Cyklos GPM 450 SPEED User manual

Operating Instructions
Issue no.
4
Sheets
35
Automatic Creasing, Perforating and
Punching Machine GPM 450 SPEED
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
17123999

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CONTENTS
1. Introduction...............................................................................................................................................4
2. Safety Risks .............................................................................................................................................5
2.1 Safety Warning ...................................................................................................................................5
2.2 General Work Safety and Health Protection........................................................................................5
3. Warnings..................................................................................................................................................6
4. Technical Parameters...............................................................................................................................7
5. Machine Description.................................................................................................................................8
6. Machine Installation................................................................................................................................11
7. Adjustment of Machine and Feeding Table.............................................................................................12
7.1 Introduction.......................................................................................................................................12
7.2 Adjustment of Table..........................................................................................................................12
7.2.1 Adjustment of Feeding Table Thrust...........................................................................................16
7.2.2 Correct Placement of Paper Pile.................................................................................................16
7.2.3 Function of Auxiliary Feeding Head............................................................................................17
7.2.4 Adjustment of Callipers...............................................................................................................17
8. Setting Machine Using Touch Screen.....................................................................................................19
8.1 Display Unit Preview and "SETTING" Screen ...................................................................................19
8.2 Overview of Touch Screen Function Icons........................................................................................19
8.2.1 Sound On/Off..............................................................................................................................19
8.2.2 Manual Control...........................................................................................................................20
8.2.3 Info.............................................................................................................................................20
8.2.4 Language Selection....................................................................................................................20
8.2.5 Service Menu..............................................................................................................................20
8.3 Setting Number and Position of Creases/Perforations.......................................................................21
8.3.1 Most Common Folds...................................................................................................................22
8.3.2 Setting the Number of Segments................................................................................................22
8.3.3 Setting the Position of Segments................................................................................................22
8.4 Setting the Speed of Processing.......................................................................................................23
8.5 Setting Batch.....................................................................................................................................23
8.6 Program Saving and Loading............................................................................................................23
8.7 Starting Working Cycle......................................................................................................................24
8.8 Manual Control..................................................................................................................................25
8.8.1 Adjustment of Top Bar Stroke.....................................................................................................26
8.8.2 Turning Off Automatic Feed........................................................................................................26
9. The Most Common Faults (Troubleshooting)..........................................................................................27
10. Recommended Machine Maintenance..................................................................................................30

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11. Machine Disposal .................................................................................................................................30
Appendix 1: Accessories ............................................................................................................................31
Appendix 2: Instructions for Table Assembly..............................................................................................34
Appendix 3: Optional Accessory.................................................................................................................35

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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.

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2. SAFETY RISKS
2.1 Safety Warning
When using GPM 450 SPEED, 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 SPEED 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 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.

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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.
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.
n) The operator must pay special attention during manipulation with rotary parts of the machine – see
yellow Warning Sign (Pos. 40, page 8).

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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
Recommended paper grammage - punching 80 - 400 g/m²
c) Creasing width*
CITO 1,0 mm - paper thickness < 0,4 mm
(mostly 80 - 200 gsm)
iron channel - paper thickness 0,4 - 0,5 mm
(mostly 200 - 400 g/m²)
d) Max. number of creases per sheet 15
e) Number of Programmes 9
f) Min. distance of creases 1 mm
g) Min. distance of crease from edge of the sheet 0 >
h) Speed 2.500 A4 sheets/ hr (with one crease)
i) Machine dimensions 1250 x 675 x 520 mm
j) Machine weight net 120 kg, gross 157 kg
(weight includes mobile table)
k) Voltage / frequency 230 V / 50-60 Hz
l) Power input, electric current 400 W, 1,0 A
m) Fuse T3,15 A / 250V
n) Noise Level 79,2 dB
* 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
1 – Front table
2 – Delivery table
3 – Front side guide
4 – Telescopic table
5 – Magnetic strip
6 – Display unit
7 – Paper brake + weight
8 – STOP button
9 – Disengaging tool
10 – Auxiliary feeding head
11 – Back stop
12 – Electric switch
13 – Waste drawer
14 – Table thrust regulation screw
15 – Table release
16 – Position regulation screw
17 – Angle regulation screw
18 – Tool thrust regulation bolt 1)
19 – Plug socket
20 – Calliper
21 – Locking bolt of the side guide
22 – Separator
23 – Calliper locking
24 – Tool base (fig. 2)
23
1
26
7
5
4
30
28
10
17
21
16
22
15
13
14
9
27
2
11
20
8
12
6
3
29
39
19
40

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25 – Top bar (fig. 1)
26 – Head thrust regulator
27 – Front table thrust scale
28 – Skew indicator of the front side guide
29 – Auxiliary feeding wheel
30 – Locking bolt of the brakes
31 – Bolts for locking the machine on the table
(fig. 5)
32 – Creasing tool screw M6x14 (fig. 3)
33 – Perforating tool screw M6x20 (fig. 2)
34 – Perforating tool screw M4x25 (fig. 2)
35 – Needle bearings of eccentric axis (fig. 1)
36 – Top bar bearings (fig. 1)
37 – Safety ring (fig. 1)
38 – Tool screw M4x5 (fig. 4)
39 – Fixing screw of calliper
40 – Warning Sign
41 – Connector plug for TriFold 360
Fig. 1: Dismounted back cover
37
18
35
25
36
41

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Fig. 2: Perforating tool 2:1- 9 TPI (571 40 465a) – standard equipment. Microperforating tool (571 40 464) as optional
accessory.
Fig. 3: Creasing tool CITO 1,0 mm (571 40 467) – standard equipment. Creasing tool CITO 1,4 mm (571 40 468) as
optional accessory.
Fig. 4: Creasing tool – iron channel for higher grammage (570 40 466)
24
33
34
32
24
38
24

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6. MACHINE INSTALLATION
When unpacked, place the machine on the table (See the Instructions for Table Assembly in Appendix 2).
Place the machine on the table, so that the heads of the table bolts (*) fit into the rubber legs of the
machine. Lock the machine to the table with the bolts (31). The delivery table (2) can be fitted when the
machine is locked. When plugged in, the machine is ready to operate. When the electric switch (12) is
switched on, the display unit (6) will light up. Setting the machine using the touch screen is described in
detail in Section 8.
Fig. 5: Machine installation on the table
31
*

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7. ADJUSTMENT OF MACHINE AND FEEDING TABLE
7.1 Introduction
Electric automatic creasing and perforating machine serves for final processing of graphic material of the
width up to 450 mm. Creasing allows easy folding of the paper and that’s why it is convenient to use the
machine in combination with a folding module. No-waste perforation enables you to tear the paper easily.
The default setting has been done for all types of tools. To change the function of the machine it is
necessary to exchange the tool (placed by the manufacturer into the waste drawer – 13). Unplug the
machine, take out the tool (9) and replace with the required tool. To replace the cutters in the tools loosen
the tool screws (32, 33, 34, 38). Replace the cutter and fit the tool back. Tighten the tool screws (32, 33)
lightly. Then place the tool into the machine and perform a trial stroke to ensure the cutter and the tool base
(24) are parallel. Other settings are done through the display unit – Section 8.8
7.2 Adjustment of Table
Place the angle regulation screw (17) in to the initial position, so that the front side guides (3) are
perpendicular to the tool. The initial position of the angle regulation screw (17) can be checked on the skew
indicator of the front side guide (30) – the back movable part of the indicator must be vertical and aligned
with the cross mark. Set the table thrust regulation screw (14) to minimum thrust. Ready the table into the
lower locked position. Lock the table by pressing the right and left edge of the table simultaneously with
your palms (fig. 6).
Fig. 6: Pressing the table before paper is loaded
The table automatically locks in the lower position. Tilt the paper brakes (7) outward. Loosen the locking
bolts of the side guides (21). Set the front side guides (3) approximately for the paper format size, so that
the position of the sheet is symmetrical with the centre of the feeding table. Rulers on the feeding table
serve for exact adjustment of the side guides (3). Place the magnetic strips (5) on the feeding table
between the front side guides (3) – two or four strips (5) according to the paper format. The magnetic strips
(5) prevent the paper on the feeding table from corrugating and improve the feeding function (fig. 7).

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Fig. 7: Correctly prepared table – even placement of the magnetic strips (position 5).
Fig. 8: Incorrectly prepared table – absence of the magnetic strips (position 5) leads to the paper deformation.

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Place 2 – 3 sheets to be processed on the feeding table. Push the sheets to the stainless steel plate, so
that they are collinear (fig. 9). This ensures the sheets are perpendicular to the tool. Push the side guides
(3) towards each other, so that there is a minimum gap between them and the sheets. Caution! This
adjustment has a great impact on correct paper feeding into the machine. If the processed paper is not
perfectly perpendicular, correct this inaccuracy by skewing the side guides (3) using the angle regulation
screw (17). Lock the adjusted position with the locking bolts of the side guides (21). Correct and incorrect
procedure is shown in figures 9 and 10.
Fig. 9: Correctly prepared table – the sheet has been pushed to the stainless steel plate
Fig. 10: Incorrectly prepared table – the sheet has not been pushed to the stainless steel plate along its whole length

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Adjust the auxiliary feeding wheels (29) to the edge of the sheet and secure with the setscrew. For
adjustment use the Allen “T” key size 2. When the wheels are adjusted, tighten the setscrews, so that the
wheels do not spin on the axle. Correct and incorrect procedure is shown in figures 11 to 14. Incorrect
adjustment of the auxiliary feeding wheels (figures 13, 14) can affect precision of paper feeding.
Fig. 11: Adjusting the feeding wheels (position 29) with the Allen “T” key
Fig. 12: Correct adjustment of the feeding wheels
Fig. 13: Incorrect adjustment of the feeding wheels – they are placed too far from the side guide

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Fig. 14: Incorrect adjustment of the feeding wheels – they are placed behind the side guide
7.2.1 Adjustment of Feeding Table Thrust
Release the feeding table by pressing the table release button (15) and set the table thrust regulation screw
(14) to minimum thrust. In "SETTING" Screen (Fig. 20) hold MOVE ROLLERS key with one hand and at
the same time use your second hand to gradually increase the feeding table thrust with the table thrust
regulation screw (14) until the feeding wheels has fed the sheet into the machine. The minimum feeding
table thrust is now set. Do not increase the feeding table thrust when not necessary, to eliminate possible
tracks on paper caused by the feeding wheel. The table thrust scale (27) helps you to adjust the thrust
precisely. Especially for the lower paper grammage, it is better to use less thrust, so as not to deform
paper.
7.2.2 Correct Placement of Paper Pile
When the table thrust is correctly adjusted, the feeding table can be loaded with a pile of paper up to the
maximum capacity of the feeding table. The pile of paper to be processed must be leafed through properly
before it is placed on to the table to minimize the possibility of feeding several sheets at once. The sheets
must be fed into the machine individually. Ideally, there is approx. a 2 mm gap between the sheets. The
sheets cannot overlap when fed into the machine. If the sheets overlap, tilt the paper brakes (7) down onto
the end of the sheet – approx. 1 to 2 cm from the end of the sheet. First tilt the paper brakes (7) without
weight, then increase it gradually until the sheets are fed into the machine individually with approx. a 2 mm
gap. Do not increase the weight on the paper brakes to eliminate possible tracks on the paper caused by
the feeding wheel and by the wheel of the auxiliary feeding head. After adjustment lock the paper brakes
(7) with the locking bolt of the brakes (32). Now press the START .. Ideally, if the feeding table is
adjusted correctly, the auxiliary feeding head (10) is not working and the sheets are fed into the machine
only by the friction system.
If the machine feeds two or more sheets at once, the machine must be stopped immediately by pressing
„STOP" (8). The sheets that have been fed into the machine must be taken out using the "MANUAL
CONTROL" Screen ( ) and icons by MOVE ROLLERS (Section 8.8). If the cycle was interrupted
when the tool stopped in the lower position, it is necessary to return the tool into the top position using the
UPPER TOOL icon from the "MANUAL CONTROL" Screen.

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Fig. 15: Example of correct placement of paper pile
Fig. 16: Example of incorrect setting of table thrust – too much thrust for the low paper grammage
7.2.3 Function of Auxiliary Feeding Head
Paper feeding is influenced by many external factors. They are humidity, static electricity, type of print, etc.
If for any reason the middle feeding wheel does not feed paper into the machine, the sensor inside the
machine immediately activates the auxiliary feeding head that will slide the sheet under the feeding wheels.
Set the thrust of the auxiliary head (10) to minimum with the head thrust regulator (28). Do not increase the
feeding wheel thrust when not necessary, to eliminate possible tracks on paper caused by the feeding
wheel.
7.2.4 Adjustment of Callipers
Always place a piece of paper that you are going to process under the callipers (20). Placement of correct
paper grammage will define an optimum gap between the wheel of auxiliary feeding head (10) and the
separator (22). This decreases wear of the friction feed system and also eliminates possible tracks on
paper caused by the feeding wheels. Place the paper cutting under the callipers by pulling the calliper
lever. The calliper automatically locks in the upper position. Place the paper cutting under the callipers and
unlock the calliper locking (23) by pulling. The gap between the auxiliary head wheel and the separator is
now defined.

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Fig. 17: Pulling callipers to the upper position
Fig. 18: Defining the gap of the friction feed system by placing paper under the callipers
If the machine has been adjusted correctly, but the friction feed system is not able to feed paper into the
machine correctly, or the feeding wheels are damaging the print (there is a distinct track from the feeding
wheel on the sheet), you can disable the friction feed, change the automatic mode to the semi-automatic
and feed paper into the machine manually.
Semi-automatic Mode
Lift the callipers (20) until the calliper locker (23) is activated and the callipers remain locked in the upper
position. he change of position of the callipers disables friction feed system, which enables us to manually
feed the sheet directly between the feeding rollers. Then the automatic feed must be turned off (Section
8.8.2 Turning Off Automatic Feed). The machine is now in the semi-automatic mode.

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8. SETTING MACHINE USING TOUCH SCREEN
8.1 Display Unit Preview and "SETTING" Screen
Fig. 19: Start-up Screen
When the electric switch (4) is turned on, the Start-up Screen (Fig. 13) displays on the touch screen
showing the machine’s name and picture. After a few seconds this screen automatically changes to the
“SETTING” screen.
Fig. 20: “SETTING” Screen
8.2 Overview of Touch Screen Function Icons
8.2.1 Sound On/Off
Press to turn on/off the sound signal for key pressing. If the sound is on, there will be a beep when the
active areas on the touch screen are pressed. If the sound is off, appears.

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8.2.2 Manual Control
Press to display the "MANUAL CONTROL" screen, see Section 8.8
8.2.3 Info
Press to display the information screen. The data are approximate. Press OK to go back to the
“SETTING” screen.
Fig. 21: “INFO” Screen
8.2.4 Language Selection
Press to display the language selection screen and choose the language.
Fig. 22: “LANGUAGES” Screen
8.2.5 Service Menu
Press to display the “SERVICE MENU” screen. This menu is password-protected and accessible only to
the manufacturer’s (distributor’s) service engineers. If you do not know the password, press to return to