Cyklos GPM 450 SA User manual

Operating Instructions
Issue no.
3
Sheets
15
Semi-automatic creasing and
perforating machine GPM 450 SA
Warnings
This document including the attachments is exclusive intellectual property of Cyklos Choltice
(producer cooperative). Any other use (copying, distribution or sale) is possible only with approval
of the chairman of the cooperative.
Valid from serial number:
16043163

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CONTENT
1. Introduction.................................................................................................................................3
2. Safety Risks................................................................................................................................3
2.1 Safety Warning.................................................................................................................3
2.2 General Work Safety and Health Protection......................................................................3
3. Warnings.....................................................................................................................................4
4. Technical Parameters.................................................................................................................6
5. Machine Description....................................................................................................................7
6. Machine Installation....................................................................................................................9
6.1 Ram Adjustment...............................................................................................................9
7. Setting Machine Using Touch Screen.......................................................................................10
7.1 Language selection.........................................................................................................10
7.2 Setting Number of Segments..........................................................................................11
7.3 Setting Position of Segments..........................................................................................11
7.4 Special Types of Folds....................................................................................................11
7.5 Saving and Loading of Program......................................................................................12
7.6 Working Cycle.................................................................................................................13
7.7 Manual Control ...............................................................................................................13
7.8 Service Menu..................................................................................................................14
8. The Most Common Faults (Troubleshooting) ............................................................................15
9. Machine Disposal......................................................................................................................15

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1. INTRODUCTION
We are presenting you with Operating Instructions that contain machine technical data and
instructions necessary for correct setting, machine start-up, operation and maintenance.
Instructions are intended for machine operation as well as for service engineers. People
manipulating, installing and operating the machine should familiarise themselves with the
instructions before they start. We would like to emphasize that service operations can be executed
only by an authorized person with proper qualification. This person should be thoroughly familiar
with control and all functions of the machine. Any repair done without authorization can lead to a
breach of the warranty. We are referring to section 2.2 – Work Safety and Health Protection
providing basic information about safety during work with the machine and an operator's health
protection. Please pay due attention to this section. Be aware that the final responsibility lies with
the individuals working with the machine.
The machine construction complies with the Directive 98/37/EC of the European Parliament and of
the Council. If all the instructions in this document are respected, you will be satisfied with
precision and performance of the machine.
We can assure you the machine received maximum care. Thoroughness of control ensures
machine precision within the scope of the acceptance standards applicable for this machine. We
believe these Operating Instructions will be a valuable guide for you.
2. SAFETY RISKS
2.1 Safety Warning
When using GPM 450 SA, all safety rules and procedures as well as all warnings regarding work
safety and health protection listed in this document must be observed. Or otherwise, considering
the bellow listed factors, a serious injury or death of a person, damage or destruction of the
machine, its parts or accessories could occur.
Factors increasing risk:
- Rotating pulleys and moving belts
- Voltage
- Noise made during processing
- Moving parts of the machine and equipment
- Sharp edges created during processing
- Dust created during processing
2.2 General Work Safety and Health Protection
This section provides the user with basic information about work safety and health protection of an
operator and all other people who come into contact with the machine.
If the GPM 450 SA is used correctly, it is a very safe machine. However, if used incorrectly, it can
be dangerous. When operating the machine, the operator is responsible for their own personal

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safety. The manufacturer is not responsible for any injury to a person or damage to the machine
caused by use or operation that is not in compliance with the Operating Instructions. The owner of
the machine is responsible for the machine being operated, maintained and serviced only by
qualified people.
The machine design is in compliance with international standards and regulations for construction
of machine tools. For the machines exported to the European Economic Area (EEA), the customer
will obtain "Declaration of Conformity" together with the accompanying technical documentation
for the machine - Operating Instructions. The machine also has the CE marking.
The CE marking on the machinery signifies that the product complies with the technical
requirements specified in all the legal regulations that apply to the machinery and that require or
allow this marking. This marking also signifies that a specified procedure was followed during the
assessment of the stated conformity.
With the document “Declaration of Conformity” the manufacturer certifies that the given machinery
complies with the requirements of the Directive 98/37/ES of the European Parliament and of the
Council and the harmonised technical standards. Directive 98/37/ES of the European Parliament
and of the Council is a document defining the generally applicable basic requirements of the health
protection and safety for the machinery operated by a user in the EEA.
The Directive 98/37/ES of the European Parliament and of the Council does not apply to the
machinery exported to the countries outside the EEA.
The customer will receive the accompanying technical documentation for the machine – Operating
Instructions. The manufacturer hereby asks the user to ensure comprehensive safety as directed
by the relevant legal proceedings, standards and regulations, the Operating Instructions and other,
by training the workers consistently.
The machine is intended for work in automatic cycles.
The machine operator monitors the process and the operating mode of the machine. Also replaces
material with the new one and checks the measurements. Operator's position by the machine is
not defined.
3. WARNINGS
Only sheets of the size listed in the parameters can be creased and perforated in the creasing and
perforating machine.
a) It is forbidden to crease and perforate foils, sheet metal or other similar materials.
b) The machine can be only used in enclosed spaces (e.g. offices, shops).
c) It is forbidden to use the machine outdoors.
d) It is forbidden to use the machine when the electric cord is damaged.
e) It is forbidden to use the machine if it makes strange sounds.

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f) It is forbidden to plug the machine into other voltage than indicated on producer’s
identification plate.
g) Read all instructions before using the machine.
h) It is not suitable for children to be near the machine.
i) It is forbidden to put fingers or hands into the machine when the electric cord is plugged in.
j) When the machine is jammed, it is necessary to unplug the machine first and then
troubleshoot.
k) When replacing a faulty electrical component, it is forbidden to use a different type of
component or different capacity component. When replacing a component, the electric cord
must be unplugged.
l) Covers can be only dismounted by a trained technician when the machine is unplugged.
m) The operator or the person appointed for operation cannot use the machine unless they
have been trained.

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4. TECHNICAL PARAMETERS
a)
Max. working width
450 mm
b)
Recommended paper grammage - creasing
80 - 400 g/m²
Recommended paper grammage - perforation
80 - 250 g/m²
c)
Crease width *
CITO 1,0 mm - paper thickness < 0,2 mm
(mostly 80 - 150 gsm)
CITO 1,4 mm - paper thickness 0,2 - 0,4 mm
(mostly 160 - 250 gsm)
iron channel - paper thickness 0,4 - 0,5 mm
(mostly 250 - 400 g/m²)
d)
Max. number of creases per sheet
15
e)
Number of Programmes
5
f)
Min./Max. distance of creases
2/ 1000 mm
g)
Min. distance of crease from edge of the sheet
0 >
h)
Speed
1500 A4 sheets/ hr (with one crease)
i)
Predefined types of fold
1/2, 1/3, 1/4, book cover
j)
Machine dimensions
1200 x 590 x 300 mm
Packing size
750 x 750 x 400 mm, on pallet 80 x 80 cm
k)
Machine weight
net 52,5 kg, gross 56,5 kg
l)
Voltage / frequency
230 V / 50 Hz, 110 V / 60 Hz
m)
Power input
2 A
n)
Fuse
T3,15 A / 250V
* Note: It is necessary to respect recommended width of creasing channel for different paper
thickness. If we use inappropriate width of crease (usually narrow creasing channel for thick paper)
inaccuracies in position of crease may appear, crease will be placed in different distance than what
we set on display. If we use thick paper in combination with narrow crease, the result is that the
paper is pressed into the creasing channel, the rollers start to slip trying to release the paper. Use
wider crease in such case.

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5. MACHINE DESCRIPTION
Content of package
-the machine GPM 450 SA 1 x
-magnetic side guide 1 x
-magnetic strip 2 x
-perforating knife 1 x
-creasing knife (fitted on the machine) 1 x
-lower creasing/perforating tool (fitted on the machine) 1 x
-supply cable 1 x
-hexagonal key 1 x
1 – Feeding table
2 – Delivery table
3 – Fixed T-square
4 – Left side guide
5 – Magnetic strip
6 – Display
7 – Control light
8 – STOP button
9 – Square bar
10 – Upper cover
11 – Magnetic stop
12 – Power supply switch
13 – Clamp
14 – Ram
15 – 6 mm hexagonal
screw
16 – Locking screw
17 – Pressing mechanism
18 – Adjusting screw
1
2
3
4
5
6
7
8
9
10
11
12

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6. MACHINE INSTALLATION
Electric creasing and perforating machine is suited for final processing of graphic materials up to
450 mm width. Creasing enables easy folding of the paper. Knife change and turning of the square
bar (9) allows making perforation. Waste-less perforation allows easy separation of the paper.
After unpacking the machine has to be put on a solid area, the delivery table is put on (2). After the
machine has been plugged into the power outlet, it is ready to operate and the display is alight (6).
When the upper cover (10) is lifted up the machine is automatically turned off and the control light
(7) turns red.
Machine is adjusted for creasing by manufacturer. To start with perforating, it is necessary to
change the knife (in the packaging included). First of all the machine has to be unplugged and the
upper cover (10) lifted up. Then we have to dismount 2 locking screws (16) located on the joist of
the hinged pressing mechanism (17). Then we lift off the hinged mechanism and fix it in the upper
position by locking screws inserted into the sideboard. Then we dismount 5 hexagonal screws (15)
and the clamp (13). For perforation it is necessary to set the square bar (9) face up by flat side
without creasing channels. We do not tighten the knife completely, we carry out a control upstroke
to make sure that the upper edge touches the slide and finally we can tighten the screws (15).
Then we carry out the assembly of the pressing mechanism (17) which we place in the original
position.
6.1 Ram Adjustment
The ram (14) with perforating or creasing tool can be moved down by the help of both adjusting
screws (18).The screws should be loosened anticlockwise gradually by 1/12 revolution approx. 30˚
(the bar moves down) and then it has to be fastened by a nut. After each 30˚ turn it is necessary to
check, whether perforating (creasing) quality is sufficient. When the ram (14) is set-up correctly it is
not needful to readjust it with each change of function (perforating, creasing).
18
14
17
16
15
13

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7. SETTING MACHINE USING TOUCH SCREEN
7.1 Language selection
After the power supply switch has been turned on, the display shows the basic menu (fig.1)
Fig. 1: The Main screen
There is a hidden icon in the left upper corner. If you press this space a language menu comes up
(fig.2).
Fig. 2: Language selection
Press an icon with required language. Then the display shows the basic menu in chosen language.
Counter reset (finished)
To reset the meter you should proceed as follows. Press the blue figure „pcs“, which is the
number of papers that have been processed last. This brings up a figure keyboard.Then we press
number „0“ and confirm it by pressing „ENTER“. That takes us back to the previous menu and
the meter shows zero.

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7.2 Setting Number of Segments
Pressing the numeric icon under the “Number of creases" sign the displays the numeric keypad.
By pressing the relevant digit, the number of creases/perforations (segments) is set. The program
enables setting of up to 15 segments. The selection of number of segments is ended by pressing
the "Enter" key. The number of segments is now set.
Fig. 3: Setting screen
7.3 Setting Position of Segments
The position of the first segment is set as the distance from the edge of the sheet. The position of
each following segment is defined as its distance from the previous segment. The "no. +" and "no.
-" serve for the choice of required segment. Choose the segment number 1 and then press the
numeric icon under the word "length". A numeric keypad is now displayed. Use the numeric
keypad to set the distance from the edge of the sheet and press "Enter". The position of the first
segment is set. Choose the segment number 2 using the "no. +" key and then press the numeric
icon under the word "length" again. Use the numeric keypad to set the distance from the first
segment and press "Enter". The second segment is set. Set all the remaining segments the same
way. When all the segments are set, press the "Return" icon to go back to the main menu. The
machine is now ready to process the task.
7.4 Special Types of Folds
By pressing “>>>” icon in Setting screen we enter to screen where most common types of fold are
displayed (fig. 4). To achieve most common folds it is necessary to crease in certain distances like
1/2, 1/3 or 1/4 of the paper. By pressing appropriate icon we can easily achieve one of the most-
used folds. First, it is necessary to prepare the required sheet the same way as for the processing.
Then press the “1/2” icon (other fold types accordingly), followed by “<<<”, “Return” and “Start”
icons. On main screen appears symbol of appropriate icon (1/2, 1/3, etc.). One sheet goes through
the machine, its length is measured and 1/2 of the length is calculated. The screen changes to the
Setting screen (fig. 3). The calculated length of the 1/2 is displayed in the “length” box. Then return
to the main screen and press the “Start” icon. We recommend to process only one sheet and
check the position of the 1/2, whether the distance was measured correctly. If the crease is not in
precisely in the required distance, return to the Setting screen and correct the distance manually.
All other folds work the same way.

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Fig. 4: Most common types of fold
7.4.1 Book cover
Amongst these types of fold there is one very special function called book cover. The machine
GPM 450 SA is excellent for making professional book and brochure covers. Book cover is defined
by 4 creases made in the middle of the sheet with fixed distances 6 mm between the first and
second crease and third and fourth crease. The distance between second and third crease is
optional depending on thickness of book. This dimension is defined by “length” icon below book
cover icon.
7.5 Saving and Loading of Program
The software allows saving up to 5 different programs. The number and position of the segments is
set according to the procedure described in Section 7.3. As soon as the last step of setting (the
required number of segments and their position) is done, the program can be saved. On the main
screen press the number in the right side of the screen showing program number. The menu for
saving and loading of a program (fig. 5) appears.
Fig. 5: Saving and loading program

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Choose the number for numbering the program using the keys "prg +" and "prg -". Press the
“Save" icon. Go back to the main menu by pressing "Return". The program is saved. Load the
program as follows: On the main screen press the number in the right side of the screen showing
program number. Choose the number of the program you want to load using the keys "prg +" and
"prg -". Press the "Load" icon. Go back to the main menu by pressing "Return". The machine is
ready to operate according to the loaded program.
Warning: The screen displays the number of the last program saved or loaded. For more effective
work the operator can change the program without saving it. In such case, the number of the last
program saved or loaded is still displayed, but the machine operates according to the operator’s
last setting, even though this setting has not been saved. If the machine is turned off and then
turned on again by the electric switch, the machine operates according to the program displayed
on the screen. The last unsaved setting is deleted.
7.6 Working Cycle
You can either choose a preset program or create your setting. First you have to adjust the
movable left side guide (4) on the feeding table according to the paper size. Between side guides
we either remove or add magnetic strips (5) which prevent paper from deflection. Then we have to
set the distance of the magnetic stop (11) on a delivery table according to the paper size. Press the
"Start" icon on the screen (fig. 1). The machine starts up and the working cycle screen is
displayed (fig. 6). There are a "Stop" icon and information about the number of processed sheets
displayed on the screen.
Fig. 6: Working cycle screen
Then we can start feeding the machine with the paper. It is very important to do this accurately.
When the machine is creasing or perforating the red diode on the main panel is on. We can put
more paper in the machine after the red light changes into green again. The machine can be
turned off by pressing the “Stop“ button on the display. In case of emergency you can use a red
„STOP“ button placed on the main panel.
7.7 Manual Control
When changing the tools it is necessary to carry out a testing upstroke (turn) to make sure that
both tools are parallel, and also to make sure that either creasing or perforating tool is leaned

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against the slide. We do it by pressing the „Move“ icon and the following menu comes up –
“Manual control” (fig. 7).
Fig. 7: Manual control
After activating the „1 turn“ icon the control upstroke is carried out. In case the crease depth is not
the same on the both sides of the paper or perforation does not result in direct separation of the
paper, we can adjust the ram (14) with a perforation knife. This can be done using the adjusting
screws (18). It is necessary to loosen the screws gradually anticlockwise (slide goes down) by
1/12 of the turn (30°), and then secure it with a nut. You should check the quality of perforation
after each turn (30°). After the machine has been adjusted for perforation, it is adjusted for
creasing as well.
Icons „Forward“ and „Backward“ are used to release stuck piece of paper from the machine.
For return to the main menu, press „Return“.
7.8 Service Menu
There is a hidden icon in the right upper corner. This icon serves for service technicians trained by
Cyklos. To access this icon you need to enter a password (fig. 8).
Fig. 8: Service screen

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8. THE MOST COMMON FAULTS (TROUBLESHOOTING)
a) upstroke stoppage: If this problem occurs during adjusting and checking the upstroke of the
ram (14), it is necessary to loosen locking nuts and then turn clockwise by the adjusting screws
(18) two revolutions (the ram goes up). When the upstroke cycle is terminated, then the red diode
is on. After the machine is turned back on the upstroke process should finish. It is necessary to
readjust the ram (14).
b) paper jam: When the paper gets jammed or damaged, it is necessary to turn the machine off
immediately (press the STOP button 8). After the machine has been stopped we have to tap on the
MOVE icon. Before we remove the paper it is necessary to carry out an upstroke (1 turn icon).
Then we can use button Backward or Forward depending on situation.
c) crease is in incorrect position compared to values set on display
It is necessary to respect recommended width of creasing channel for different paper thickness. If
we use inappropriate width of crease (usually narrow creasing channel for thick paper)
inaccuracies in position of crease may appear, crease will be placed in different distance than what
we set on display. If we use thick paper in combination with narrow crease, the result is that the
paper is pressed into the creasing channel, the rollers start to slip trying to release the paper. Use
wider crease in such case. Look for correct crease width in chapter 2, c.
9. MACHINE DISPOSAL
When the lifetime period is over, it is forbidden to dispose of the machine into the common waste.
The machine must be disassembled and metallic, non-metallic, plastic, rubber and electronic parts
sorted. These parts are disposed of in the relevant points of recycling. Some parts of the machine
can contain dangerous substances that are harmful to the environment and health.