAK several times from the inverter. Overcurrent during acceleration (Inverter display: E.OC1)
  • Page 305 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Motor overload shut-off (Inverter display: E.THM) If this error occurs frequently, call your local 5134 The electronic thermal alarm built into the dealer. inverter has detected an overload of the motor of overheating in the motor due to poor cooling, and has stopped the output from the inverter.
  • Page 306 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Parameter problem (Inverter display: E.PE) 5190 A parameter saved for the inverter is bad. If this error occurs frequently, call your local No error code for inverter dealer.
  • Page 307 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Overvoltage during acceleration (Inverter display: E.OV1) 5220 During acceleration, regenerative energy has caused the main circuit DC voltage in the inverter to exceed the specified value. Overvoltage during constant speed (Inverter display: E.OV2)
  • Page 308 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Stall prevention (Inverter display: E.OLT) If this error occurs frequently, call your local 5260 dealer. The operating frequency has been dropped to “0” by the stall preventer function.
  • Page 309 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter communication error (Inverter display: N/A) 5301 The control board P109512 (QPM-290) for the Merge Stacker P109512 (QPM-290) received NAK several times from the inverter. Overcurrent during acceleration (Inverter display: E.OC1)
  • Page 310 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter overload shut-off (Inverter display: E.THT) The output current of the inverter has been more 5330 than 150% of the rated current. Because the output current is less than 200%, overcurrent cutoff has not occurred.
  • Page 311 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Current leakage protection (Inverter display: E.GF) 5380 A ground fault has occurred in the power supply circuit of the motor, and the inverter stopped the output. Output phase failure protection (Inverter display: E.LF)
  • Page 312 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter Alarm Overcurrent During Constant Speed (Inverter Display: E.OC2) 5611 During constant-speed operation, the output current of the inverter became double the rated current. Inverter Alarm Overcurrent During Acceleration (Inverter Display: E.OC1)
  • Page 313 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter Alarm Motor Overload Shut-off (Inverter Display: E.THM) If this error occurs frequently, call your local 5631 The electronic thermal alarm built into the dealer. inverter has detected an overload of the motor of overheating in the motor due to poor cooling, and has stopped the output from the inverter.
  • Page 314 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter Alarm Current Leakage Protection (Inverter Display: E.GF) 5680 A ground fault has occurred in the power supply circuit of the motor, and the inverter stopped the output.
  • Page 315 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter Alarm Overcurrent During Constant Speed (Inverter Display: E.OC2) 5711 During constant-speed operation, the output current of the inverter became double the rated current. Inverter Alarm Overcurrent During Acceleration (Inverter Display: E.OC1)
  • Page 316 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter Alarm Fin Overheat (Inverter Display: E.FIN) Turn off the power. Wait about 30 minutes and 5740 turn on the power again. If this error occurs The cooling fins on the inverter have overheated, frequently, call your local dealer.
  • Page 317 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter Alarm Parameter Problem 5790 (Inverter Display: E.PE) A parameter saved for the inverter is bad. If this error occurs frequently, call your local No Error Code for Inverter dealer.
  • Page 318 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter Alarm Overvoltage During Acceleration (Inverter Display: E.OV1) 5920 During acceleration, regenerative energy has caused the main circuit DC voltage in the inverter to exceed the specified value.
  • Page 319 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Inverter Alarm Input Phase Failure (Inverter Display: E.ILF) 5952 A phase failure has occurred in one of the three input phases (R, S and T) to the inverter, or there...
  • Page 320 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions A520a Servo Amplifier for B2 Stacker Transport Speed Reduction Motor: 6000-6099 Overcurrent 1 (Amplifier Display: oc1) 6001 The output current of the servo amplifier exceeds the rated value. Direct detection by internal...
  • Page 321 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Memory Error (Amplifier Display: dE) Turn off the power. Wait about 30 minutes and 6009 turn on the power again. If this error occurs The parameter stored in the servo amplifier is frequently, call your local dealer.
  • Page 322 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Internal Braking Resistor Overheat (Amplifier Display: rH1) 6022 The power consumption of the braking resistor built in the servo amplifier exceeds the upper If this error occurs frequently, call your local limit.
  • Page 323 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Absolute Data Lost 3. (Amplifier Display: dL3) 6030 The absolute data of the encoder is lost. (Multi- If this error occurs frequently, call your local turn data fault in encoder) dealer.
  • Page 324 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions No Error Codes (Amplifier Display: N/A) If this error occurs frequently, call your local 6050 An unexpected error occurs on the servo dealer. amplifier. (An error which does not correspond to any of the errors 6000 through 6049 has occurred.)
  • Page 325 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Circuit Trouble (Amplifier Display: ct) Turn off the power. Wait about 30 minutes and 6108 turn on the power again. If this error occurs There is a fault in the supply power voltage inside frequently, call your local dealer.
  • Page 326 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Close all the covers and make sure the Main Power Undervoltage Emergency Stop button is released. (Amplifier Display: LvP) Additional Information 6121 This error may be occurred even you open/close...
  • Page 327 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Absolute Data Lost 2. (Amplifier Display: dL2) 6129 The absolute data of the encoder is lost. (Multi- turn data fault in encoder) Absolute Data Lost 3. (Amplifier Display: dL3)
  • Page 328 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions No Error Codes (Amplifier Display: N/A) If this error occurs frequently, call your local 6150 An unexpected error occurs on the servo dealer. amplifier. (An error which does not correspond to any of the errors 6100 through 6149 has occurred.)
  • Page 329 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Overvoltage during acceleration (Inverter display: E.OV1) 6820 During acceleration, regenerative energy has caused the main circuit DC voltage in the inverter to exceed the specified value. Overvoltage during constant speed (Inverter display: E.OV2)
  • Page 330 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Stall prevention (Inverter display: E.OLT) If this error occurs frequently, call your local 6860 dealer. The operating frequency has been dropped to “0” by the stall preventer function.
  • Page 331 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Overcurrent during acceleration (Inverter display: E.OC1) 6910 During acceleration, the output current of the inverter became double the rated current Overcurrent during constant speed (Inverter display: E.OC2)
  • Page 332 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Fin overheat (Inverter display: E.FIN) Turn off the power. Wait about 30 minutes and 6940 turn on the power again. If this error occurs The cooling fins on the inverter have overheated, frequently, call your local dealer.
  • Page 333 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions CUnet Error 7000-8999 1st Regist Unit/1st Process Unit QPM-307 (1) CUnet Error: 7001-7099 7001-7027 7028-7030 Problem with M121 cutter 1F adjusting motor 7031-7049 If this error occurs frequently, call your local dealer.
  • Page 334 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions 1st Regist Unit/1st Process Unit QPM-307 (5) CUnet Error: 7401-7499 7401-7427 7428-7430 Problem with M129 cutter 3MR adjusting motor 7431-7449 If this error occurs frequently, call your local dealer.
  • Page 335 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions 7850-7877 If this error occurs frequently, call your local 7878-7880 Problem with M245 cutter 2R adjusting motor dealer. 7881-7899 2nd Regist Unit/2nd Process Unit QPM-307 (3) CUnet Error: 7901-7999...
  • Page 336 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Merge Conveyor QPM-307 (2) CUnet Error: 8301-8399 8301-8327 8328-8330 Problem with M329 upper tail guide motor 8331-8349 If this error occurs frequently, call your local dealer. 8350-8377...
  • Page 337 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions 8850-8877 Problem with M547 vacuum belt unit up/down If this error occurs frequently, call your local 8878-8880 motor dealer. 8881-8899 B2 Stacker QPM-307 (3) CUnet Error: 8901-8999...
  • Page 338 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Panel CF saving error 9022 The compact flash (CF) is broken. A part of the data in the CF is damaged. Previous job loading error 9031 The compact flash (CF) is broken.
  • Page 339 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Input signal enable/disable data range error 9040 The data in the QPW-795 EEPROM board is damaged. Set the administrator - administrator settings The QPW-795 EEPROM board is broken.
  • Page 340 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions 1st regist unit control board WDT 9140 The CPU on the board has become “lost” in a program loop. 2nd regist unit control board EEPROM connection error...
  • Page 341 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Merge conveyor control board EEPROM loading error 9311 The data in the QPW-795 EEPROM board is damaged. The QPW-795 EEPROM board is broken. If this error occurs frequently, call your local dealer.
  • Page 342 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Merge stacker control board EEPROM Saving Error If this error occurs frequently, call your local 9412 The data in the QPW-795 EEPROM board is dealer. damaged. The QPW-795 EEPROM board is broken.
  • Page 343 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions B2 Stacker Control Board EEPROM Saving Error If this error occurs frequently, call your local 9512 The data in the QPW-795 EEPROM board is dealer. damaged. The QPW-795 EEPROM board is broken.
  • Page 344 If an Error Code Is Displayed on SmartStacker Code Description and Causes Solutions Sheet feeder communication error Turn off the power. Wait about 30 seconds and 9620 turn on the power again. If this error occurs The ARCNET communication error occurs in frequently, call your local dealer.

  • Page 345: If A Warning Screen Is Displayed On Smartstacker

    If a Warning Screen is Displayed on SmartStacker If you try to start the machine before a changeover is complete, the Warning screen will be displayed. See the table below and follow the instructions. To clear the Warning screen, press the OK button.
  • Page 346 If a Warning Screen is Displayed on SmartStacker Warning Warning Screen Causes and Solutions Code Remove the scoring unit (option). Install the transport unit when the finished length is 105 mm / 4.13” or below. 2nd Process Unit Locking Knob Transport Unit Remove the transport unit.
  • Page 347 If a Warning Screen is Displayed on SmartStacker Warning Warning Screen Causes and Solutions Code Check if the stack table is not at the lower limit. Recovery after overloading the stack table up/down mechanism. 1. Remove any stacks on the stack table.
  • Page 348 Run - Main screen of the FLC, the job sent from the FLC cannot be processed on the SmartStacker. Select the job which can be processed on the SmartStacker. The B2 stacker is full. Remove the stack. The stack number set on the panel did not reach the stack number which was delivered to the B2 Stacker.

  • Page 349: If An Error Code Is Displayed On Flc

    JDF file of large number of sheets. Communication error If this error occurs frequently, call your local 1100 The session start message was received Inline dealer. while the line is in a session or not ready. SmartStacker User's Manual...
  • Page 350 Inline dealer. press." Check that the LAN cable between the FLC Connection error on communication with the and the SmartStacker (at the back of the 2000 Both machine during the session Merge Stacker) is connected correctly. If this error occurs frequently, call your local dealer.
  • Page 351 The job loaded is not correct. 5090 The barcode on the banner sheet does not Near Line Load the correct job on the Sheet Feeder. match when restarting the job after pausing. SmartStacker User's Manual...
  • Page 352 Check that the Firewall is turned off. The DFE 6000 Nearline Cannot start http communication for DFE. port may be used for the other service. Select the other port. If the same error still occurs, call your local dealer. SmartStacker User's Manual...
  • Page 353 (JobID = {0}) Failed to load the job. 9102 If this error occurs frequently, call your local (JobID = {0}) Both dealer. 9103 Failed to load the job list. Failed to load the job. 9104 (JobID = {0}) SmartStacker User's Manual...

  • Page 354: If A Warning Message Is Displayed On Flc

    Press the “+” mark to select the job. Select the job on the FLC screen and run The job received in advance becomes the parent the job. job and the later job becomes the child job. SmartStacker User's Manual...

  • Page 355: Pole Lamp And Up/Down Buttons

    Lighting The table is ready for feeding. Blinking The table is raising. Blinking The table is lowering. B2 Stacker Blinking The table is raising. Blinking The table is lowering. Lighting The table is at the lowest position. SmartStacker User's Manual...

  • Page 356: Problems With Cutting Quality

    Cutting is Skewed in the 1st Process Unit Problem Possible Cause and Solution • Replace the plastic balls with steel balls. The sheet is not aligned with the register guide. Trim is left in the sheet path of the First Process Unit. SmartStacker User's Manual...

  • Page 357: Problems With The Sheet Feeder

    (See page 188 for details.) • Normally, the feed table should stop when the top sheet in the stack is about 8mm / 0.31” below the feed rotor. Top Sheet in Stack 26030 About 8 mm 40401C1 About 0.31" SmartStacker User's Manual...
  • Page 358 (See page 184 for details.) 26030 40401F1 • Set the blower air outlet in a lower The blower air outlet is Blower Position Adjusting Knob too high. position. (See page 183 for details.) 26030 40401G1 Blower Pressure Lever SmartStacker User's Manual...
  • Page 359 • Adjust the feed rotor suction point. The leading edge of the sheet is curled. (See page 189 for details.) 26030 40401I1 • Lower the vacuum piston. The vacuum piston is too high. (See page 181 for details.) 1 mm 0.04" 26030 40501E2 SmartStacker User's Manual...

  • Page 360: Double Feeding

    • Increase the grip area of the separator. The grip area of the separator is too narrow. (See page 181 for details.) 26030 40501A1 • Increase the separator angle. The separator is not producing enough (See page 181 for details.) pressure. 26030 40501B1 SmartStacker User's Manual...
  • Page 361 1 mm 0.04" 26030 40501E1 • Decrease the vacuum setting to reduce The pump is producing too much vacuum. the vacuum at the vacuum piston head and the feed rotor. (See page 182 for details.) Vacuum 26030 40501F1 SmartStacker User's Manual...
  • Page 362 Problems with the Sheet Feeder Problem Possible Cause and Solution • Set the blower air outlets in a higher The blower air outlets are Blower Position Adjusting Knob too low. positions. (See page 183 for details.) 26030 40401G1 Blower Pressure Lever SmartStacker User's Manual...

  • Page 363: Clearing The Sheets After A Jam

    26030 plete job. 40601A1 be rejected to the waste tray in the 1st or 2nd Process unit as an incomplete job. Waste Tray in 1st Process Unit Waste Tray in 2nd Process Unit SmartStacker User's Manual...

  • Page 364: Removing The Jammed Sheets

    1st Process Unit. 26030 40701A1 2nd Process Unit and Merge Conveyor (Upper) Release Lever (Upper) Release Lever (Lower) (Lower) Handwheel Turn this handwheel to rotate the rollers in the 2nd Process Unit. 26030 40701B1 SmartStacker User's Manual...
  • Page 365 This guide opens when the release lever is turned. Handwheel Turn this handwheel to rotate the rollers in the Merge Stacker. 26030 40701C1 Handle Shaft Pull Down This guide lowers when the handle shaft is pulled and lowered. SmartStacker User's Manual...
  • Page 366 Turn this handwheel to rotate the transport rollers in the B2 Stacker. Release Lever Handwheel Turn this handwheel This guide opens to rotate the feed roll- when the release ers in the B2 Stacker. lever is turned. 10606650901B1 SmartStacker User's Manual...
  • Page 367 If a Jam Occurs B2 Stacker (Option) 10606650901C1 Feeder (Option) SmartStacker User's Manual...
  • Page 368 This page is intentionally left blank.

  • Page 369: 7 Maintenance

    7 Maintenance This chapter explains how to clean and lubricate the machine, and replace the consumables. WARNING Turn off the Power switch before performing any main- tenance operation. Otherwise, a sudden start of the machine can cause severe personal injury or damage the machine.

  • Page 370: Smartstacker

    Turn off the Power switch before cleaning the sensor. Otherwise, if any button is pressed by accident, it can cause severe personal injury. 1st Regist Unit / 1st Process Unit B140 B141 B120 B110 B150 Reflector Reflector B151 SmartStacker User's Manual...
  • Page 371 SmartStacker 90-degree Turn Conveyor / 2nd Regist Unit Reflector B211 B220 B231 B212 B232 B253 B251 B260 Reflector B252 SmartStacker User's Manual...
  • Page 372 SmartStacker Merge Conveyor B340 B322 B310 B320 B332 B330 B590 B593 B594 B595 10606660101B1 SmartStacker User's Manual...
  • Page 373 Unlock the latches and lift the cover up. Reflector for B420 B446 Clean the reflector through this hole. The reflector can be cleaned only B420 when the delivery conveyor and the fork mechanism are lowered. B462 B448 B461 SmartStacker User's Manual...
  • Page 374 SmartStacker B2 Stacker (Optional) B525 B550 B526 B524 B521 B523 B520 B522 Reflectors Reflectors B510 B512 10606660101A1 SmartStacker User's Manual...

  • Page 375: Cleaning The Air Filter

    Frequency of Cleaning the Air Filter for Power and Board Box: Once a month • Wash the filter with water. • If the filter is still contaminated, re- place it with a new filter. 1st Regist Unit 2nd Regist Unit Back View SmartStacker User's Manual...
  • Page 376 SmartStacker Merge Conveyor Merge Stacker B2 Stacker (Optional) SmartStacker User's Manual...

  • Page 377: Cleaning The Belts

    Cleaning the Belts Frequency of Cleaning the Transport Belts: Once a week Wipe the belts using a dry cloth. If the belts are still contaminated, use an alcohol-soaked cloth. 1st Regist Unit Transport Belt 90-degree Turn Conveyor Vacuum Belt SmartStacker User's Manual...
  • Page 378 SmartStacker Merge Stacker Vacuum Belt Unlock the latches and raise the delivery unit. Conveyor Belt Transport Belt SmartStacker User's Manual...
  • Page 379 SmartStacker B2 Stacker (Optional) Vacuum Belt SmartStacker User's Manual...

  • Page 380: Lubrication

    = Apply grease with a brush = Lubricate with oil = Apply grease with a grease gun 90-degree Turn Conveyor Chain x 2 Gripper 26030 60104A1 26030 60104A2 Move the gripper by hand, and lubricate the chains with supplied oil. SmartStacker User's Manual...
  • Page 381 SmartStacker Merge Conveyor SmartStacker User's Manual...

  • Page 382: Checking The Sheet Guide

    These sheet guides may bend if they are kept being pressed by the cutter holder. Check the sheet guides once a week. 1st Process Unit Sheet Guides 2nd Process Unit Sheet Guides SmartStacker User's Manual...
  • Page 383 2nd Process Unit Keep the removed trim guides on this. Remove two locking screws on the cutter unit. Hold the handle and draw out the cutter unit until it stops. The rail stops at the bearing here. SmartStacker User's Manual...
  • Page 384 SmartStacker If the sheet guides are pressed by the cutter holder, turn the pulley manually and move the sheet guides. Check the sheet guides whether they bend or not. Pulley Pulley 26030 60105A1 SmartStacker User's Manual...
  • Page 385 Be careful with the upside and downside of the guide. 26030 60105A2 To remove the lower sheet guide, move it down. After checking and attaching the sheet guides, return the cutter unit. Tighten two locking screws for cutter unit. Attach the removed trim guides again. SmartStacker User's Manual...

  • Page 386: Checking The Rollers

    2nd Process Unit Roller • See page 383 and draw out the cutter unit. Check for chips fallen on the frame. • If you find many chips, rollers should be replaced. Contact a service technician. Frame 26030 60106A1 SmartStacker User's Manual...

  • Page 387: Optional Sheet Feeder

    • Blow the paper dust inside of the vacuum piston and the holes on the suction head away with compressed air. • Wipe the piston using a dry cloth. If it is difficult to remove the dirt on the vacuum piston, wipe with alcohol or kerosene. SmartStacker User's Manual...
  • Page 388 Optional Sheet Feeder Frequency of Cleaning the Air Filter for Power and Board Box: Once a month • Wash the filter with water. • If the filter is still contaminated, re- place it with a new filter. SmartStacker User's Manual...

  • Page 389: Replacing The Separator And Suction Rubbers

    If the suction rubber is broken or deteriorates, replace it with the new one which is supplied in the accessories. Turn off the Power switch. Pull out the suction rubber to remove it from the groove. Install the new suction rubber. 26030 60202B1 SmartStacker User's Manual...
  • Page 390 This page is intentionally left blank.

  • Page 391: 8 Appendix

    8 Appendix This chapter lists the specifications for this machine.

  • Page 392: Specifications

    Specifications 8-1-1 Specifications of SmartStacker Model SmartStacker Sheet Size (Before Cut) Width x Length Width x Length Merge Stacker B2 Stacker Max. 762 x 530 mm or 30.000” x 20.865” Max. 762 x 530 mm or 30.000” x 20.865” Min. 279.4 x 330 mm or 11.000” x 12.995”...
  • Page 393 Infeed registration: Rear Height registration for inline: 1,000±10 mm or 39.37”±0.39” from the floor Height registration for near line/offline: 1,020±10 mm or 40.16” ±0.39” from the floor Merge Stacker: 700±10 mm or 27.6”±0.39” from floor Stack Delivery Height SmartStacker User's Manual...
  • Page 394 3-phase 208 V, 60 Hz, 14 A 3-phase 400 V, 50 or 60 Hz, 7.1 A B2 Stacker (Option) 3-phase 200 to 220 V, 50 or 60 Hz, 3.4 A Noise Level SmartStacker with Sheet Feeder eq: 80.0 dB SmartStacker eq: 78.7 dB Machine Weight 1st Regist Unit: 336 kg or 740.1 lb...

  • Page 395: Specification Requirement On Pc For Flc

    Windows 7 Professional (64 bit), Windows7 (32 bit), Windows8 (32 bit, 64 bit), Operating System Windows10 (32 bit, 64 bit) Computer Memory 4 GB or more Hard Disk Drive 512 GB or more Screen Resolution 1,920 x 1,080 pixels Installation Destination C:\Program Files\Horizon\FLC SmartStacker User's Manual...

  • Page 396: Accessories

    Adjusting Tool 2 pcs 26030 70201D1 26030 70201C1 Bolt Caps 8 pcs Air Filter for Power and Board Box 5 pcs 26030 70201D2 Ground Wires (Long) 2 pcs Ground Wires (Short) 5 pcs 26030 70201F1 26030 70201E1 SmartStacker User's Manual...
  • Page 397 Accessories Ground Wires (Yellow/Green) 1 pc Ground Wires (Black) 1 pc 26030 70201G1 26030 70201G2 Cables for SmartStacker 1 pc Power Cable 1 pc For 200V-220V (Except for UL Version) 26030 70201G3 26030 70201G4 Power Cables 2 pcs Transformer 1 pc...
  • Page 398 Stubby Screwdriver 1 pc T-handle Hexagon Wrench (4mm) 12090 90201K1 13074 11202J1 Reversible Screwdriver 1 pc Tweezers 1 pair 26030 70201N1 26030 70201K3 Oil Applicator 1 pc Allen Wrench 1 pc 17 mm 16060 26030 70201T1 70201K1 SmartStacker User's Manual...
  • Page 399 Accessories used for First and Second Process Unit Trim Guides 1 pc Screws 4 pcd PW10 SB10-16 26030 70201H2 26030 70201H1 These are used to lock the units. Air Hose for Trim Ejection 1set Air Duct Hose Clamp Air Hose 26030 70201L1 SmartStacker User's Manual...
  • Page 400 Accessories used for Merge Stacker Step 1 pc Anti-drop Guide 1 pc 26030 26030 70201J2 70201J1 Manual Cases 2 pcs Side Guide 1 pc 26030 26030 70201J3 70201J4 Stopper 1 pc Locking Bracket 1 pc 26030 26030 70201J5 70201J6 SmartStacker User's Manual...

  • Page 401: Optional Sheet Feeder Accessories

    M5-12CRZP x4 B4-8B x3 B5-10TP x 2 26030 70201J9 8-2-2 Optional Sheet Feeder Accessories Pump and Manual 1 each Label 1 pc 23053 11201B1 Slope Plates (small) 1 pc Slope Plates (large) 1 pc 26030 26030 70202C1 70202C2 SmartStacker User's Manual...
  • Page 402 15 sets Red LAN Cable 1 pc SB6-16 26030 70201R1 26030 70401B1 Cable (No.20) 1 pc Cable (No.11) 1 pc 26030 26030 70401B3 70401B2 Feed Guides 2 pcs Smaller feed guides 2 pcs 26030 26030 70202H1 70202H2 SmartStacker User's Manual...
  • Page 403 Accessories Suction Cup (N8) 10 pcs Suction Cup (N5) 10 pcs 26030 26030 70201S1 70201S1 Separator 1 pc Wedge 4 pcs 26030 70201Q1 13074 11201P1 Ground Wire (550mm) 1 pc 26030 70201E1 SmartStacker User's Manual...

  • Page 404: Component Parts For Flc-H

    Vertical Articulated Arm and User’s Manual 1 set 26030 26030 70203C1 70201J3 Install this case inside the frame of Install this to the work table to lock the work table. the monitor. Installation CD-ROM 1 set 26030 70201O1 SmartStacker User's Manual...

  • Page 405: Optional B2 Stacker Accessories

    M5-12CRZP x 2 106066 70204F1 Entrance Unit Bracket 2 pcs Timing Belt for Entrance Unit 1 pc 106066 70204T1 106066 70204G1 B5-10ZP x 8 Middle Unit 1 set Register Unit 1 set 106066 70204X1 M5-12CRZP x 5 106066 70204W1 SmartStacker User's Manual...
  • Page 406 70204I1 Duct500 1 pc Unit Locking Bracket 1 pc B5-10ZP x 8 B5-10ZP x 2 106066 106066 70204L1 70204K1 Connector Bracket 1 pc Base Frame 1 pc 106066 70204M1 B4-8ZP x 2 106066 M5-12CRZP x 9 70204N1 SmartStacker User's Manual...
  • Page 407 Hoisting Hooks 4 pcs PW16 x 4 106066 70204R1 TT4-8TP x 3 106066 70204Q1 Edge Saddle 1 pc Edge Saddle 1 pc 106066 106066 70204Y1 70204S1 Round Bushing 2 pcs Cable Clamp 2 pcs 106066 106066 70204V1 70204Z1 SmartStacker User's Manual...
  • Page 408 Power Input Wires for Inverter 3 pcs 106066 70205A1 106066 70205E1 Output Cable for Inverter 1 pc Ground Wire for Inverter 1 pc 106066 106066 70205D1 70205F1 LAN Cable for Inverter 1 pc Grease 1 pc 106066 70204U1 106066 70205G1 SmartStacker User's Manual...
  • Page 409 1 pc L-shaped Bracket R 1 pc SB8-16 x 2 SB8-16 x 2 106066 PW8 x 2 70205L1 PW8 x 2 106066 70205M1 Container 1 pc Left Lower Cover 1 pc TT4-8TP x 4 106066 70205N1 106066 70205O1 SmartStacker User's Manual...
  • Page 410 Power Box 1 set M5-12CRZP x 6 M5-12CRZP x 6 106066 106066 70205T1 70205U1 Bracket for Rear Lower Cover 1 pc Ground Wire 1 pc Between B2 Stacker and Merge Conveyor B5-10ZP x 2 106066 70205D1 106066 70205V1 SmartStacker User's Manual...
  • Page 411 This page is intentionally left blank.
  • Page 412 Manufacturer: www.horizon.co.jp/ Phone:+81-75-934-6700, Fax:+81-75-934-6708,...

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