Baum 2020 User manual

PAGE 1 TP10243-3
BAUM 2020
1ST STATION FOLDER W/PILE FEED
INSTRUCTION MANUAL
©BaumfolderCorp.,2005 PrintedinU.S.A. TP10243-3
BAU
M

TP10243-3 PAGE 2
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.
• Be sure to replace any safety decals that may have been detached for any reason.
Baumfolder Corporation reserves the right to make changes in design or to make additions or
improvements in its products without imposing any obligation upon itself to install them on its
previously manufactured products. It is recommended that modifications to this equipment not be
made without the advice and express written consent of Baumfolder Corporation.
©2005 BAUMFOLDERCORPORATION
All Rights Reserved
FOLDERIDENTIFICATION
MODEL NO: _______________________________ SERIAL NO: _____________________________
SALES AGENCY:____________________________________________________________________
INSTALLED BY: _____________________________________________ DATE: ________________
PHONE NO: _______________________________

PAGE 3 TP10243-3
CONTENTS
DESCRIPTION PAGE
I.) Safety .................................................................................................................................................................. 6
II.) IntroductionOverview ........................................................................................................................................ 7
III.) Transportation/Installation................................................................................................................................7
IV.) SquaringtheMachine........................................................................................................................................ 7
V.) ElectricalConnections ....................................................................................................................................... 8
1.0 .Wiring the Pump (3 phase) ................................................................................................................... 8
1.1. WiringthePump (1phase).................................................................................................................................8
1.2. Other Connections ............................................................................................................................... 8
1.3 .Tapping the Transformer...................................................................................................................... 9
1.4 .Pump Connections ................................................................................................................................9
VI.) "QUICKSTART"INSTRUCTION'S .............................................................................................................. 10
VII.) InstallingFoldPlates&StackerDelivery ...................................................................................................... 21
VIII.) OperatorControls ............................................................................................................................................ 21
1.0 .Setting Folding Speed ......................................................................................................................... 21
1.1 .Setting StackerBelt Speed................................................................................................................... 21
1.2 .Emergency Stop Button....................................................................................................................... 21
1.0 ControlPanelBAN-5 ................................................................................................................................ 22
1.1 .Displays............................................................................................................................................... 22
1.2 .Machine Status Indicators .................................................................................................................. 22
1.3 .Machine Control Pushbuttons ............................................................................................................ 22
1.4 .Keypad Buttons with Selection Indicators.......................................................................................... 23
1.5 .Keypad Buttons for Selection Adjustments........................................................................................ 23
2.0 RUNMODEFUNCTIONS ................................................................................................................................23
2.1 .Machine Setup and Diagnostic Mode................................................................................................. 23
2.2 .Counter Setup Mode ........................................................................................................................... 27
2.3 .Easy Mode and Continuous Cycle Mode ........................................................................................... 28
2.4 .Learn Mode ......................................................................................................................................... 28
2.5 .Make Ready Mode .............................................................................................................................. 29
2.6 .Network Job Mode .............................................................................................................................. 30
2.7 .Production Mode ................................................................................................................................ 30
3.0 LOGIC BOARD STATUS INDICATORS ............................................................................................................. 31
4.0 ProcessVariablesDefinitions.................................................................................................................. 32
4.1 .Total Input Count ................................................................................................................................ 32
4.2 .Total Output Count ............................................................................................................................. 32
4.3 .Batch Down Count .............................................................................................................................. 32
4.4 .Number of Batches .............................................................................................................................. 32
4.5 .CurrentRate......................................................................................................................................... 32
4.6 .MainDriveRunTime .......................................................................................................................... 32
4.7 .MainDriveVelocity............................................................................................................................. 32
4.8 .WasteCount(DCT500) ....................................................................................................................... 32
5.0 COUNTER SETUP VARIABLES ....................................................................................................................... 32
5.1 .Batch Preset......................................................................................................................................... 32
5.2 .Batch Output Type.............................................................................................................................. 32
5.3 .Batch OutputTime .............................................................................................................................. 33
5.4 .Sheet Length ....................................................................................................................................... 33
5.5 .GapLength .......................................................................................................................................... 33
5.6 .Suction Length .................................................................................................................................... 33
6.0 SYSTEM MESSAGES ANDRUN MESSAGES ....................................................................................................... 34
6.1 .Power-Up Fault Messages .................................................................................................................. 34
6.2 .Run Time Fault Messages ................................................................................................................... 35
6.3 .Machine Run Error Messages ............................................................................................................. 36

TP10243-3 PAGE 4
CONTENTS
DESCRIPTION PAGE
IX.) PileFeederOperation ...................................................................................................................................... 37
1.0 .Loading ............................................................................................................................................... 37
1.1 .Hold-down Locations .......................................................................................................................... 37
1.2 .AirandVacuum Setting....................................................................................................................... 37
1.3 .Front Blow Tube Settings.................................................................................................................... 38
1.4 .VacuumWheel .................................................................................................................................... 38
X.) RegisterOperation .......................................................................................................................................... 39
1.0 .Double Sheet Detector ........................................................................................................................ 39
XI.) BaumsetAdjustment ........................................................................................................................................ 40
1.0 .Adjusting Folding Rollers ................................................................................................................... 40
XII.) SettingFoldPlates ........................................................................................................................................... 41
XIII.) SettingDeflectors ............................................................................................................................................ 41
XIV.) StackerOperation ........................................................................................................................................... 42
XV.) Scoring/Slitting/Perforating........................................................................................................................... 43
1.0 .SlitterShaftRemoval ........................................................................................................................... 43
1.1 .Scoring ................................................................................................................................................ 44
1.2 .Perforating ........................................................................................................................................... 45
1.3 .Slitting ................................................................................................................................................. 46
1.4 . Trimming .............................................................................................................................................. 47
1.5 .TrimmingaStripfromCenterofSheet ................................................................................................. 48
1.6 .BladeInstallation ................................................................................................................................. 48
XVI.) Lubrication/Maintenance................................................................................................................................. 50
XVII.) TechnicalSpecifications .................................................................................................................................. 51
XVIII.) Accessories ...................................................................................................................................................... 51
XIX.) Troubleshooting ............................................................................................................................................... 52
XX.) OperatingTips ................................................................................................................................................. 54
XXI.) PrinciplesofMechanicalFolding .................................................................................................................... 56
XXII.) Jobsetupexample............................................................................................................................................. 57
XXIIi.) FoldingChart ................................................................................................................................................... 61
XXIV.) ManualUsage ................................................................................................................................................... 63
XXV.) TypicalLayout&SheetOrientation ................................................................................................................ 64
XXVI.) Impositions ....................................................................................................................................................... 65
#1 4-PAGE ............................................................................................................................................... 65
#2 4-PAGE,DOUBLEIMPOSITION ........................................................................................................ 65
#3 6-PAGE, STANDARD......................................................................................................................... 65
#4 6-PAGE,ACCORDION ....................................................................................................................... 65
#5 8-PAGE,PARALLELIMPOSITION .................................................................................................... 65
#6 8-PAGE,RIGHTANGLE ..................................................................................................................... 65
#7 8-PAGE,RIGHTANGLEOBLONG ..................................................................................................... 66
#8 8-PAGE,RIGHTANGLEDOUBLEIMPOSITION ............................................................................... 66
#9 8-PAGE,PARALLELOVER &OVER .................................................................................................. 66
#10 12-PAGEBOOK,SADDLESTITCH ................................................................................................... 66
#11 12-PAGEBOOK,SADDLESTITCH ................................................................................................... 66
#12 12-PAGELETTERFOLD,HEADSOUT ............................................................................................. 66
#13 12-PAGELETTERFOLD,HEADSIN ................................................................................................. 67
#14 12-PAGELETTERFOLD,ACCORDION............................................................................................. 67
#15 16 -PAGE,THREE RIGHTANGLEBOOKIMPOSITION .................................................................... 67
#16 12-PAGEFOLDER,HEADSOUT ....................................................................................................... 67
#17 24-PAGEBOOKLET ........................................................................................................................... 67
#18 32-PAGEBOOK .................................................................................................................................. 67
XXVII.) Service ............................................................................................................................................................ 68

PAGE 5 TP10243-3
List of Tables
DESCRIPTION PAGE
Table 1. Machine Setup Parameter List "A" ........................................................................................................................ 24
Table2. MachineMonitor ParameterList ............................................................................................................................ 24
Table 3. Machine Setup Parameter List "B" ......................................................................................................................... 25
Table4.MachineDiagnosticParameter List......................................................................................................................... 26
Table 5. Future Features List ................................................................................................................................................ 26
Table 6. Machine Usage Status Parameter List ..................................................................................................................... 27
Table 7. Output Type Animations ........................................................................................................................................ 27
Table 8. Count Source Selection ........................................................................................................................................... 28
Table 9. Learn Mode Status ................................................................................................................................................. 28
Table 10. Suction Mode Symbols ........................................................................................................................................ 29
Table 11. Suction Length Function ....................................................................................................................................... 29
Table12. Determining theLarge DisplayContents............................................................................................................... 30
Table13. ResetmodeSelection............................................................................................................................................. 31
Table14.LEDStatusIndicators............................................................................................................................................ 31
Table 15. Output Delay and Duration ................................................................................................................................... 33
Table 16. Power Up Fault Messages..................................................................................................................................... 34
Table 17. Run Time Fault Messages ..................................................................................................................................... 35
Table 18. Machine Run Error Messages ............................................................................................................................... 36

TP10243-3 PAGE 6
SAFETY FIRST
Your new Baum paper folding machine has been designed
in accordance with the latest safety specifications. The
warning and caution labels on the machine must remain in
place. Make sure all guarding provided is in place before
starting up and running the machine.
Due to the nature of the work process of paper folding
machines, there are parts and areas on the machine which
cannot be completely covered without interfering with the
operation of the machine. Therefore, sound personal work
habits and strict observance of all safety precautions is
required for the protection of the operator, co-workers, and
the machine.
Be sure to follow these
safety precautions:
1. Study the safety instructions at your plant and those
provided in this manual.
2. Study the operating instructions carefully before
operating the machine.
3. Make sure that your co-workers are familiar with the
work process, potential danger areas,
and all necessary safety measures.
4. Make sure that the machine is in good working order
before turning it on.
5. If the machine suddenly stops for whatever reason, do
not restart it right away. Someone may have stopped
the machine, but failed to press the emergency (Stop)
button. If the machine is restarted unexpectedly, your
co-worker could be seriously injured.
6. Always press the emergency (Stop) button first if you
stop the machine for adjustments or maintenance work
which must not be done while the machine is in
operation.
7. For extensive maintenance or repair work, turn off the
main power supply.
8. Never use improper or defective tools.
9. After making adjustments or after doing maintenance
or repair work, always make sure that all tools and
other objects are removed from the machine. Other-
wise, they might fall into the machine, causing severe
damage or injuries.
10. Make sure that all safety devices are in place before
restarting the machine.
11. Never clean moving parts of the machine (rollers,
shafts, etc.) or remove any test sheets or paper jams
while the machine is running.
12. Keep the floor around the entire machine clean.
Immediately clean up any oil, grease, or paint spills
from the floor. Remove tools, cleaning cloths, and
paper scraps from all work areas.
13. Never allow unauthorized personnel to make adjust-
ments on the machine, remove problem sheets, or start
the machine.
14. Never climb over the machine or crawl into it while it is
turned on.
15. Immediately repair or replace any safety devices which
have become ineffective or are missing.
16. Report any exposed cables or exposed electrical
connections.
17. Always have a certified qualified electrician perform all
electrical maintenance.
18. Do not make adjustments or perform maintenance with
the power on.
19. Become familiar with and follow the safety labels on
the next page. Replace any of these labels that are
damaged or lost.
Additional Notes:
20. Do not attempt to remove a paper jam, no matter how
minor it may appear to be, while the machine is
running.
21. When cleaning the fold rolls, use the handwheel for
turning. Be sure the power to the machine is off.
22. Turn off the machine before making any adjustments to
the scoring, perforating, or slitting attachments. Keep
hands and clothing away from the slitter shafts when
the machine is running.

PAGE 7 TP10243-3
INTRODUCTIONOVERVIEW
The 1st station [parallel] folder with pile feeder
contains the following main components (Figure 1):
1. Pile Feeder
2. Register
3. 1st Station Folder (Parallel)
4. Fold Roller Gapsets
5. Fold Plates
6. Slitter Shafts (not shown)
7. Delivery (Stacker)
8. Operator Controls
9. Double Sheet Detector (Caliper)
10. Vacuum Pump (not shown)
11. Handwheel
Figure2Figure2
Figure2Figure2
Figure2
Figure1Figure1
Figure1Figure1
Figure1
TRANSPORTATION/INSTALLATION
As soon as you receive your new folder, and before
removing the machine from the skid, check carefully for any
damage to the shipments. If any damage is found, promptly
contact your Baumfolder sales representative.
To lift the folder from the skid, place the fork lift rails
under the lower rails as shown in Figure 2. Note that the
fork lift must have at least a 1500 lb. capacity.
Remove all rust protection coating after unpacking the
folder.
Level the machine on the floor. Place a spirit level on
the #2 fold roller (Figure 3) and on the feeder crossmembers.
SQUARINGTHEMACHINE
It is essential that this folding machine is square in
order for it to work properly. To square the machine,
measure diagonally across corners from feeder frame to
folder frame (Figure 4). Dimensions shown are approxi-
mate. Be sure that the measurements taken are identical
within 1/16-inch. If the machine is out of square, shift the
frames in the direction needed until the proper squareness is
obtained.
Figure4Figure4
Figure4Figure4
Figure4
Figure3Figure3
Figure3Figure3
Figure3
#2FOLDROLL#2FOLDROLL
#2FOLDROLL#2FOLDROLL
#2FOLDROLL

TP10243-3 PAGE 8
Figure5
1.2 OtherConnections
Refer to the serial number plate for electrical
requirements. The serial number plate notes the voltage,
phase and hertz, minimum time delay fuse, total machine
amperage, and minimum wire conductor size for the main
power connection.
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. Refer to local building electrical codes for proper
and safe connections.
For the following items, refer to Figure 6. Run a power
cable from your distribution box to the main control box on
the pile feeder. Turn the main power switch to zero. Using
the appropriate tool, open the latches on the control box
door and open the door.
NOTE: The door is connected to the main box by a ground
wire that should not be removed.
GND
W2 U2 V2
U1 V1 W1
THERMALS
#1 #2 #3
#4 #5
G/Y
ELECTRICALCONNECTIONS
1.0WiringthePump(2020/3phase)
Connectthepressure/vacuumpump
atthepumpjunctionbox(Figure5)
usingtheattachedcable.Followthe
instructionstotheleftfortheproper
connections
Turnthemainpowerswitchtothe
"ON"position.Switchthepumpon
momentarilyandcheckforproper
rotationasindicatedbytherotation
arrowonthepump.Immediatelyturn
offthepumpiftherotationiswrong.
Iftherotationisincorrectinterchange
anytwoofthethreewires#1,#2or
#3inthepumpmotorterminalbox.
1.1WiringthePump(2020/1phase)
Connectthepressure/vacuumpump
atthepumpjunctionbox(Figure5)
usingtheattachedcable.Followthe
instructionstotheleftfortheproper
connections
GND
G/Y
W2 U2 V2
U1 V1 W1
THERMALS
#1 #2
#3
#4
Note:Dottedlineindicatesthechange
youneedtomakeifthepump
isrunningbackwards.
1 PHASE ONLY

PAGE 9 TP10243-3
1.3 TappingtheTransformer
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
controlbox.
To tap the transformer, read the incoming voltage at the
main disconnect. Then move the wire numbered 11L1 on the
transformer to the corresponding tap on the transformer.
Tighten all screw connections and close the door before
switching the machine on.
A connector is provided for power connection to the
stacker. The stacker must be plugged into the socket for the
machine to operate, if not, install the blind plug attached to
the box.
A connector is provided for power connection to the
second station (8-page) fold unit. If no additional folding
station is to be connected, the connector must be closed off
with a blind plug.
1.4 PumpConnections
Connect the air hoses to the pump. The small diameter
hose is connected to the vacuum side of the pump. Connect
it to the barbed fitting above the ball valve on one end and
the other end to the vacuum solenoid valve on the pile feeder.
Connect the larger diameter hose to the remaining outlet
port on the pump and to the barbed fitting on the pile feeder
at the end of the blow bar.
Troubleshooting tips and actions required for the
display messages that may appear on the control readout
may be found the "Diagnostic Messages" section of the
manual.
Figure6
1X1
1X2
1X7
1X10
1X12
2
3
1
4
6
75
8

TP10243-3 PAGE 10
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. To CLEAR Message turn Power
OFF at the Main Power Switch—WAIT
5 SECONDS, then turn Power back on.
1. Turn on Main Power Switch on left side of control enclosure.
- Wait until control finishes self-test.
2. Load paper on Pile Feed Table. Press Pile up GREEN Button
Pile will raise automatically to correct height.
NOTE: To STOP Pile—Press RED Button
3. To START Drive Motor & Pump—Press GREEN Button ABOVE the symbol.
To STOP Drive Motor —Press RED Button BELOW the symbol or Press EMER-
GENCY STOP BUTTON
RAISING AND LOWERING THE PILE FEEDER LIFT TABLE
1. After loading paper onto Pile Feeder Lift Table, Press the GREEN Button
This will raise the paper to the proper feeding height automatically. You
can stop the Pile Feeder Lift Table by Pressing the RED Pile Feeder
STOP Button
2.
To lower the Pile Feeder Table, you must first Press the REDPile Feeder
STOP Button