Baum 2020 User manual

PAGE 1 TP10243-1
BAUM 2020
1ST STATION FOLDER W/PILE FEED
INSTRUCTION MANUAL
©Baumfolder Corp., 1999 Printed in U.S.A. TP10243-1
BAUMFOLDER

TP10243-1 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.
© 1999 BAUMFOLDER CORPORATION
All Rights Reserved
FOLDER IDENTIFICATION
MODEL NO: _______________________________ SERIAL NO: _____________________________
SALES AGENCY:____________________________________________________________________
INSTALLED BY: _____________________________________________ DATE: ________________
PHONE NO: _______________________________

PAGE 3 TP10243-1
CONTENTS
DESCRIPTION PAGE
I.) Safety ................................................................................................................................................................. 6
II.) Warning Labels ................................................................................................................................................ 7
III.) Introduction Overview .................................................................................................................................... 8
IV.) Transportation/Installation ............................................................................................................................. 8
V.) Squaring the Machine ..................................................................................................................................... 8
VI.) Electrical Connections .................................................................................................................................... 9
1.0 .Wiring the Pump................................................................................................................................. 9
1.1 .Other Connections .............................................................................................................................. 9
1.2 .Tapping the Transformer .................................................................................................................. 10
1.3 .Pump Connections ............................................................................................................................. 10
VII.) Installing Fold Plates & Stacker Delivery ................................................................................................... 11
VIII.) Operator Controls .......................................................................................................................................... 11
1.0 .Setting Folding Speed ........................................................................................................................ 11
1.1 .Setting Stacker Belt Speed................................................................................................................. 11
1.2 .Emergency Stop Button ..................................................................................................................... 11
1.0 Control Panel BAN-5 .............................................................................................................................. 12
1.1 .Displays .............................................................................................................................................. 12
1.2 .Machine Status Indicators ................................................................................................................. 12
1.3 .Machine Control Pushbuttons ........................................................................................................... 12
1.4 .Keypad Buttons with Selection Indicators ........................................................................................ 13
1.5 .Keypad Buttons for Selection Adjustments ....................................................................................... 13
2.0 RUN MODE FUNCTIONS ............................................................................................................................... 13
2.1 .Machine Setup and Diagnostic Mode ............................................................................................... 13
2.2 .Counter Setup Mode .......................................................................................................................... 17
2.3 .Easy Mode and Continuous Cycle Mode........................................................................................... 18
2.4 .Learn Mode ........................................................................................................................................ 18
2.5 .Make Ready Mode ............................................................................................................................. 19
2.6 .Network Job Mode ............................................................................................................................. 20
2.7 .Production Mode ................................................................................................................................20
3.0 LOGIC BOARD STATUS INDICATORS .............................................................................................................. 21
4.0 Process Variables Definitions ................................................................................................................. 22
4.1 .Total Input Count .............................................................................................................................. 22
4.2 .Total Output Count ............................................................................................................................ 22
4.3 .Batch Down Count............................................................................................................................. 22
4.4 .Number of Batches............................................................................................................................. 22
4.5 .Current Rate ....................................................................................................................................... 22
4.6 .Main Drive Run Time ....................................................................................................................... 22
4.7 .Main Drive Velocity .......................................................................................................................... 22
4.8 .Waste Count (DCT500) ..................................................................................................................... 22
5.0 COUNTER SETUP VARIABLES ........................................................................................................................ 22
5.1 .Batch Preset ....................................................................................................................................... 22
5.2 .Batch Output Type ............................................................................................................................. 22
5.3 .Batch Output Time ............................................................................................................................ 23
5.4 .Sheet Length ...................................................................................................................................... 23
5.5 .Gap Length ........................................................................................................................................ 23
5.6 .Suction Length ................................................................................................................................... 23
6.0 SYSTEM MESSAGES AND RUN MESSAGES ...................................................................................................... 24
6.1 .Power-Up Fault Messages.................................................................................................................. 24
6.2 .Run Time Fault Messages ................................................................................................................. 25
6.3 .Machine Run Error Messages ........................................................................................................... 26

TP10243-1 PAGE 4
CONTENTS
DESCRIPTION PAGE
IX.) Pile Feeder Operation .................................................................................................................................... 27
1.0 .Loading .............................................................................................................................................. 27
1.1 .Hold-down Locations ......................................................................................................................... 27
1.2 .Air and Vacuum Setting .................................................................................................................... 27
1.3 .Front Blow Tube Settings .................................................................................................................. 28
1.4 .Vacuum Wheel................................................................................................................................... 28
X.) Register Operation ......................................................................................................................................... 29
1.0 .Double Sheet Detector ....................................................................................................................... 29
XI.) Baumset Adjustment ...................................................................................................................................... 30
1.0 .Adjusting Folding Rollers ................................................................................................................. 30
XII.) Setting Fold Plates .......................................................................................................................................... 31
XIII.) Setting Deflectors ........................................................................................................................................... 32
XIV.) Stacker Operation .......................................................................................................................................... 32
XV.) Scoring/Slitting/Perforating .......................................................................................................................... 33
1.0 .Slitter Shaft Removal ......................................................................................................................... 33
1.1 .Scoring ............................................................................................................................................... 33
1.2 .Perforating ......................................................................................................................................... 33
1.3 .Slitting................................................................................................................................................ 34
1.4 .Trimming ........................................................................................................................................... 34
1.5 .Trimming a Strip from Center of Sheet ............................................................................................ 35
1.6 .Blade Installation ............................................................................................................................... 35
XVI.) Lubrication/Maintenance .............................................................................................................................. 36
XVII.) Technical Specifications ................................................................................................................................37
XVIII.) Accessories ...................................................................................................................................................... 37
XIX.) Troubleshooting .............................................................................................................................................. 38
XX.) Operating Tips ................................................................................................................................................ 40
XXI.) Principles of Mechanical Folding ................................................................................................................. 42
XXII.) Folding Chart .................................................................................................................................................. 43
XXIII.) Manual Usage ................................................................................................................................................. 45
XXIV.) Typical Layout & Sheet Orientation ............................................................................................................ 46
XXV.) Impositions ...................................................................................................................................................... 47
#1 4 - PAGE............................................................................................................................................. 47
#2 4 - PAGE, DOUBLE IMPOSITION .................................................................................................. 47
#3 6 - PAGE, STANDARD ..................................................................................................................... 47
#4 6 - PAGE, ACCORDION ................................................................................................................... 47
#5 8 - PAGE, PARALLEL IMPOSITION .............................................................................................. 47
#6 8 - PAGE, RIGHT ANGLE ................................................................................................................ 47
#7 8 - PAGE, RIGHT ANGLE OBLONG .............................................................................................. 48
#8 8 - PAGE, RIGHT ANGLE DOUBLE IMPOSITION....................................................................... 48
#9 8 - PAGE, PARALLEL OVER & OVER ........................................................................................... 48
#10 12 - PAGE BOOK, SADDLE STITCH ............................................................................................. 48
#11 12 - PAGE BOOK, SADDLE STITCH ............................................................................................. 48
#12 12 - PAGE LETTER FOLD, HEADS OUT ...................................................................................... 48
#13 12 - PAGE LETTER FOLD, HEADS IN .......................................................................................... 49
#14 12 - PAGE LETTER FOLD, ACCORDION ..................................................................................... 49
#15 16 - PAGE, THREE RIGHT ANGLE BOOK IMPOSITION........................................................... 49
#16 12 - PAGE FOLDER, HEADS OUT ................................................................................................. 49
#17 24 - PAGE BOOKLET ....................................................................................................................... 49
#18 32 - PAGE BOOK .............................................................................................................................. 49
XXVI.) Service ............................................................................................................................................................ 50

PAGE 5 TP10243-1
List of Tables
DESCRIPTION PAGE
Table 1. Machine Setup Parameter List "A" ...................................................................................................................... 14
Table 2. Machine Monitor Parameter List ......................................................................................................................... 14
Table 3. Machine Setup Parameter List "B"....................................................................................................................... 15
Table 4. Machine Diagnostic Parameter List ...................................................................................................................... 16
Table 5. Future Features List ............................................................................................................................................... 16
Table 6. Machine Usage Status Parameter List ................................................................................................................... 17
Table 7. Output Type Animations ....................................................................................................................................... 17
Table 8. Count Source Selection .......................................................................................................................................... 18
Table 9. Learn Mode Status ................................................................................................................................................ 18
Table 10. Suction Mode Symbols ....................................................................................................................................... 19
Table 11. Suction Length Function ..................................................................................................................................... 19
Table 12. Determining the Large Display Contents ............................................................................................................ 20
Table 13. Reset mode Selection ........................................................................................................................................... 20
Table 14. LED Status Indicators .......................................................................................................................................... 21
Table 15. Output Delay and Duration ................................................................................................................................. 21
Table 16. Power Up Fault Messages .................................................................................................................................... 24
Table 17. Run Time Fault Messages ................................................................................................................................... 25
Table 18. Machine Run Error Messages ............................................................................................................................. 26

TP10243-1 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 TP10243-1
WARNING LABELS
WARNING GUARD MISSING
DO NOT OPERATE
50944
WARNING
GUARD MISSING
DO NOT OPERATE
50945
CAUTION – HAZARDOUS MOVING PARTS – GUARDS MUST BE IN PLACE WHEN
OPERATING FOLDER – KEEP HANDS, HAIR & LOOSE ARTICLES AWAY FROM MOVING PARTS.
50215
CAUTION - HAZARDOUS MOVING PARTS
DO NOT OPERATE MACHINE
WITHOUT GUARD IN PLACE
40686
C A U T I O N
HIGH VOLTAGE
EXISTS WHEN
DOOR IS OPEN
REMOVE VOLTAGE
AT POWER SOURCE
BEFORE SERVICING
42877
39379
CHANGE SPEEDS " ONLY"
WHEN FOLDER IS RUNNING

TP10243-1 PAGE 8
INTRODUCTION OVERVIEW
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
Figure 2
Figure 1
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.
SQUARING THE MACHINE
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.
Figure 4
Figure 3

PAGE 9 TP10243-1
ELECTRICAL CONNECTIONS
1.0 Wiring the Pump (2020 / 3 phase)
Connect the pressure/vacuum pump at the pump
junction box (Figure 5) using the attached cable. Follow the
instructions below for the proper connections.
There are six wires from the control box to the pump.
Wire #1 connects to the pump motor wires #1 & #7. Wire #2
connects to the pump motor wires #2 & #8. Wires #3
connects to the pump motor wires #3 & #9. Wires #4 & #5
connect seperately to the two pump motor wires marked
"THERMAL". Wire #6 is not used and should be taped off.
The remaining pump motor wires #4, #5, & #6 should be
connected together with a wire nut. The green wire is the
ground that is attached to the motor frame.
Turn the main power switch to the "ON" position.
Switch the pump on momentarily and check for proper
pump rotation as indicated by the rotation arrow on the
pump. Immediately turn off the pump if the rotation is
wrong.
If the rotation is incorrect interchange any two of the
three wires #1, #2, or #3 in the pump motor terminal box.
1.1 Wiring the Pump (2020 / 1 phase)
Connect the pressure/vacuum pump at the pump
junction box (Figure 5) using the attached cable. Follow the
instructions below for the proper connections.
There are six wires from the control box to the pump.
Wire #1 connects to the terminal marked 1 in the pump
motor. Wire #2 connects to the terminal marked 4 in the
pump motor. Wires #3 ,#4 ,#5 & #6 are not used and should
be taped off separately. The green wire is the ground that is
attached to the motor frame.
Figure 5
1.2 Other Connections
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.

TP10243-1 PAGE 10
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.
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 Pump Connections
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.
Figure 6
1X1
1X2
1X7
1X10
1X12
2
3
1
4
6
75
8

PAGE 11 TP10243-1
OPERATOR CONTROLS
The main operator control panel (Figure 8) is located at
the pile feeder. See the "Control Panel" section for a detailed
description of all the buttons.
1.0 Setting Folding Speed
The speed of the fold rollers may be set while the folder
is running! This is done by adjusting the speed control
potentiometer located on the top left side of the main control
panel. Clockwise rotation speeds the folder up; counter-
clockwise rotation slows the folder down.
1.1 Setting Stacker Belt Speed
An infinite speed range between high and low is set by
turning the control knob (Figure 9-1).
1.2 Emergency Stop Button
When an emergency stop button (8-1 & 9-2) is pressed,
the result is:
Sheet feed - stop
Folder drive - stop
Pile lift - stop
The pressure/vacuum pump continues to operate. The
emergency stop button must be pulled to release before the
machine can be restarted. An error message "StoP" will
appear on the readout.
The emergency stop buttons are found at the main
operator control panel (8-1) and the delivery control (9-2).
Figure 9
Figure 7
Figure 8
INSTALLING FOLD PLATES & STACKER
DELIVERY
Install the fold plates into the folder. When installing
the fold plates, take note of the symbol on the fold plate stop
(Figure 7-1). The swing deflector may only be brought
forward when the deflector symbol is also in the forward
position. Lock the fold plates in position with the clamp
levers (7-2). See "Fold Pan" section for fold plate setting
procedure.
Attach the delivery stacker (3-2) by hooking the hanger
brackets onto the round rods at the exit end of the folder.
Plug the stacker power cable into the corresponding outlet
on the main control enclosure on the pile feeder (Figure 6-
1).
Pull the handwheel (Figure 1-11) to manually turn the
fold rollers to be sure that they are operating smoothly.
Check for any foreign material, and be sure that the deflec-
tors do not touch the fold rollers.
+
h
0
+
+
+
1
2
3
456
7
8
9
10
1
BAUMFOLDER
CORPORATION

TP10243-1 PAGE 12
1.0 Control Panel BAN-5
Figure 1. Control Panel.
1.1 Displays
01) Large Display
Eight digit multi use display composed of 7-
segment LEDs.
02) Small Display
Three digit multi use display composed of 7-
segment LEDs.
03) Ten segment bar graph display
The suction length display is used to display the
Suction Length as a percentage of Sheet Length.
This allows a range from 5% to 50%.
1.2 Machine Status Indicators
04) Suction Indicator
The suction indicator will track the suction
output. The LED will turn on when the suction
output turns on.
05) Pile indicator
The indicator is lit when the feeder is in auto-
matic feed mode. The indicator will flash if the
feeder is in reverse mode (Continuous Feeder) or
moving down (Pile feeder)
+
h
0
+
+
+
1
2
3
456
7
8
9
10
BAUMFOLDER
CORPORATION
9 13 11 16 26 27 22 23 4 5 7 615 3
18 19 20 21 34 35
1 29 30 31 32 33
25 2824 28 12 10 1417
36
06) Input Indicator
The input indicator shows the status of the suction
photo-eye.
07) Output Indicator
The output indicator lights when the Batch Preset
is reached and the user has selected a batching
option. The output indicator is lit during the time
the batching option is active.
Batching options are Feed interruption, Speed up
table, Marking table or Kicker.
1.3 Machine Control Pushbuttons
08) Main Drive Start
09) Main Drive Stop
10) Pump Start
11) Pump Stop
12) Feeder Start
13) Feeder Stop
14) Pile Feeder Up, Continuous Feeder Start
15) Pile Feeder Stop, Continuous Feeder Stop
16) Pile Feeder Down, Continuous Feeder Reverse
17) Emergency Stop

PAGE 13 TP10243-1
1.4 Keypad Buttons with Selection Indicators
18) Show Output Count
19) Show Batch Count and Number of Batches
20) Show Current Rate
21) Show Input Count
22) Learn Mode
23) Make Ready Mode
1.5 Keypad Buttons for Selection Adjustment
24) Gap Minus
25) Gap Plus
26) Suction Length Minus
27) Suction Length Plus
28) Batch Preset Minus
29) Batch Preset Plus
30) Counter Setup Mode
31) Machine Setup Mode
32) Batching Time Minus
33) Batching Time Plus
34) Network Job Mode
35) Reset
36) Potentiometer Speed adjustment
2.1 Machine Setup/Diagnostic Mode
Pushing this key puts the controller in machine setup
mode.
Machine setup mode provides a method to view and
optionally change operating parameters for the controller.
The decimal points in the large display (1) will move from
side to side to indicate that various parameters may be
changed. In this mode, the small display gives the selected
parameter number, while the large display (1) shows a
parameter value. The suction length display (3) is disabled.
Parameter Group Selection
The plus and minus keys are used to select the various
parameter groups: machine setup parameters, machine
monitor parameters, machine diagnostic parameters, knife
status parameters, and machine usage parameters.
Parameter Selection within a Group
If the large display (1) decimal points are moving, this
set of minus and plus buttons will select the machine
parameters within each group, see tables 1-6.
Select Parameter Adjustment
If the large display (1) decimal points are moving, this
set of minus and plus buttons will move through the set of
values for the selected parameter, see tables 16.
+
+
+
2.0 Run Mode Functions
After turning on the main switch, thecontrol automati-
cally runs a self test. During this self test all displays and
indicator lights come on for approxmately 4 seconds. After
a successful self test, the display reverts to the previous
count screen active before power shutdown. In this mode,
various job parameters can be displayed on the large display
(1) and the small display (2) shows the gap length. The
suction length display (3) is active in this mode and shows
the suction length as a percentage of sheet length.
The DCT500 mode select keys perform the same
function in all modes, except Counter Setup. This allows a
user to quickly switch between the operating modes on the
counter. Select Make-Ready is not a mode unto itself, but
rather is a modifier to all modes.
During the self test operation, do not press any
button. Pressing of a button will cause an error
message to appear in the main display.
!

TP10243-1 PAGE 14
2.1.1 Machine Setup Parameters
Table 1. Machine Setup Parameter List
P00: Input Factor
Each sheet sensed by the Sheet count sensor is multi-
plied by the Factor number and added to theTotal Input
Count, but does not effect the Batch Down Count, Number
of Batches or the Rate. The Factor can range from 1 to 24. If
the Input Factor is changed, it also changes the value of the
Output Factor to the same setting.
P01: Output Factor
This number is added to the Total Output Count but
does not effect the Batch Down Count, Number of Batches
and the Rate. The Factor can range from 1 to Input Factor
setting.
2.1.2 Machine Monitor Parameters
Table 2. Machine Monitor Parameter List
P10: Machine Speed (Velocity)
This selection shows the machine speed in meters/
minute.
P11: Job Run Time
Displays the time duration this job has ran. Time
displayed in .01 Hours. This information becomes part of the
job record.
P12: Job Stop Time
Display the time duration this job has been interrupted.
Time displayed in .01 Hours. This information becomes part
of the job record.
P13: Job Make Ready Time
Displays the length of time that the Make Ready
feature was enabled. Time displayed in .01 Hours. This
information becomes part of the job record.
Parameter Function Type Variable Displayed
P00 Input Factor Setup Variables Adjustable 1-24
P01 Output Factor Setup Variables Adjustable 1 to Input Factor
P02 Tremat Setup Variables Adjustable 1 or 0
P03 Knife Setup Variables Adjustable 1 or 0
P02: Tremat
This is an unavailable option.
P03: Knife
This is an unavailable option.
#Function Type Variable Displayed
P10 Machine Speed Process Variable Based on input Meters/Minute
P11 Job Run Time Process Variable Based on input Hours
P12 Job Stop Time Process Variable Based on input Hours
P13 Job Make Ready Time Process Variable Based on input Hours
P14 Pause Time Process Variable Based on input Hours
P15 Job Number Process Variable Based on Input Number 1 - 9999
P16 Employees Number Process Variable Based on input 1 - 255
P14: Pause Time
Display the length of time that the Job was Paused.
Time displayed in .01 Hours. This information becomes part
of the job record.
P15: Job Number
A Job Number may be entered so that production
data may be recorded against it. This is an operator entry.
This information becomes part of the job record.
P16: Employees Number
An Employee may be assigned a number. When
the employee operates the machine, his number may be
entered. This information becomes part of the job record.

PAGE 15 TP10243-1
2.1.3 Machine Setup Parameters
Table 3. Machine Setup Parameter List
P20: Units of Measurement
This selection specifies the unit of measurement used to
display all lengths. Inches (SAE) is the default selection.
Available choices are Meters (measurement displayed in cm)
and Inches (measurement displayed in inches and tenths of
inches).
P21: Language
This selection specifies the Language used to display
fault messages. Available choices are ENGLISH,
DEUTSCH, and CODES, see Tables 1618, Error Message
Translation. English is the default selection.
P22: Network Address
This selection specifies the unit address used for
Network communication. Available choices are 0 through
255. Address 0 is the default selection. Network functions
are not available in software version 2.6.0
P23: Pause
P24: Network Enable
Network components must be installed and enabled in
Maintenance Mode. Enable Network by selecting 1.
Disable network by selecting 0.
#Function Type Variable Displayed
P20 Units of Measure Setup Variables Adjustable Inches, Meters
P21 Language Setup Variables Adjustable English, German, Codes
P22 Network Address Setup Variables Adjustable 0-255
P23 Pause Setup Variables Adjustable 1 or 0
P24 Network Setup Variables Adjustable 1 or 0
P25 Easy Setup Variables Adjustable 1 or 0
P26 Software Version Machine Configuration Fixed V X.X.X
P27 Machine Type Machine Configuration Fixed Set at Factory
P28 Serial Output Type Machine Configuration Fixed Off, Display, or Network
P25: Easy Mode
Enable Easy Mode by selecting 1. Disable Easy Mode
by selecting 0.
Easy Mode has two sheet control methods, Easy setup or
Continuous cycle. Easy setup will run any job with a 1 inch
sheet gap. The sheet gap display contains 3 dashes and the
Suction Length bar graph is turned off.
In Continuous cycle setup, the suction cycle is determined by
the sheet gap setting, sheet length setting and the suction
length setting. Sheet error detection methods are turned off.
P26: Hardware and Firmware Version
This selection shows the hardware and firmware
versions of the unit. The left side of the display shows logic
board type. The right side of the display shows the firmware
version (2.X.X).
P27: Machine Type
This selection, in maintenance mode, shows the selected
machine configuration.
P28: Serial Output Type
This selection, in maintenance mode, shows selected
serial output type.

TP10243-1 PAGE 16
P28: Serial Output Type
This selection, in maintenance mode, shows selected
serial output type.
2.1.4 Diagnostic Parameters
Table 4. Machine Diagnostic Parameter List
P30: Input Port 1 Status
P31: Input Port 2 Status
P32: Input Port 3 Status
P33: Input Port 4 Status (Extension)
This selection shows the inputs status(see table4).
2.1.5 Future Features
Table 5. Future Features List
P34: Output Port 1 Status
P35: Output Port 2 (Extension)
This selection shows the outputs status (see table 4).
# Function Type Variable Displayed
P40 Last Knife Eye Time 1 Not used Not used Not used
P41 Last Knife Eye Time 2 Not used Not used Not used
P42 Last Knife Eye Time 3 Not used Not used Not used
P43 Strokes knife 1 Not used Not used Not used
P44 Strokes knife 2 Not used Not used Not used
P45 Strokes knife 3 Not used Not used Not used
P30 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 Button Button Button Stop Button Start Button Relay K3
P31 Status Input Port 2
P31.1 P31.2 P31.3 P31.4 P31.5 P31.6 P31.7 P31.8
Pile Sensor Double Pile Sheet Start Sheet Stop Thermal Wrong Sheet Emerg.Stop
Sheet Fault Bottom Button Button Fault Fault Drive Stop
Button
P32 Status Input Port 3
P32.1 P32.2 P32.3 P32.4 P32.5 P32.6 P32.7 P32.8
Ergonomic Not used Not used Not used Not used Suction Delivery Photo eye
Pile Load Controller Count Input Suction
Eye Fail Wheel
P33 Status Input Port 4 (Extension Port)
P33.1 P33.2 P33.3 P33.4 P33.5 P33.6 P33.7 P33.8
Not used Not used Not used Not used Not used Not used Not used Not used
P34 Status Output Port 1
P34.1 N P34.2 P34.3 P34.4 P34.5 P34.6 P34.7 P34.8
Not used Not used Not used Not used Pile Down Pile up Release Compress
is active is active Drive Start Start (K4)
P35 Status Output Port 2 (Extension Port)
P35.1 P35.2 P35.3 P35.4 P35.5 P35.6 P35.7 P35.8
Not used Not used Not used Not used Not used Not used Not used Not used

PAGE 17 TP10243-1
2.1.6 Machine UsageStatus Parameters
Table 6. Machine Usage Status Parameter List
P50: Power On Time
This selection shows the time in 1/100 hour during the
main switch of the machine is on.
P51: Machine Run Time
This selection shows the time in 1/100 hour during the
main drive contactor of the machine is on.
P52: Total Input Sheets
This selection shows the total input counts in 1000
sheets
Exit Machine Setup and Diagnostic Mode
Pressing any of these keys will cause the controller to
change to a new mode.
2.2 Counter Setup Mode
Pushing this key puts the counter in counter setup
mode.
Counter setup mode is used to prepare the controller to
run a job. The large display (1) shows the batch preset on
the left-hand side and the batching output time on the right
hand side. The decimal points in the large display (1) will
move from side to side to indicate that a parameter may be
changed. The small display (2) shows the batching type. The
suction length display (3) is active.
Change Batching Type
The minus and plus buttons move through a list of four
output devices. The chosen Type is then activated when the
batch down-count goes to zero. Feed interruption stops the
feeding of sheets for the batching time setting.
# Function Type Variable Displayed
P50 Power on time Machine Status Based on Inputs Time in 1/100 Hours
P51 Machine run time Machine Status Based on Inputs Time in 1/100 Hours
P52 Total Input Sheets Machine Status Based on Inputs Number in 1000 Sheets
h
0
+
The speed up-table output activates the marking table
output for the batching time duration.
The MKE mode is an unavailable option.
The kicker is a future feature.
The output types are represented by animated symbols.
The sequence of frames for the animations is shown in
table 7.
Table 7. Output Type Animations
Batch Preset Adjustment
These buttons cause the batch preset value to increment or
decrement. The preset will be reloaded after the user leaves
the setup mode only if the value has been changed.
+
Feed Interruption Speed Up Table MKE Table Kicker
Frame
1
Frame
2
Frame
3
Frame
4
Frame
5
Frame
6
Frame
7
Frame
8
Not
Available
Future
Feature

TP10243-1 PAGE 18
Batching Time Adjustment
The batching time adjustments allow the user to select
the time duration associated with the currently selected
output type. Two output types and times are available.
1. Feed interrupt has a range of 0.0 to 9.9 seconds.
2. Speed-up Table has a range of 0.00 to 5.00 seconds.
Select Count Source
The Output Count and Input Count keys select between
count at delivery and feeder, respectively. One key LED
will always be lit in Counter Setup to show the current
count source, see table 8. Chasing LEDs will activate in
the small display signifying the start setup mode. The next
sheet fed through will be timed from leading edge to
trailing edge and the delay time will be set to one half the
sheet time. Please note this must be redone if the delivery
speed is changed.
Table 8. Count Source Selection
Exit Counter Setup Mode
Pressing any of these keys will cause the counter to
change to a new mode.
2.3 Easy Mode and Continuous Cycle
Mode
2.3.1 Easy Mode and Continuous Cycle Mode
Enable EASY mode at parameter P25, see Table 3.
Select Easy Mode
Pressing this button enables the selection of either the
EASY mode or cYcL mode.
+
The batching count source will be the feeder
photoeye.
The batching count source will be whatever is
connected as the delivery photoeye.
0
+
+
Pressing these buttons will toggle between the EASY
mode or cYcL mode. Set EASY in the large display and
press again.
Select Continuous Cycle Mode
Pressing this button enables the selection of either the
EASY mode or cYcL mode
Pressing these buttons will toggle between the EASY
mode or cYcL mode. Set cYcL in the large display and
.press again.
Exit Run Mode
Pressing any of these keys will cause the counter to
change to a new mode.
2.4 Learn Mode
This key places the controller in learn mode. Learn
mode can only be activated if the folder is idle.
The learn mode allows the user to setup the suction
valve controller. Both manual and automatic setup is
accomplished in this mode. The large display (1) shows
two separate data items. The suction mode is shown on the
left and the sheet length is shown on the right. The small
display (2) shows the current gap length. The suction
length display is active. During Learn Mode, the Learn
Mode key LED indicates whether a valid sheet has been
learned.
Table 9. Learn Mode Status
When the LED is on, pushing the sheet start button will
feed a single sheet of paper. If the sheet is fed properly, the
indicator LED will go off. The suction mode will be set to
automatic. The length of the sheet will be set as the current
sheet length. The suction length will be set based on table
11 and the gap length will be set to 4 cm /1.50 inches.
No valid sheet has been read yet, the system is in
Single Sheet mode.
A valid sheet has been read and the DCT500 has
been setup to run. Single Sheet mode is off.
Job

PAGE 19 TP10243-1
Table 10. Suction Mode Symbols
Table 11. Suction Length Function
TWT-180 Mode
Leading Edge Control
Leading and Trailing Edge Control
+
+
+
If P06 is set to 0 (no knife is active) and 10 cm /4.0 inches.
If P06 is setting to 1, knifes are active.
Gap Length Adjustment
The minus and plus keys adjust the gap length. The gap
length range is 0.2 to 98.0 (0.5cm to 250cm).
Suction Length Adjustment
This is the same as in run mode
The suction length adjustment keys allow the user to
change the amount of suction applied to the current sheet
length. The display shows the percentage in 5% steps. All
of the bars must be totaled to get the value. The range of
adjustment is 5% to 50% of the current sheet length. If the
suction length is manually adjusted while the Learn Mode
LED is on, the suction length will no longer be the Single
Sheet suction length of 6.0. The new suction length will
be based on the current sheet length and suction setting.
+
Select Suction Mode
These keys toggle between automatic control and cycle
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. No adjustments are made for
slipped sheets or process changes. The automatic mode
corrects for process changes and controls the timing of the
suction valve to maintain the user-selected gap. If the gap
is less than 1.5 (4.0 cm), the right hand decimal point of
the small display (2) will flash and the Leading edge
control will be active. If the gap is greater than or equal to
1.5 (4.0 cm), full Leading and Trailing edge control is
maintained. Refer to table 10 for suction mode symbol
definitions.
Sheet Length Adjustment
The sheet length adjustment keys allow the user to
override the automatic Learn Mode setting. When the user
changes the sheet length, the suction length will be
adjusted according to table 11. If a different suction length
is desired, the value may be overridden with the suction
length adjustment keys. The sheet length range is 10 cm /4
inches to 250 cm / 98.5 inches.
Sheet Length Setting Resultant Suction Length Percentage
Greater than or equal to 30 cm. 30% of Sheet Length
Less than 30 cm., and greater than or equal to 27 cm. 25% of Sheet Length
Less than 27 cm., and greater than or equal to 24 cm. 20% of Sheet Length
Less than 24 cm., and greater than or equal to 21 cm. 15% of Sheet Length
Less than 21 cm. 10% of Sheet Length.
h
0
Exit Learn Mode
Pressing any of these keys will cause the controller to
change to a new mode.
2.5 Make Ready Mode
This key places the controller in the make ready mode.
The key LED goes on. In this mode the folder will only
feed single sheets and a batching output is issued for every
two sheets fed. This allows the operator to easily set up the
batching time.

TP10243-1 PAGE 20
2.7 Production Mode
Enter Run Mode and Select Large Display Content
These keys do not operate as mode select keys in
counter setup. In all other modes, the keys both select the
large display (1) contents and place the counter into run
mode. Pushing one of the buttons will light the buttons
associated LED and cause the parameter to be displayed. If
both the input and output count keys are pressed simulta-
neously, then both LEDs go on and the waste count is
displayed. See Process Variable Definitions.
Table 12. Determining the Large Display Contents
When the folder is started the counter will start up in
the run mode, the normal operating mode of the counter.
In this mode, various job parameters can be displayed on
the large display (1) and the small display (2) shows the
gap length. The suction length display (3) is active in this
mode and shows the suction length as a percentage of sheet
length.
Gap Length Adjustment
The gap length adjustment keys allow the user to
change the current gap length. The range of adjustment is
0.2 to 98.0 (0.5 cm to 250 cm).
Suction Length Adjustment
The suction length adjustment keys allow the user to
change the amount of suction applied to the current sheet
length. The display shows the percentage in 5% steps. All
of the bars must be totaled to get the value. The range of
adjustment is 5% to 50% of the current sheet length.
h
h
h
h
h
h
Output Count
Batch Count Down
Number of Batches
Current Rate
Input Count
Waste Count
Large Display Contents
h
+
+
h0
This mode is only available if a STA-NET adapter is
installed and activated through maintenance mode. In this
mode the small display (2) always shows the word Job.
The large display (1) shows either PAuSE or a job
number which can be read from the network. The suction
length display is disabled.
Select Job Number
This set of plus and minus keys step the large display
(1) through pause mode and a list of available job numbers.
While in network job mode, the folder is considered to be
paused.
Load Job and Return to Run Mode
When this button is pushed the selected job will be
loaded into the counter and the counter will return to run
mode. If the large display (1) was showing the message
PauSE, the network job mode will end, but no job will be
loaded.
Exit Network Job Mode
Pressing any of these keys will cause the counter to
change to a new mode.
++
++
h
Exit Make Ready Mode
Pressing any of these keys will cause the controller to
change to a new mode.
2.6 Network Job Mode
Pushing this key puts the counter in network job mode