Baum 2020 Instruction Manual
  1. Manuals
  2. Brands
  3. Baum Manuals
  4. Folding Machines
  5. 2020
  6. Instruction manual

Baum 2020 Instruction Manual

1st station folder w/pile feed
Hide thumbs Also See for 2020:
Table of Contents

Advertisement

Quick Links

Download this manual See also: Service Manual
BAUM
BAUM 2020
1ST STATION FOLDER W/PILE FEED
INSTRUCTION MANUAL
©Baumfolder Corp., 2005
Printed in U.S.A.
TP10243-3
PAGE 1
TP10243-3

Advertisement

Table of Contents
loading

Related Manuals for Baum 2020

Summary of Contents for Baum 2020

  • Page 1 BAUM BAUM 2020 1ST STATION FOLDER W/PILE FEED INSTRUCTION MANUAL ©Baumfolder Corp., 2005 Printed in U.S.A. TP10243-3 PAGE 1 TP10243-3...
  • Page 2 © 2005 BAUMFOLDER CORPORATION All Rights Reserved WARNING • Do not operate this machine without all guarding in place. • Do not make adjustments or perform maintenance on this machine with power on. • Keep the machine and the work area clean and free of spills to prevent accidents. •...

  • Page 3: Table Of Contents

    CONTENTS DESCRIPTION PAGE Safety .................................. 6 II.) Introduction Overview ............................7 III.) Transportation/Installation ..........................7 IV.) Squaring the Machine ............................7 Electrical Connections ............................8 1.0 . Wiring the Pump (3 phase) ........................8 1.1. Wiring the Pump (1 phase)..........................8 1.2.
  • Page 4 CONTENTS DESCRIPTION PAGE IX.) Pile Feeder Operation ............................37 1.0 . Loading ............................... 37 1.1 . Hold-down Locations .......................... 37 1.2 . Air and Vacuum Setting ........................37 1.3 . Front Blow Tube Settings ........................38 1.4 . Vacuum Wheel ............................ 38 Register Operation ............................
  • Page 5 List of Tables DESCRIPTION PAGE Table 1. Machine Setup Parameter List "A" ........................24 Table 2. Machine Monitor Parameter List ..........................24 Table 3. Machine Setup Parameter List "B" ......................... 25 Table 4. Machine Diagnostic Parameter List ......................... 26 Table 5. Future Features List ..............................26 Table 6.

  • Page 6: Safety

    SAFETY FIRST restarting the machine. 11. Never clean moving parts of the machine (rollers, Your new Baum paper folding machine has been designed shafts, etc.) or remove any test sheets or paper jams in accordance with the latest safety specifications. The while the machine is running.

  • Page 7: Ii.) Introduction Overview

    INTRODUCTION OVERVIEW Level the machine on the floor. Place a spirit level on the #2 fold roller (Figure 3) and on the feeder crossmembers. The 1st station [parallel] folder with pile feeder contains the following main components (Figure 1): Pile Feeder SQUARING THE MACHINE Register 1st Station Folder (Parallel)

  • Page 8: Electrical Connections

    The main power is connected directly to the line side of the main power switch. In a 2020 single phase use L1 and L2 only. All electrical connections are to be made by a certified electrician.

  • Page 9: Tapping The Transformer

    1.3 Tapping the Transformer Pass the power cable through the strain relief and the hole provided in the control box. Connect the power cable to the open terminals on the main disconnect in the control box. The incoming ground wire should be attached to the ground stud located in the lower right-hand corner of the control box.

  • Page 10: Vi.) "Quick Start" Instruction's

    BAUMFOLDER 2000 Series “QUICK START” INSTRUCTIONS TURNING THE MAIN SWITCH ON When you turn on the Main Power Switch located on the side of the Control Box , you must let the Control automatically run a self-test. During the self-test DO NOT Press any buttons. Pressing of a button will cause an Error Message to appear in the Main Display.
  • Page 11 Then Press the GREEN Button to lower Pile Feed Table. The Table will lower and stop automatically in its lowest position. STARTING PRODUCTION WITH THE BAUM 2020 To START the Folder Drive, Press the GREEN Button on the Control Panel just ABOVE the symbol, this will Start the Folder Drive and the Pump will automatically come on.
  • Page 12 The Easy-Mode is used for folds that require half of the sheet length or less going into the foldplate. These folding applications normally operate with a 1.0 Inch sheet gap. If you are folding half of the sheet length or more into the foldplate you must have a greater gap. TURN THE EASY-PARAMETER ON/OFF Press the Machine Setup button...
  • Page 13 Look to the right hand end of the counter display. If an “ 1 “ appears in the display the Easy- Parameter is turned on. If an “ 0 “ is displayed, the Easy-Parameter is turned off, see Figure E1. To turn the Easy-Parameter on or off, Press the Plus (+) button for the batch...
  • Page 14 SELECT CONTINUOUS CYCLE MODE It is recommended to use the continuous cycle mode when the job requires more than ½ of the sheet length to go in the #1 fold plate or if the product has a window that will be sensed as the trailing edge of the sheet.
  • Page 15 TO START FEEDING Press the GREEN Button to START the Folder Drive and the Pump. Press the GREEN Button ABOVE the symbol to START the Vacuum Solenoid. The Sucker Wheel will pull a sheet from the Feeder onto the Register. TO STOP FEEDING Press the RED Button BELOW the symbol.
  • Page 16 EXAMPLE: Hold the MINUS Button, this will automatically count back to P00 (group P0). Now by Pressing the Button will take you to the next Parameter Group P10 – P20 - P30 – P40 – P50 – P60 Pressing directly UNDER the left 3 digits of the Large 8 digit display, this will select the individual Parameters in a select group.
  • Page 17 PAGE 17 TP10243-3...
  • Page 18 To get out of the Machine Parameter Settings Mode, Press again. The displays will return to normal operations. BATCH COUNTING SETUP To enter Batch Count Set-Up, Press This will bring up 3 display functions on the Control Panel. First is the Small 3 digit display – this display must show If the display shows any other Mode, the Batch Counter will not function.
  • Page 19 Buttons directly UNDER the 2 digit display until the desired delay number is displayed. EXAMPLE: This is set-up for 10 pieces in a Batch with a 1.5 second delay between Batches. To return back to RUN mode, Press Button and set either the Batch Size or Time Delay to Zero and the Folder will run continuously.
  • Page 20 RESETTING THE TOTAL COUNTER To reset the Total Counter, Press Button ; ensure the red LED is illuminated. Press Button and HOLD DOWN for 3 SECONDS, The Large 8 digit display will begin to Count BACKWARDS from 5.4.3.2.1, then display CLEARED, the Counter is then ZERO. You MUST Press and HOLD Button as the display is counting BACKWARDS, if at anytime the...

  • Page 21: Vii.) Installing Fold Plates & Stacker Delivery

    INSTALLING FOLD PLATES & STACKER OPERATOR CONTROLS DELIVERY The main operator control panel (Figure 8) is located at the pile feeder. See the "Control Panel" section for a detailed Install the fold plates into the folder. When installing description of all the buttons. the fold plates, take note of the symbol on the fold plate stop (Figure 7-1).

  • Page 22: Control Panel Ban-5

    Control Panel BAN-5 BAUMFOLDER CORPORATION Figure 1. Control Panel. 1.1 Displays 06) Input Indicator 01) Large Display The input indicator shows the status of the suction Eight digit multi use display composed of 7- photo-eye. segment LED’s. 07) Output Indicator 02) Small Display The output indicator lights when the Batch Preset Three digit multi use display composed of 7-...

  • Page 23: Keypad Buttons With Selection Indicators

    1.4 Keypad Buttons with Selection Indicators Machine Setup/Diagnostic Mode 18) Show Output Count 19) Show Batch Count and Number of Batches 20) Show Current Rate Pushing this key puts the controller in machine setup 21) Show Input Count mode. 22) Learn Mode 23) Make Ready Mode Machine setup mode provides a method to view and optionally change operating parameters for the controller.

  • Page 24: Table 1. Machine Setup Parameter List "A

    2.1.1 Machine Setup Parameters Parameter Function Type Variable Displayed Input Factor Setup Variables Adjustable 1-24 Output Factor Setup Variables Adjustable 1 to Input Factor Tremat Setup Variables Adjustable 1 or 0 Knife Setup Variables Adjustable 1 or 0 Table 1. Machine Setup Parameter List P02: Tremat P00: Input Factor This is an unavailable option.

  • Page 25: Table 3. Machine Setup Parameter List "B

    2.1.3 Machine Setup Parameters Function Type Variable Displayed Units of Measure Setup Variables Adjustable Inches, Meters Language Setup Variables Adjustable English, German, Codes Network Address Setup Variables Adjustable 0-255 Pause Setup Variables Adjustable 1 or 0 Network Setup Variables Adjustable 1 or 0 Easy Setup Variables...

  • Page 26: Table 4. Machine Diagnostic Parameter List

    P28: Serial Output Type This selection, in maintenance mode, shows selected serial output type. 2.1.4 Diagnostic Parameters Status Input Port 1 P30.1 P30.2 P30.3 P30.4 P30.5 P30.6 P30.7 P30.8 Pile Motor Function Pile Down Pile Stop Pile Up Compress. Compress. Drive Start Energized Control K1...

  • Page 27: Counter Setup Mode

    2.1.6 Machine UsageStatus Parameters Function Type Variable Displayed Power on time Machine Status Based on Inputs Time in 1/100 Hours Machine run time Machine Status Based on Inputs Time in 1/100 Hours Total Input Sheets Machine Status Based on Inputs Number in 1000 Sheets Table 6.

  • Page 28: Easy Mode And Continuous Cycle Mode

    Batching Time Adjustment Pressing these buttons will toggle between the EASY mode or cYcL mode. Set EASY in the large display and The batching time adjustments allow the user to select the time duration associated with the currently selected press again.

  • Page 29: Make Ready Mode

    If P06 is set to 0 (no knife is active) and 10 cm /4.0 inches. If Select Suction Mode P06 is setting to 1, knifes are active. These keys toggle between automatic control and cycle Gap Length Adjustment mode. In the cycle mode, the suction valve will be on for the suction length and off for the remainder of the sheet length plus the gap length.

  • Page 30: Network Job Mode

    Exit Make Ready Mode Production Mode Enter Run Mode and Select Large Display Content These keys do not operate as mode select keys in Pressing any of these keys will cause the controller to counter setup. In all other modes, the keys both select the change to a new mode.

  • Page 31: Logic Board Status Indicators

    Reset Function Pressing and holding this key will result in a reset function being activated after a 5-second countdown. The function is based on the current large display selection, see Reset while showing Output Count will reset all job table 12. The large display (1) will show countdown to variables.

  • Page 32: Process Variables Definitions

    The Current Rate is rounded to the nearest hundreds. Process Variables Definitions Current Rate can range from 0 to 99,999,900. This process variable is not stored in memory. 4.1 Total Input Count 4.6 Main Drive Run Time Total Input Count increments by the factor setting each time an input is received at the Input Count input.

  • Page 33: Batch Output Time

    5.3 Batch Output Time This parameter, accessible in the Batch Setup mode, specifies the output duration or delay that will be used when the Batch Count Down reaches zero. Available ranges are determined by the Batch Output Type selected. The Table below shows the ranges for each output type.

  • Page 34: System Messages And Run Messages

    6.0 System Messages and Run Messages 6.1 Power-Up Fault Messages Messages that are displayed during power on self-test. If PLC System Errors are shown in the display, call service. ENGLISH GERMAN CODES TYPE DESCRIPTION 88888 88888 88888 Information The controller is performing its lamp test. MEM TEST MEM TEST MEM TEST Information The controller is performing its RAM test.

  • Page 35: Run Time Fault Messages

    6.2 Run Time Fault Messages Run time fault messages are only displayed when the unit is in Run mode. Fault errors can still occur, but the corresponding fault message will not be displayed until the unit is switched to Run mode. Run time fault messages are PLC System Errors or errors in the whole Electric System.

  • Page 36: Machine Run Error Messages

    6.3 Machine Run Error Messages Machine Run Error Messages help the operator to indicate a production problem. ENGLISH GERMAN CODES TYPE DESCRIPTION Stop Stop1 Stop1 Information One of the stop buttons is depressed. ACTION: Make sure all stop buttons are cleared and connectors X21, and X22 are seated.

  • Page 37: Ix.) Pile Feeder Operation

    PILE FEEDER OPERATION 1.0 Loading the Pile Feeder Set the right hand side guide (Figure 11-1) to half the sheet using the scale (11-2). The vacuum wheel is in the center of the sheet. Lock the guide in place using the lever (11-3).

  • Page 38: Front Blow Tube Settings

    1.3 FRONT BLOW TUBE SETTINGS The front blow consists of two tubes (Figure 13-1 & 2 and Figure 15-1 & 2) instead of the traditional one tube. The numbers on the left hand side of the tubes correspond to the chart (Figure 15-3) found on the side of the main control enclosure.

  • Page 39: Register Operation

    The fluted knob (19-6) provides microadjust-ment of the side guide (19-2). Knurled knobs (19-7) provide bias adjust- ment for the side guide for adjusting sheets that are not square or for other unusual conditions. The double sheet control (Figure 20) is adjusted to the thickness of the paper being fed by pulling up the lever (20- 1) and inserting two paper strips (20-2) of the sheets to be folded in the clip at the back of the lever.

  • Page 40: Baumset Adjustment

    A double sheet strikes the scanner on the microswitch, With single sheet thickness, the scanner remains un- interrupting the sheet flow-through. touched and sheets move freely. BAUMSET ADJUSTMENT Figure 21 1.0 Adjustment of Folding Rollers Folding accuracy is determined largely by precise adjustment of the folding rollers. Using the Baumset precision adjustment device, the correct setting of the rollers can be made simply by inserting the appropriate paper thickness between the adjustment plates.

  • Page 41: Xii.) Setting Fold Plates

    SETTING OF FOLD PLATES Be sure that the adjustment screw (23-2) is in contact with the support rail on both sides. Clamp the fold plates with the clamping screw (Figure 23-3). NOTE: The sheet-stop (23-4) should be moved to the desired Check the symbols on the fold plate stop (Figure 23-1) for fold length according to the scale (23-5) by loosening the installation of the fold plate swing deflectors (Figure 24-1)

  • Page 42: Xiv.) Stacker Operation

    Check that the adjustment screws (26-4) are in contact with the support rail (26-5) on both sides. The basic position is marked by a notch (26-6) in the fold-plate frame. Setting Stationary Deflector (Separate sheet deflector) (Figure 27-1) The stationary sheet deflectors are installed and clamped in place in the same way as the fold plates.

  • Page 43: Xv.) Scoring/Slitting/Perforating

    SCORING/SLITTING/PERFING Your new folder is capable of many different applications that compliment the folding performance and provide for greater productivity. The folder is equipped with slitter shafts that are quickly set up for the required operation. These shafts accommodate the mounting of the standard and optional accessories available that perform scoring, slitting and perforating functions. 1.0 Slitter Shaft Accessories Removal To remove slitter shafts, remove knob (Figure 29-1).

  • Page 44: Scoring

    1.1 Scoring The folder can be used to score a sheet and deliver it flat, or to score a sheet after a fold or folds have been made. To ensure accuracy in making right angle folds, always score the sheet where the fold or folds are to be made.

  • Page 45: Perforating

    1.2 Perforating The folder may be used for perforating either the heads of booklets (to allow the air to escape in making right-angle folds) or to slot perforate sheets delivered flat, using blades and strippers best adapted for a particular job. All perforating blades are mounted on the upper shaft and run a side of the steel collar on the lower shaft with the flat side of the blade just touching the anvil.

  • Page 46: Slitting

    1.3 Slitting (Cutting) Sheets Folders may be used to cut folded or flat sheets apart. Two or more cuts may be made if duplicate sets of slitters are used. Be careful when mounting slitter blades to collars in order to avoid ragged edges which can be caused by two conditions: 1) Nicks or burrs on the collars or blades.

  • Page 47: Trimming

    1.4 Trimming Edges of Booklets Figure 30 shows the setup of cutting blades and strippers for trimming edges of booklets or outer edges of circulars running two or more up. Cutting blades are attached to blade holder collars so that the bevel of blades on the upper shaft are directed toward the strip being trimmed and the bevel of blades on the lower shaft are directed away from the strip.

  • Page 48: Trimming A Strip From Center Of Sheet

    1.5 Trimming a Strip from Center of Sheet Figure 31 shows the setup for taking a quarter inch trim out of the center of a sheet. Two or more trims may be made as long as duplicate sets of cutters and strippers are used and this setup adhered to. A strip three sixteenths of an inch wide is the minimum trim.
  • Page 49 Center Trimming Spacers for setting width of strip Slitting Blades are located tight against the sharp, flat side of the anvil. Center trim Center stripper wire. Lay wire stripping collar. in center groove and twist ends Note: Grooves in Rotates loose on together at the bottom.

  • Page 50: Xvi.) Lubrication/Maintenance

    Check periodically. Check vanes for wear after 15,000 hours of service. Refer to parts manual for ordering parts. Register Flat Belt Drive Shaft (hex shape) Check for wear periodically. Lubricate with Baum Lubricant "W". Lithium base grease or equivalent periodically. Support Bars Lubricate the three support bars on which the register guide slides periodically using Lithius base grease.

  • Page 51: Xvii.) Technical Specifications

    220 Volt, 3 phase, 60 Hz, 21 Amperes See serial plate on folder ACCESSORIES In addition to the various folding, slitting, perforating and scoring functions the Baum 2020 can perform even more productive functions using the following accessories and more. • Jam Detectors •...

  • Page 52: Xix.) Troubleshooting

    TROUBLESHOOTING PROBLEM CAUSE REMEDY Sheets stick together Inadequate ink drying, cut Fan out thoroughly when particularly along sides. with blunt guillotine blade. piling, increase blower air. Suction wheels picks Excessive suction. Reduce vacuum setting. up double sheets. Air blow improperly set Increase air blow Sheets stick together Double sheet stop...
  • Page 53 TROUBLESHOOTING - continued PROBLEM CAUSE REMEDY Sheets fails to re-emerge Product too thick for folding. Consult Baum technical rep. from buckle plate. Not enough roll pressures. Check Baumset settings. Sheet remains lying on Electrostatic charge in Fit discharge unit at the...

  • Page 54: Xx.) Operating Tips

    screws for the slitter shaft accessories facing out, so you OPERATING TIPS don't have to turn the shafts to get to the screws. Setup TIPS FOR FOLDING When setting up a job on your folder, watch so the sheet doesn't end up with either the RH or LH edge along the edge The following section contains a number of hints drawn of a fold pan or register plate.
  • Page 55 Fixing Crooked Perforations If misaligned perforations appear after the parallel folding station, first check for correct squareness setting of the register guide relative to the buckle plate stop. If square, the sheet deflector following the last buckle plate must be set back slightly on the side on which the sheet is tending to advance.

  • Page 56: Xxi.) Principles Of Mechanical Folding

    Principles of Mechanical Folding The buckle folding principle In buckle folding, each station consists of three rollers and a buckle plate. The first two rollers are arranged one vertically above the other and they carry the incoming sheet into the buckle plate until it reaches a feed guide stop that can be adjusted as required.

  • Page 57: Xxii.) Job Setup Example

    JOB SETUP EXAMPLE This sheet is only a guide to setup and operation of the Baum 2015/2018/2020 Pile feed folders. Jobs will vary and procedures will need to be modified. 1. Hand fold a sample as close as possible of the job to be run.
  • Page 58 JOB SETUP EXAMPLE many steel marbles can drive the sheet too hard and causing feeding problems. 1. Place register holddowns in proper locations for the sheet width being fed. Note that for 11x17 sheets being fed in the 11 inch width, place a register holddown between the LH see-thru guide and the vacuum wheel to keep air from cupping the sheet and causing stumbling.
  • Page 59 JOB SETUP EXAMPLE 1. Set the foldplates to the proper open and closed positions by rotating the stop blocks and placing the correct symbol for either open of closed to the position closest to the fold rollers. Then set the desired fold depths using the scale on the belt and reading at the yellow mark on the indicator.
  • Page 60 JOB SETUP EXAMPLE TP10243-3 PAGE 60...

  • Page 61: Xxiii.) Folding Chart

    DEFLECTOR OPEN SHEET STOP MAIN DRIVE DEFLECTOR OPEN DEFLECTOR CLOSED DEFLECTOR CLOSED SHEET STOP IMPOSITIONS 18 MOST POPULAR FOLDS PAGE 61 TP10243-3...
  • Page 62 On a buckle folder, the sheet is laid flat on a register table and then enters the fold pan assembly where it comes to a stop against the stationary fold plate stop. A series of buckles then forms throughout the sheet. The buckles whithin the fold pan are kept very small by the narrow channel design.

  • Page 63: Xxiv.) Manual Usage

    MANUAL USAGE Use this manual when you need to know how to set-up your folder to end up with a particular folded piece or, if possible, when planning the layout before printing the job. In most cases, the page numbers and their orientations after the fold are included.

  • Page 64: Xxv.) Typical Layout & Sheet Orientation

    TYPICAL LAYOUT AND SHEET ORIENTATION Each numbered Imposition Block in this manual contains: A. Imposition Title B. Fold Pans Used C. Sheet Layout D. Folded Sample SIDE GUIDE 2. Dashed lines represent folds. Page numbers or letters without circles are face up. Page numbers or letters with circles are on the underside of the sheet.

  • Page 65: Xxvi.) Impositions

    4-PAGE 4-PAGE, DOUBLE 6-PAGE, STANDARD Parallel: 1 IMPOSITION Parallel: 1, 3 May be folded two or Parallel: 1, 2, 3 May be folded two or more up and cut apart. May be folded two or more up and cut apart. more up and cut apart.

  • Page 66: 8 - Page, Right Angle Oblong

    8-PAGE, TWO RIGHT 8-PAGE, RIGHT 8-PAGE, PARALLEL ANGLE OBLONG ANGLE DOUBLE OVER & OVER Parallel: 1 IMPOSITION Parallel: 1, 2, 4 8-Page: 1 Parallel: 1 May be run two or 8-Page: 1, 2, 3 more up and cut apart. 12-PAGE BOOK, 12-PAGE BOOK, 12-PAGE LETTER SADDLE STITCH...

  • Page 67: 12 - Page Letter Fold, Heads In

    12-PAGE LETTER 12-PAGE LETTER 16-PAGE, THREE FOLD, HEADS IN FOLD, ACCORDION RIGHT ANGLE BOOK Parallel: 1 Parallel: 1 IMPOSITION 8-Page: 1, 3 8-Page: 1, 2 Parallel: 1 8-Page: 1 16-Page: 1 May be run two or more up and cut apart.

  • Page 68: Xxvii.) Service

    BAUMFOLDER C O R P O R A T I O N Quality Bindery Equipment Since 1917 1660 Campbell Road Sidney, Ohio 45365-0728 Phone: 937/492-1281 or 800/543-6107 Fax: 800/452-0947 Internet: www.baumfolder.com E-mail: baum@bright.net TP10243-3 PAGE 68...

Table of Contents