Count KF-200 User manual

KF-200
Knife Folding Machine
Serial Number ___________________________
Date ___________________________________
12-2016
Version 1.0

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Table of Contents
INTRODUCTION ............................................................................................................................... 5
PREFACE....................................................................................................................................... 5
SPECIFICATIONS........................................................................................................................... 5
ELECTRICAL SPECIFICATIONS........................................................................................................... 6
SAFETY PROCEDURES ...................................................................................................................... 6
BEFORE USE:................................................................................................................................ 6
DURING USE: ............................................................................................................................... 6
AFTER USE: .................................................................................................................................. 6
CARE AND MAINTENANCE............................................................................................................... 7
BEARINGS/BUSHINGS:................................................................................................................. 7
SENSOR EYE: ................................................................................................................................ 7
KEEP THE ROLLERS CLEAN: .......................................................................................................... 7
IMPORTANT NOTES BEFORE OPERATING THE KF-200 .................................................................... 7
DOUBLE FEEDING: ....................................................................................................................... 7
KNOB SETTINGS:.......................................................................................................................... 7
START DELAY: .............................................................................................................................. 7
COMPONENT IDENTIFICATION........................................................................................................ 8
SETTING UP YOUR KF-200 ............................................................................................................... 9
DELIVERY TRAY INSTALLATION .................................................................................................... 9
BI-PASS TRAY INSTALLATION....................................................................................................... 9
PAPER STOP ASSEMBLIES .......................................................................................................... 10
REGISTER GUIDE INSTALLATION................................................................................................ 11
Connecting KF-200 to ACCUCREASER / FC114A ............................................................................ 12
CONNECTING TO OTHER EQUIPMENT ...................................................................................... 12
MAIN POWER ............................................................................................................................ 13
TOUCH SCREEN CONTROLLER ....................................................................................................... 14
TOUCH SCREEN OPERATION...................................................................................................... 14
COUNT LOGO AND SERVICE ACCESS ......................................................................................... 14
AUTO SETUP SCREEN................................................................................................................. 15
PAPER THICKNESS...................................................................................................................... 15
KNOB SETTINGS / GAP ADJUSTMENT........................................................................................ 16

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MEASURE SHEET........................................................................................................................ 17
RUN SCREEN .............................................................................................................................. 17
MICRO ADJUSTING THE FOLD POSITION................................................................................... 18
REPEAT LAST JOB....................................................................................................................... 18
BI-PASS MODE ........................................................................................................................... 18
TRANSPORT OPERATION ........................................................................................................... 19
AUTO FOLD SETUP......................................................................................................................... 19
HALF FOLD SETUP:..................................................................................................................... 19
TRI-FOLD SETUP:........................................................................................................................ 20
Z FOLD SETUP: ........................................................................................................................... 20
LETTER FOLD SETUP:.................................................................................................................. 20
GATE FOLD SETUP: .................................................................................................................... 20
DOUBLE PARALLEL FOLD SETUP: ............................................................................................... 21
MANUAL SETUP......................................................................................................................... 21
SAVING MANUAL FOLD JOBS .................................................................................................... 22
RECALLING MANUAL FOLD JOBS ............................................................................................... 22
IN FEED REGISTER GUIDE .............................................................................................................. 23
ADJUSTING THE MICRO SKEW OF THE IN-FEED REGISTER........................................................ 23
DELIVERY TABLE............................................................................................................................. 24
CHECKING THE SENSORS ........................................................................................................... 25
ROTATING PLASTIC COVER ........................................................................................................ 25
TROUBLE SHOOTING ..................................................................................................................... 26

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INTRODUCTION
PREFACE
The KF-200 is a precision folding machine. With its intuitive touchscreen design it can perform 6
different types of automated setup folds of pre-creased paper. It has a manual feature that
allows for the fold to be placed virtually anywhere on the sheet. When properly setup and using
pre-creased sheets, the knife blade folding mechanism will prevent the cracking of digitally
printed material when folded. The infeed register guide allows the machine to be rolled up to
several different manufactured creasing machines. It is very important to keep it free of
excessive dust, dirt and foreign matter. We recommend that you keep the machine covered
when not in use.
SPECIFICATIONS
Net Weight: KF-200………………………………………………………..224 lbs
Overall Dimensions: ………………………………………………………………….67”Lx28”Wx47”H
Boxed Dimensions: ………………………………………………………………….49”Lx34.5”Wx52.5”H
Boxed Weight: ………………………………………………………………….395 lbs.
Min. Sheet Size: .……………………………………………………….………..4.75”x5.5”
Max. Sheet Size: ….………………………………………………………………14.5”x33”
Paper Weight Range: (gsm) …………………………………………………………….120-350
Max Speed: (sheets per hour) …………………………………………………………4,600

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ELECTRICAL SPECIFICATIONS
Power Requirement: 110v/220v, 60/50 HZ, AC 15AMP
Circuit Protection: 5 AMP Circuit Breaker
NOTE: Older buildings, overloaded lines, and bad grounds can affect the operation of your KF-
200. A regulated dedicated line is recommended. Operating the machine through a power
strip is not recommended.
SAFETY PROCEDURES
BE ALERT! BE CAREFUL!
BEFORE USE:
Read through the owner’s manual. Follow instructions CAREFULLY.
Don’t install the machine on uneven ground.
NEVER use in a wet area. Electric shock could occur.
Use at least a 15 amp power source at 110 v
Use a GROUNDED outlet and a GROUNDED circuit. Do no use ungrounded
equipment on the same circuit.
Always use a dedicated line. DO NOT use with line splitting surge protector.
Make sure all safety covers are in place. The top cover has an interlock switch which
will disable the unit if removed.
Open and close the plastic cover slowly.
DURING USE:
Exercise caution with long hair, loose fitting clothes when near the machine nip,
while in operation.
Keep fingers and hands away from belts, folding blades, and rubber rollers.
Keep fingers away from any moving part.
Keep cords clear of moving parts.
Do not place any liquid on any surface of machine.
Do not put heavy matter on machine.
AFTER USE:
Turn off machine at the top panel, then unplug the main power cord. This will
prevent damage to your machine by power/voltage spikes.
To unplug cords, always grasp the plug body, never pull on cords to disconnect.
Wire fatigue and possible shock could result from improper disconnect procedures.
Disconnect the power before cleaning the inner machine.
Clean all rollers, belts and moving parts.
Cover the Machine.

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CARE AND MAINTENANCE
The KF-200 is a precision machine. It is very important to keep it free of excessive dust, dirt and
foreign matter. We recommend that you keep the machine covered when not in use.
BEARINGS/BUSHINGS: The bearings are sealed roller bearings and are designed to be self
lubricating, however dirt and dust can get into them causing clogging and dirt build up. It is
recommended to oil them weekly under heavy use or monthly under light use. The bushings for
the knife blades are Bronze and require lubrication more frequently. Oil these once a week
under heavy use with a light machine oil or 3-1 oil.
SENSOR EYE: Clean the lower reflector tape located on the plate under the infeed register
regularly. Clean with water damp rag only. Dust will cause the beam to not reflect correctly.
Clean when necessary.
KEEP THE ROLLERS CLEAN: Excess paper dust will cause slippage of the paper. You must
clean the rollers regularly to ensure good registration. To do this, unplug the machine carefully,
lift plastic cover, and use a clean wet rag with water only and clean each roller. If you do keep
your KF-200 clean and in top condition, it will give you years of service.
IMPORTANT NOTES BEFORE OPERATING THE KF-200
To ensure the smooth operation of this machine please read the following. If you do not
understand these sections of how to operate the machine you may cause damage and
unintentionally void your warranty.
DOUBLE FEEDING: The KF-200 is designed to run a single sheet. If a double sheet is fed
through the machine it will lock up. If the machine is not turned off immediately you may cause
damage to the motor driver and void the warranty.
KNOB SETTINGS: The knob settings are directly related to how well the machine will run.
Please read the section on Knob settings before operation.
START DELAY: When pressing the RUN button there is a 2 second delay for the transport
motor to turn as the knife blades preform a homing cycle.

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COMPONENT IDENTIFICATION
REFERENCES
Note: We are continuously improving and changing the machine. Specifications and
information in this manual are updated as per the change and without any notice.
Register Table Assembly
Delivery Tray
Micro Skew Adjustment
Motorized Delivery
Paper Stop
Touch Screen Pg. 13
Register Table Assembly Pg. 10
Register Guide Rail Pg. 10
Motorized Delivery Pg. 23
Micro Skew Adjustment Pg. 22
Power Switch Pg. 12
Gap Settings Pg. 16
Delivery Tray Pg. 9
Register Guide Rail
Touch Screen
Power Switch
Gap Knobs

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SETTING UP YOUR KF-200
This machine is 90% ready to go when it arrives on your dock. There are only a few items that
need to be put into position before it is ready to use. Those items are below:
DELIVERY TRAY INSTALLATION
The motorized delivery is recommended to be installed by two people but can be done with one
although it is more difficult. Locate the exit support shaft of the machine. Install the hooks on
the delivery tray to the cuts outs show on the shaft below. Now support the end of the tray and
position the arms into the larger slots on the exit panel.
Upper Position shown below
Plug delivery table into matching power receptacle on folder cover. Warning: Do not plug
delivery table to any other power source!
BI-PASS TRAY INSTALLATION
Cut outs on shaft for
delivery mounting

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As shown below there are hooks that hold the bi-pass tray into position. If the magnetic paper
stops have already been placed you should remove them for easier installation of the tray. Then
angle upward and insert the hook into the slot then rotate downward to place the lower hook
into the slot.
PAPER STOP ASSEMBLIES
There are two different paper stops. One will have a bend and one will be straight. The straight
paper stop is the rear or back paper stop. The bent paper stop is the operator side paper stop.
There is no paper stop for the non-operator side. The support arm acts as the stop for that side.
They hold their position using a magnet which makes it easy for adjustment. The positions for
the paper stops will change for each individual job. If the paper stops are set too close the
paper will hit them as it exits the machine and will cause a paper jam. If they are set too loose
the paper will stack in an unorganized manner. Getting the position correct is imperative to
smooth operation of the machine.

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REGISTER GUIDE INSTALLATION
The register guide for the machine is recommended to be installed by two people but can be
done with one although it is more difficult. Start by removing the knobs located on the lower
support arms. Next locate the entry pins. Install the hooks on the front of the register guide to
the pins. Support the entry side of the register guide and rotate one of the support arms up to
the slotted bracket and install the knob you removed earlier. Repeat for the other side. Tighten
the knobs to hold position until the machine is rolled up to the creasing machine. Install the
balls from the parts box into the holes along the register belt.
Rest the hooks on the pins above then attach the arms below.

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Connecting KF-200 to ACCUCREASER / FC114A
The KF-200 is designed to run in line with the Count Accucreaser and The Count FC-114 A
creasing machines. To Connect them, there is a hook on the non operator side of the KF-200
register that needs to be attached to the exit shaft of the creasing machine as seen below.
Once attached make sure the hook is against the non operator side frame so the plastic cover
does not interfere. Once the machines are lined up lock the casters so the machines do not
move if bumped.
CONNECTING TO OTHER EQUIPMENT
The KF-200 can run behind many different manufacturers creasing machines. The in-feed
register is height adjustable. Make sure when adjusting the height that the paper is coming out
between the balls and plate of the infeed register. It is also very important that the paper
enters the register guide as close to the non-operator frame as possible. This helps the register
guide to ensure the paper has the time to register completely.

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MACHINE OPERATION
There is one main power switch on the KF-200 located on the lower portion of the operator side
cover. Everything else is controlled by the Touch Screen. All paper run through the KF-200
folding machine must be creased.
MAIN POWER
On the operator side cover on the right side is the main power switch. This is the on and off
power for the machine. When switched on the led lights will illuminate just in front of the
knobs. This is how you know the machine is on. Do not leave the machine on when not in use.

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TOUCH SCREEN CONTROLLER
THE TOUCH SCREEN CONSISTS OF FIVE SECTIONS:
1. Count Logo and Service Access
2. Auto Setup
3. Manual Setup
4. Repeat Last Job
5. Bi-Pass Mode
TOUCH SCREEN OPERATION
When the machine is turned on the display may take up to 7 seconds for the home screen to
display. There is a screen saver that will turn the display off if the machine is not touched within
30 minutes. The power light will stay illuminated letting you know the machine is still on.
COUNT LOGO AND SERVICE ACCESS
If the logo is pressed a password screen is displayed. This is for factory and service access only.
This Screen is for manufacturer use only. The password is not given out.
1
2
4
3
5

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AUTO SETUP SCREEN
From the home screen press the Auto Setup button. The select fold screen appears. Press the
desired image to select that fold.
Select the fold you want by pressing the image.
PAPER THICKNESS
Select the thickness of paper to be folded. This is important as thinner stocks will fold
differently than thicker stocks. This allows us to change the offset for the perfect fold.
By pressing a thickness, you will be directed to the knob setting screen.

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KNOB SETTINGS / GAP ADJUSTMENT
This adjustment is very important and affects the operation of the machine dramatically. The
knobs are positioned from left to right. Knob 1 is on the left and knob 2 is on the right. Knob 1
controls gap 1 and knob 2 controls gap 2. The knob setting screen will display the
recommended setting below the image. This is a starting point and some adjustment may need
to take place once this setting has been made. Example if you are getting motor lock ups or
paper jams you will need to increase the gap adjustment on knob 2. If you are getting
registration or skewing you may need to adjust the gap lower on knob 1. It is important to read
the warning on the side of the knob setting screen. The following gap adjustments are the
suggested for the paper weight and fold patterns listed. Note: the finished results can be
affected by the type of stock, type of finish, grain direction, and quality of paper. The values
listed in the table are only suggested values.
Make sure the setting is correct on the machine before pressing the OK, I HAVE MADE THE
ADJUSTMENT Button.

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MEASURE SHEET
The KF-200 will automatically set the distance of the fold using the smart measure feature. With
one sheet on the register guide or ready to feed from the creasing machine press the start
measuring button. The knife blades will move into position, then the transport will start to run,
feeding in the sheet. Depending on the thickness of stock you selected, the sheet will either
feed out the slot in the top of the plastic cover or the bi-pass tray.
Once measured press accept to go to the run screen.
RUN SCREEN
On the Run Screen there is a counter that will count how many sheets are run through the
machine. It can be reset by pressing the counter reset. When the run button is not selected you
can jog the machine forward and backward using the jog arrows. There is an adjust button that
will allow you to micro adjust the distance for each fold. There is a fold blade control button
that will allow you to adjust the knifes manually out of the way if necessary to clear a paper jam.
There is a parameters button that is used to change the default offsets of the machine. This is a
password protected button. If you feel you need to change the default parameters please
contact our customer service department for instructions.

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MICRO ADJUSTING THE FOLD POSITION
It is very important to understand the relationship of the fold offset versus the crease offset.
When folding a creased stock the nature of the creased paper when folded is to follow the
crease. If possible, adjust the crease before micro adjusting the crease.
If you wish to move the position of the fold relative to the lead edge you would need to adjust
the position of the crease and not necessarily the position of the fold. If you still feel you need
to adjust the fold press the adjust button from the run screen. You can micro adjust each fold
by pressing the arrow keys each direction. Each press will adjust by 1/10th of a mm. Each
adjustment is relative to the one before it so if you adjust fold 1 by 3 clicks it will also move fold
2 as well in the same direction. To keep the subsequent folds in their same locations you would
then need to adjust them each back the number of clicks you adjusted the previous location, in
this case 3 clicks.
REPEAT LAST JOB
Press the repeat last job button to go directly to the run screen and repeat the last job fold
settings.
BI-PASS MODE
Press the Bi-Pass mode button to enter Bi-Pass mode. This mode will allow paper to flow directly
through the folding unit without folding the stocks. For some lighter stocks the knob setting
must be set to the highest setting to allow for clearance of the exit roller.

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TRANSPORT OPERATION
The Run Button will start the knife home function. Once the blades are in position the
transport will start. This is about a 2 second delay and is normal. Press it again to stop
the transport. Each Mode has a timeout feature to preserve the life of the machine.
A document may be slowly advanced through the transport by pushing and holding one
of these buttons.
EXAMPLE:
The motor should advance transport at slow speed and stop
whenever your finger is lifted.
Controls on-off function of motor.
EXAMPLE:
Machine will run at mode and speed previously selected.
Machine will stop.
AUTO FOLD SETUP
HALF FOLD SETUP: Press the Auto Setup Button > Half > Paper Thickness > Adjust the Knob
Setting > OK, I have made the Adjustment > Start Measuring > Physically Run a sheet through
the machine for the sensor to measure > Accept > Run.

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TRI-FOLD SETUP: Press the Auto Setup Button > Tri-Fold > Paper Thickness > Adjust the Knob
Setting > OK, I have made the Adjustment > Start Measuring > Physically Run a sheet through
the machine for the sensor to measure > Accept > Run.
Z FOLD SETUP: Press the Auto Setup Button > Tri-Fold > Paper Thickness > Adjust the Knob
Setting > OK, I have made the Adjustment > Start Measuring > Physically Run a sheet through
the machine for the sensor to measure > Accept > Run.
LETTER FOLD SETUP: Press the Auto Setup Button > Tri-Fold > Paper Thickness > Adjust the
Knob Setting > OK, I have made the Adjustment > Start Measuring > Physically Run a sheet
through the machine for the sensor to measure > Accept > Run.
GATE FOLD SETUP: Press the Auto Setup Button > Tri-Fold > Paper Thickness > Adjust the
Knob Setting > OK, I have made the Adjustment > Start Measuring > Physically Run a sheet
through the machine for the sensor to measure > Accept > Run.