Cyklos GPM 450 verSA User manual

Operating Instructions
Issue no.
1
Sheets
21
Creasing, Perforating and Punching
Machine GPM 450 verSA
Attention
This document including its appendices is the exclusive intellectual property of Cyklos Choltice, Producer
Cooperative. Any other use (copying, distribution or sale) is possible only with the approval of the chairman
of the cooperative.
Valid from serial number:
201929297

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Content
1. Introduction..................................................................................................................................... 3
2. Safety Risks...................................................................................................................................... 3
2.1 Warning................................................................................................................................... 3
2.2 General Work Safety and Health Protection........................................................................... 3
3. Warnings and Recommendations ................................................................................................... 4
4. Technical Parameters...................................................................................................................... 5
5. Machine Description ....................................................................................................................... 6
5.1 Introduction............................................................................................................................. 6
5.2 Exchangeable tools.................................................................................................................. 7
6.1 Adjustment of Top Bar Stroke................................................................................................. 8
7. Setting the Machine Using Touch Screen............................................................................................ 9
7.1 Overview of Touch Screen Function Icons .............................................................................. 9
7.1.1 Sound On/Off .................................................................................................................. 9
7.1.2 Manual Control................................................................................................................ 9
7.1.3 Info................................................................................................................................. 10
7.1.4 Language Selection........................................................................................................ 11
7.1.5 Speed of Processing....................................................................................................... 11
7.1.6 Service Menu................................................................................................................. 11
7.2 Setting the Number and Position of Creases/Perforations................................................... 12
7.2.1 Crease Positon –Manual Setting................................................................................... 12
7.2.2 Crease Position –Automatic Setting............................................................................. 13
7.3 Program Saving and Loading ................................................................................................. 14
8. The Most Common Faults (Troubleshooting) ................................................................................... 15
9. Recommended Machine Maintenance ............................................................................................. 15
10. Machine Disposal ............................................................................................................................ 15
Appendix 1: Accesories.......................................................................................................................... 16
Appendix 2: Optional Accessories......................................................................................................... 19

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1. INTRODUCTION
We are presenting you with Operating Instructions that contain machine technical data and
instructions necessary for the correct setting, start-up, operation, and maintenance of the machine.
The Operating Instructions are intended for machine operators as well as for service engineers. The
individuals manipulating, installing and operating the machine should familiarise themselves with the
instructions before they start. We would like to emphasize that service operations may only be
executed by authorized individuals with proper qualifications. They should be thoroughly familiar
with the control and all functions of the machine. Any repair done without authorization may render
the warranty null and void. Reference is made to Section 2.2 –Work Safety and Health Protection
providing basic information about the safe use of the machine and 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 Directive 98/37/EC of the European Parliament and of the
Council. If all the instructions in this document are respected, the machine will render satisfactory
and precise performance.
We can assure you that the machine has received maximum care. The thoroughness of control
ensures machine precision within the scope of the acceptance standards applicable to this machine.
We believe these Operating Instructions will be a valuable guide for you.
2. SAFETY RISKS
2.1 Warning
When using the GPM 450 verSA, all safety rules and procedures, as well as all warnings regarding
work safety and health protection listed in this document, must be observed. 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 workplace safety and health protection
of the operator and any other individuals who come into contact with the machine.

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If the GPM 450 verSA 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 may not be held liable for any personal injury or damage to the machine
caused by use or operation at variance with these Operating Instructions. The owner of the machine
is responsible for the machine being operated, maintained and serviced only by qualified personnel.
The machine design is in compliance with international standards and regulations for the
construction of machine tools. For the machines exported to the European Economic Area (EEA), the
customer will obtain a "Declaration of Conformity" together with the accompanying technical
documentation for the machine - Operating Instructions. Also, the machine bears 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.
The manufacturer certifies by means of the “Declaration of Conformity” that the machinery
concerned complies with the requirements of Directive 98/37/CE of the European Parliament and of
the Council and those of the harmonized technical standards. Directive 98/37/CE of the European
Parliament and of the Council is a document defining the generally applicable basic requirements for
health protection and safety of machinery operated at the user’s facility within the EEA.
Directive 98/37/CE of the European Parliament and of the Council does not apply to the machinery
exported to countries outside the EEA.
The customer will receive the accompanying technical documentation for the machine –Operating
Instructions. The manufacturer hereby requests that the user trains its staff accordingly in order to
ensure comprehensive safety as directed by the relevant laws, standards and regulations, these
Operating Instructions and other documents.
The machine is intended for work in automatic cycles.
The machine operator monitors the process and the operating mode of the machine, replacing
material and checking the dimensions. The Operator's position by the machine is not defined.
3. WARNINGS AND RECOMMENDATIONS
Only sheets of the size listed in the parameters can be creased, perforated and punched by GPM 450
verSA.
a) The operator or the individual appointed for operation cannot use the machine unless they
have been trained.
b) Only sheets of the size listed in the parameters can be creased, perforated and punched by
GPM 450 verSA.
c) It is forbidden to crease and perforate foils, sheet metal or other similar materials.
d) The machine can be only used in interior spaces (e.g. offices, shops), it is not allowed to use
the machine outdoors.

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e) It is forbidden to use the machine when the electric cord is damaged.
f) It is forbidden to use the machine if it makes strange sounds.
g) It is forbidden to connect the machine to voltage different from that indicated on the
manufacturer’s identification plate.
h) Read all instructions before using the machine.
i) Keep the children away from the machine.
j) It is forbidden to put fingers or hands into the machine when the electric cord is plugged in.
k) Covers can be only dismounted by trained personnel when the machine is unplugged.
l) Do not replace faulty electrical components with components of different type or different
capacity. When replacing a component, the electric cord must be unplugged.
4. TECHNICAL PARAMETERS
a)
Working width
450 mm
b)
Recommended paper grammage
80 –400 gsm (creasing, punching)
80 –250 gsm (perforating)
c)
Crease width
CITO 1.0 mm –paper thickness < 0.4 mm
(recommended grammage 80 –200 gsm)
“Iron Channel”1.9 mm –paper thickness 0.4 –0.5 mm
(recommended grammage 200 –400 gsm)
d)
Max. number of creases per sheet
15
e)
Number of programs
15
f)
Min./max. distance between creases
1/999 mm
g)
Speed
1.500 sheets A4/h (with single crease)
h)
Machine dimensions
1.075 x 635 x 390 mm
i)
Packing size
740 x 530 x 675 mm
j)
Weight
Nett 77 kg, Gross 81 kg
i)
Voltage / Frequency
230V / 50Hz –0,5A
110V / 60Hz –0,7A (USA)

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5. MACHINE DESCRIPTION
5.1 Introduction
The GPM 450 verSA is a creasing, perforating and punching machine where the parameters of
individual operations are entered on the touch screen. Loading the sheet of paper is manual, but the
feed of each paper is already done by a stepper motor. The creasing allows for easy folding of the
paper, whereas waste-free perforation allows you to tear off the paper easily.
Fig. 1: View of the machine –right side
Fig. 2: View of the machine –left side

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Position
Name
Position
Name
1
Right Cover
14
Front Right Guide
2
Left Cover
15
Side Guide Lock
3
Front Table
16
STOP Button
4
Waste Drawer
17
Tilt Display Button
5
Exchangeable Tool
18
Main Switch
6
Delivery Table
19
Display (Touch Screen)
7
Rear Side Guide
20
Upper Cover
8
Back Stop
21
Front Bottom Cover
9
Rear Tilt Cover
22
Production Label
10
Front Tilt Cover
23
Fuse Label
11
Warning Sign
24
Plug Socket
12
Front Left Guide
25
Power Cable
13
Levelling Strip
5.2 Exchangeable Tools
In standard equipment, the machine is supplied with the three exchangeable tools described below.
The default setting has been done for all types of tools. A change of the machine function requires
the tool to be replaced. Creasing tools are placed by the manufacturer into the Waste Drawer (4).
Loosen the tool screws (11, 12, 13, 14, 15) in order to replace the knives in the tools. Replace the
knife and fit the tool back. Tighten the tool screws (11, 12). Do not overtighten the tool screws (13,
14, 15). Then place the tool into the machine and perform a trial stroke (see Section 6.1) to ensure
the knife and the tool base is parallel (1). Now tighten the screws (31, 32) completely. Now the tool is
ready for use.
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.

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Fig. 4: Creasing tool –iron channel 1.9 mm for heavy grammage (570 40 466)
Fig. 5: Perforating tool 2:1- 9 TPI (571 40 465a) –standard equipment. Micro perforating tool (571
40 464) as optional accessory.
Pozn.: The list of optional tools can be found in the end of this document –Appendix 2: Optional
Accessories
6. MACHINE INSTALLATION
After unpacking, place the machine on a flat firm surface and attach the Delivery Table (6). Connect
the machine to the power supply, after that the machine is ready for operation. The perforation
function is factory set. For the creasing function replace the tool included in the packaging (Section
5.2).
6.1 Adjustment of Top Bar Stroke
Unless the depth of a crease on both sides of the sheet is identical or unless the sheet is torn away
evenly after perforation, the top bar can be moved down using the tool thrust regulation screws. The
screws should be loosened anticlockwise by approx. 30°, 1/12 of the revolution (the bar moves
downward) and then secure them with a nut. Try the quality of perforation after each turn of the
screw by 30° and, if satisfactory, do not turn the screws anymore. When the adjustment of
perforation is finished, the machine is also to be adjusted for creasing. If the perforating/creasing
force exceeds the limit (engine output is exceeded) and the top bar remains in the lower position,
use the Main Switch (18) to switch the machine off and then wait for 20 seconds before you re-start
the machine. Press (Manual control –Section 7.1.2), then (tool backward) next to the field
UPPER TOOL. The tool is now unlocked and the thrust can be adjusted using the tool thrust
regulation screws. Activate (tool forward) to make a trial stroke.

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7. SETTING THE MACHINE USING TOUCH SCREEN
When the machine is switched on with the Main Switch (18), the Home Screen appears on the
display.
Fig. 6: Home Screen
7.1 Overview of Touch Screen Function Icons
7.1.1 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.
7.1.2 Manual Control
Manual control is mostly used when replacing the tools or when loosening jammed paper from the
machine. Press (manual control) on the Home Screen (Fig. 6) and the following menu is displayed
(Fig. 7). Press the move forward/backward icons , next to the MOVE ROLLERS field to set the
machine’s rollers running. Icons and define the continuity of the run of the rollers. –rollers
are turning only if the arrow is held. –rollers start running and rotate until the icon is pressed
again. Use (tool backward) next to the UPPER TOOL field if the perforation/creasing force gets too
high and the top bar remains in the lower position. Press to unlock the tool and adjust the thrust
by using the tool thrust regulation screws. Activate (tool forward) to make a trial stroke. Refer to
Section 6.1 for how to use the icons of the UPPER TOOL field. Press OK to go back to the Home
Screen.

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Fig. 7: “MANUAL CONTROL” Screen
7.1.3 Info
Press to display the information screen. The data are approximate. Press OK to go back to the
Home Screen.
Fig. 8: Information Screen

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7.1.4 Language Selection
Press to display the language selection pop-up menu and choose the language.
Fig. 9: “LANGUAGES” Screen
7.1.5 Speed of Processing
To adjust the speed of processing press on the Home Screen (Fig. 6). Change speed of rollers
rotation using + and –keys. The machine is set for 100 meaning 100% speed of the machine. The
minimum value is 50. Lower speeds are suitable for processing papers complicated to feed. When
you have finished the setting, press OK to confirm.
Fig. 10: “SPEED OF PROCESSING” Screen
7.1.6 Service Menu
Press to display the “SERVICE MENU” screen (Fig. 11a). 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 the Home Screen. Entering the correct password and confirming by
OK displays the “SERVICE MENU” screen. Press OK to go back to the Home Screen.

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Fig. 11a: “SERVICE MENU” Screen – Password
Fig. 11b: “SERVICE MENU” Screen
Note: Description of service screen is not part of this manual because this screen is not accessible to
end user.
7.2 Setting the Number and Position of Creases/Perforations
7.2.1 Crease Positon –Manual Setting
Press CREASE POSITION MANUAL on the Home Screen (Fig. 6) to display the following menu.
Fig. 12: “CREASE POSITION MANUAL” Screen

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Press the numeric icon next to the NO. OF CREASES field on the touch screen to display the numeric
keypad. By pressing the relevant digit, the number of crease/perforation/punch lines (segments) is
set. You can set as many as 1 –15 segments. The selection of the number of segments is ended by
pressing the ENTER key. The number of segments is now set.
Setting the 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. Use the +and - keys to
choose the required segment. Select 1 in the numeric field next to CREASE NO. and this activates the
DISTANCE numeric icon. 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. Using
the +key choose segment number 2 and then press the numeric icon under DISTANCE 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 in the same way.
7.2.2 Crease Position –Automatic Setting
Press CREASE POSITION AUTOMATIC on the Home Screen (Fig. 6) to display the following menu.
Fig. 13: “CREASE POSITION AUTOMATIC” Screen
The most commonly used folds are created by placing the crease at exactly defined relative distances
of the paper like 1/2, 1/3, 1/4, etc. The most common creases are easily set by pressing the
corresponding button. First, place the required sheet of paper to be processed on the feeding table.
Then press 1/2 (proceed similarly for other types of the fold). A single sheet is run through the
machine without processing; the machine measures the sheet (Fig. 12a) and saves the sheet length in
the memory. Values are displayed in their respective fields when the sheet has passed through. Make
a test. Once the test is completed, it is recommended to check the measured length before
processing the rest of the batch. If the crease is not precisely at the required distance, correct the
distance manually. Then press the checkmark to return to the Home Screen and press START to
run the working process.

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Note: One of the predefined fold types is BOOK COVER. It is defined by 4 creases in the middle of the
sheet. After pressing this icon pop-up menu appears allowing you to set the width of the hinge and
width of the edge of the book cover.
Fig. 13a: “PAPER LENGTH MEASURING” Screen
7.3 Program Saving and Loading
The software allows saving 15 different programs. Press the numeric key under the field PROGRAM
on the Home Screen. The program saving and loading menu (Fig. 14) is displayed. Use the +and -
keys to list values between 1and 15. You can save your jobs under 1 –15.
Press SAVE if you have your job ready and wish to save it. It is possible to name a job you wish to
save. The name changes along with the program number. Load the program in a similar manner. Use
+and -to choose a saved program you wish to load. Press LOAD. Press OK to go back to the Home
Screen. The number of the loaded program is displayed under the PROGRAM field. The machine is
ready to operate according to this program.
Fig. 14:“PROGRAM SAVING AND LOADING” Screen
Warning: The touch screen displays the number of the last program saved or loaded. For the sake of
effectiveness, the operator can change this program by a different 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 touch screen. The last unsaved setting is deleted.

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8. THE MOST COMMON FAULTS (TROUBLESHOOTING)
a) Upper Tool blocked:
If the upper tool gets stuck when adjusting and testing the stroke depth, first loosen the lock nuts
and then turn the adjusting screws clockwise up to 2 turns (the upper tool moves upwards). When
the stroke cycle is interrupted, the LED lights up red. An interrupted stroke cycle should be
completed after starting the machine. The upper tool must be readjusted.
b) Paper Jam:
If paper is jammed or damaged in the machine during operation, the machine must be switched off
immediately by the STOP button. After stopping the machine, select the Manual control. Before
ejecting the paper, it is necessary to perform one control stroke of the tool (the upper tool may be in
the lower position). Then we can use the icons "Forward" or "Back".
c) The position of the crease on the paper is not in accordance with the values shown on
the display
Exceeding the recommended creasing values, meaning using CITO tool 1.0 mm for too thick paper
may cause inaccuracies. The position of the crease on the paper will not match the values shown on
the display. The inaccuracy is due to the thick paper being pressed into the narrow groove and the
subsequent feed rollers slipping while trying to pull the pressed paper out of the groove. In this case,
an iron tool with 1.9 mm wide groove must be selected.
9. RECOMMENDED MACHINE MAINTENANCE
Clean dust from the machine after each job using, for example, compressed air.
Grease the bearings with bearing grease annually.
10. MACHINE DISPOSAL
After the end of the service life, it is forbidden to dispose of the machine in the municipal waste. The
machine must be disassembled, and metallic, non-metallic, plastic, rubber and electronic parts
sorted. These parts are disposed of at the relevant points of recycling. Some parts of the machine can
contain hazardous substances that are harmful to the environment and health.

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APPENDIX 1: ACCESORIES
571 40 467 Creasing Tool (CITO channel 1.0 mm) 1 x
571 40 466 Creasing Tool –“Iron Channel” 1.9 mm 1 x
571 40 465a Perforating tool 2:1 1 x
A perforating tool (571 40 465a) is fitted in the machine for transit. Creasing Tool CITO 1.0 mm (571
40 467) and Creasing Tool –“Iron Channel” 1.9 mm (571 40 466) are kept in the waste drawer (4).
Note: The tools for GPM 450 verSA, GPM 450 SPEED and AirSpeed 450 are identical. Only AirSpeed
450 is wider, a small metal-sheet extension needs to be fitted on this tool; the extension is kept in the
waste drawer, see the picture.

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574 46 978 DELIVERY TABLE (6) 1x
574 59 577 BACK STOP (8) 1x
574 59 563 REAR SIDE GUIDE (7) 2x

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574 59 490 FRONT LEFT GUIDE (12) 1x
574 59 496 LEVELLING STRIP (13) 4x
413 00 008/0 ALLEN KEY NO. 5 1x

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345 00 226/0 POWER CABLE 1x
APPENDIX 2: OPTIONAL ACCESSORIES
Punching tool for wire binding –square 4 x 4 mm, 3:1 (571 40 462)
Punching tool for wire binding –square 5 x 5 mm, 2:1 (571 40 529)
Punching tool for wire binding –square 6 x 6 mm, 2:1 (571 40 593)

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Punching tool for wire binding –round, diameter 4 mm, 3:1 (571 40 475)
Punching tool with calendar semi-circle –square 4 x 4, 3:1 (571 40 463)
Punching tool with calendar semi-circle –round, diameter 4 mm, 3:1 (571 40 476)
Punching tool for coil binding –oval 4 x 5 mm (571 40 594, 571 40 609, 571 40 625)
Punching tool rectangle - 21 holes, 3x8 mm (571 40 624)
Micro perforating tool 30 TPI (571 40 464)
Partial perforating tool (571 40 571)