Count KF-250 User manual

KF-250
Knife Folding Machine
Serial Number ___________________________
Date ___________________________________

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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-250.................................................................... 7
DOUBLE FEEDING: ....................................................................................................................... 7
KNOB SETTINGS:.......................................................................................................................... 7
START DELAY: .............................................................................................................................. 7
COMPONENT IDENTIFICATION........................................................................................................ 8
SETTING UP YOUR KF-250 ............................................................................................................... 9
DELIVERY TRAY INSTALLATION.................................................................................................... 9
BI-PASS TRAY INSTALLATION..................................................................................................... 10
PAPER STOP ASSEMBLIES .......................................................................................................... 10
MACHINE OPERATION................................................................................................................... 11
MAIN POWER ............................................................................................................................ 11
TOUCH SCREEN CONTROLLER ....................................................................................................... 12
TOUCH SCREEN OPERATION...................................................................................................... 12
COUNT LOGO AND SERVICE ACCESS ......................................................................................... 12
AUTO SETUP SCREEN................................................................................................................. 13
PAPER THICKNESS...................................................................................................................... 13
KNOB SETTINGS / GAP ADJUSTMENT........................................................................................ 14
MEASURE SHEET........................................................................................................................ 15
RUN SCREEN .............................................................................................................................. 15

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MICRO ADJUSTING THE FOLD POSITION................................................................................... 16
REPEAT LAST JOB....................................................................................................................... 16
TRANSPORT OPERATION ........................................................................................................... 17
AUTO FOLD SETUP......................................................................................................................... 17
HALF FOLD SETUP:..................................................................................................................... 17
TRI-FOLD SETUP:........................................................................................................................ 18
Z FOLD SETUP: ........................................................................................................................... 18
LETTER FOLD SETUP: ................................................................................................................. 18
GATE FOLD SETUP: .................................................................................................................... 18
DOUBLE PARALLEL FOLD SETUP:............................................................................................... 19
MANUAL SETUP......................................................................................................................... 19
SAVING MANUAL FOLD JOBS .................................................................................................... 20
RECALLING MANUAL FOLD JOBS............................................................................................... 20
FEED TABLE ASSEMBLY.................................................................................................................. 21
FEED TABLE ASSEMBLY (bottom) .............................................................................................. 22
ADJUSTING THE FEED RAIL ........................................................................................................ 23
LOADING THE FEEDER ............................................................................................................... 23
SETTING THE AUTOMATIC FEEDER............................................................................................ 24
CONTINUOUS FEEDING ............................................................................................................. 24
FEEDING NOTES......................................................................................................................... 25
DELIVERY TABLE............................................................................................................................. 25
CHECKING THE SENSORS ........................................................................................................... 26
ROTATING PLASTIC COVER........................................................................................................ 26
TROUBLE SHOOTING ..................................................................................................................... 27

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INTRODUCTION
PREFACE
The KF-250 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 independent feeder allows the machine to be a stand alone
solution for creased paper coming off any type of creasing 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.
SPECIFICATIONS
Net Weight: KF-250………………………………………………………..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/60 HZ or 220v/50 HZ, AC 20 AMP
Circuit Protection: 20/5 AMP Circuit Breaker
NOTE: Older buildings, overloaded lines, and bad grounds can affect the operation of your KF-
250. 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.
Do not install the machine on uneven ground.
NEVER use in a wet area. Electric shock could occur.
Use at least a 20 amp power source at 110 vac.
Use a GROUNDED outlet and a GROUNDED circuit. Do not 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 in the up or open position.
Open and close the plastic cover slowly.
DURING USE:
Exercise caution with long hair and loose fitting clothes when near the machine nip
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 side cover, 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-250 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 reflect incorrectly. 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-250 clean and in top condition, it will give you years of service.
IMPORTANT NOTES BEFORE OPERATING THE KF-250
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-250 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.
Feed Table Assembly
Delivery Tray
Motorized Delivery
Paper Stop
Delivery Tray Pg. 9
Power Switch Pg. 11
Touch Screen Pg. 12
Gap Settings Pg. 14
Feed Table Assembly Pg. 21
Feed Guide Rail Pg. 21
Motorized Delivery Pg. 25
Feed Guide Rail
Touch Screen
Power Switch
Gap Knobs

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SETTING UP YOUR KF-250
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!
Cut outs on shaft for
delivery mounting

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BI-PASS TRAY INSTALLATION
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.
First, angle upward and insert the upper hooks into the upper slots and then rotate downward
to place the lower hooks into the lower slots.
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.