Cyklos AIRSPEED 450 User manual

Operating Instructions
Issue no.
4
Sheets
38
Automatic Creasing, Perforating
and Punching Machine
AIRSPEED 450
Attention
This document including its appendices is exclusive intellectual property of Cyklos (producer cooperative)
Choltice. Any other use (copying, distribution or sale) is possible only with approval of the chairman of the
cooperative.
Valid from serial number:
201926663

Operating Instructions | AirSpeed 450
2
CONTENTS
1. Introduction...............................................................................................................................................4
2. Safety Risks..............................................................................................................................................4
2.1 Warning...............................................................................................................................................4
2.2 General Work Safety and Health Protection........................................................................................4
3. Warnings ..................................................................................................................................................5
4. Technical Parameters...............................................................................................................................7
5. Machine Description .................................................................................................................................8
5.1. Introduction ........................................................................................................................................8
5.2 Exchangeable tools.............................................................................................................................9
6. Machine Installation................................................................................................................................11
7. Setting the Machine................................................................................................................................11
7.1 Setting the Table...............................................................................................................................11
7.1.1 Setting the Table Upper Position.................................................................................................13
7.2 Setting the Separator ........................................................................................................................13
7.3 Setting Air Blowers Gap ....................................................................................................................14
7.4 Setting Rotary Perforating (Cutting) and Guiding Pulleys ..................................................................14
7.4.1 Setting Perforation or Cutting Thrust...........................................................................................15
7.5 Setting Delivery Table .......................................................................................................................15
7.6 Adjustment of Top Bar Stroke............................................................................................................16
8. Setting the Machine Using Touch Screen...............................................................................................17
8.1 Touch Screen Preview......................................................................................................................17
8.2 Overview of Touch Screen Function Icons ........................................................................................17
8.2.1 Sound On/Off..............................................................................................................................17
8.2.2 Manual Control ...........................................................................................................................18
8.2.3 Info .............................................................................................................................................18
8.2.4 Language Selection....................................................................................................................18
8.2.5 Service Menu..............................................................................................................................19
8.3 Setting the Feed................................................................................................................................20
8.4 Setting the Number and Position of Creases/Perforations.................................................................21
8.4.1 Most Common Folds...................................................................................................................21
8.4.2 Setting the Number of Segments................................................................................................22
8.4.3 Setting the Position of Segments................................................................................................22
8.5 Setting the Speed of Processing .......................................................................................................23
8.6 Loading Paper...................................................................................................................................23
8.7 Setting Batch.....................................................................................................................................23

Operating Instructions | AirSpeed 450
3
8.7.1 Total Batch .................................................................................................................................23
8.7.2 Partial Batch ...............................................................................................................................24
8.8 Program Saving and Loading............................................................................................................24
8.9 Starting Working Cycle......................................................................................................................25
8.9.1 Working Screen..........................................................................................................................26
8.10 Manual Control................................................................................................................................27
8.10.1 Rotary Perforating, Cutting........................................................................................................27
8.10.2 TriFold 360 Connection.............................................................................................................27
9. Recommended Machine Maintenance....................................................................................................28
10. Machine Disposal .................................................................................................................................28
Appendix 1: Accessories.............................................................................................................................29
Appendix 2: Table Assembling Instructions.................................................................................................32
Appendix 3: Optional Accessory.................................................................................................................33
3.1 Strike Tools.......................................................................................................................................33
3.1.1 Removing Punching Tool Pins....................................................................................................34
3.2 Rotary Tools......................................................................................................................................35
Appendix 4: Ultrasound Set for Double Sheet Detection.............................................................................36
Appendix 5: The Most Common Faults (Troubleshooting) ..........................................................................37

Operating Instructions | AirSpeed 450
4
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 emphasise that service operations may only be executed by
authorised individuals with proper qualification. They should be thoroughly familiar with the control and all
functions of the machine. Any repair done without authorisation may render the warranty null and void.
Reference is made to Section 2.2 – Work Safety and Health Protection providing basic information about
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. 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 AirSpeed 450, 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 work safety and health protection of the
operator and any other individuals who come into contact with the machine.

Operating Instructions | AirSpeed 450
5
If the AIRSPEED 450 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 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 harmonised 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
Only sheets of the size listed in the parameters can be creased and perforated in the creasing and
perforating machine.
a) The operator or the individual appointed for operation cannot use the machine unless they have
been trained.
b) It is forbidden to crease and perforate foils, sheet metal or other similar materials.
c) The machine can be only used in enclosed spaces (e.g. offices, shops).
d) It is forbidden to use the machine outdoors.
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.

Operating Instructions | AirSpeed 450
6
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) Do not replace faulty electrical components with components of different type or different capacity.
When replacing a component, the electric cord must be unplugged.
l) Covers can be only dismounted by trained personnel when the machine is unplugged.
m) The operator must pay special attention during manipulation with rotary parts of the machine – see
yellow Warning Sign (Pos. 40, page 9) – DO NOT OPEN/REMOVE SAFETY COVER UNTIL
MACHINE STOPS

Operating Instructions | AirSpeed 450
7
4. TECHNICAL PARAMETERS
a)
Working width
115 – 456 mm, min. sheet size 115 x 130 mm
b)
Recommended paper grammage
80 – 400 g/m² (creasing, punching)
80 – 250 g/m² (perforating)
c)
Crease width*
CITO 1.0 mm – paper thickness < 0.4 mm
(recommended grammage 80 – 200 g/m²)
“Iron Channel” 1.9 mm – paper thickness 0.4
–0.5 mm
(recommended grammage 200 – 400 g/m²)
d)
Min./max. number of creases per sheet
0/40
e)
Max. number of perforating wheels
13 (for more info refer to Appendix 3)
f)
Number of programs
60
g)
Min./max. distance between creases
1/999 mm
h)
Min. distance of crease from front edge
0 >
i)
Speed
3.000 sheets A4/h (with single crease)
4.300 sheets A4/h (0 crease, only rotary
perf./cutting)
j)
Input capacity
70 mm
k)
Machine dimensions
1.320 x 755 x 475 mm
1.320 x 755 x 1.225 mm (including table)
l)
Machine weight
net 140 kg, gross 188.5 kg
(including mobile table)
m)
Voltage / frequency
50/60 Hz
n)
Power
400 W
o)
Fuse
T2 A / 250V
p)
Noise level
65 dB
*Note: Respect the recommended width of creasing channel for different paper thickness. If use inappropriate width of
crease is used (usually narrow creasing channel for thick paper), inaccuracies in the position of crease may appear,
resulting in the crease being placed at a distance different from what was set on the touch screen. If thick paper is
used in combination with a narrow crease, it will result in the paper being pressed into the creasing channel, and the
rollers starting to slip in an attempt to release the paper. Use wider crease channel in such case.

Operating Instructions | AirSpeed 450
8
5. MACHINE DESCRIPTION
5.1. Introduction
The electric automatic creasing and perforating machine serves for the processing of graphic material of up
to 450 mm in width. The creasing allows for easy folding of the paper, thereby making the machine
convenient for use in combination with a folding module. Waste-free perforation allows you to tear off the
paper easily.
Fig. 1: View of the Machine
1 – Waste drawer
2 – STOP button
3 – Separator position regulation screw
4 – Electric switch
5 – Back stop
6 – Rear side guide
7 – Delivery table
8 – Table position regulation screw
9 – Side guide lock
10 – Side guides turning screw
11 – Front table
12 – Side guide
13 – Front auxiliary table
14 – Levelling strip
15 – Touch screen
16 – Front stop (Fig. 8)
17 – Exchangeable tool
18 – Front cover
19 – Plug socket (Fig. 2)
20 – Tool thrust regulation screw (Fig. 2)
21 – Needle bearing
22 – Safety ring
23 – Top bar (Fig. 1)
24 – Top bar bearing
9
13
14
11
12
5
8
6
7
10
1
15
3
2
4
17
18
41

Operating Instructions | AirSpeed 450
9
25 – Guiding, perforating pulley
26 – Thrust pulley
27 – Rear upper cover
28 – Shaft
29 – Fixing sleeve
30 – Perforating (Cutting) kit
40 – Warning Sign
41 – Front Air Blow Regulatory Adjustment Screw
Fig. 2: Rear View of the Machine
5.2 Exchangeable tools
In standard equipment, the machine is supplied with the three exchangeable tools described below. Special
tools, such as calendar semi-circle, are available as additional optional accessories (see Appendix 3).
The default setting has been done for all types of tools. A change of the machine function requires the tool
to be replaced (placed by the manufacturer into the waste drawer – 1). Use the electric switch (4) to switch
off the machine, slide out the tool (17) and put in the tool you wish to use.
Loosen the tool screws (31, 32, 33, 34) in order to replace the knives in the tools. Replace the knife and fit
the tool back. Tighten the tool screws (33, 34). Do not overtighten the tool screws (31, 32). Then place the
tool into the machine and perform a trial stroke (see Section 7.6) to ensure the knife and the tool base are
parallel (35). Re-tighten the screws (31, 32). Now the tool is ready for use.
19
27
24
22
20
21
23
29
25
26
30
28
40

Operating Instructions | AirSpeed 450
10
Fig. 3: Perforating tool 2:1- 9 TPI (571 40 465a) – standard equipment. Microperforating tool (571 40 464) as optional
accessory.
Fig. 4: Creasing tool CITO 1.0 mm (571 40 467) – standard equipment. Creasing tool CITO 1.4 mm (571 40 468) as
optional accessory.
Fig. 5: Creasing tool – iron channel 1.9 mm for heavy grammage (570 40 466)
35
32
33
31
35
34
35

Operating Instructions | AirSpeed 450
11
6. MACHINE INSTALLATION
Unpack the machine, take it out of the box and remove the four transport bolts at the base of the machine.
Put the machine on the table (refer to Appendix 2 for the table assembly instructions) and use the screws
(36) to attach it to the table. Once the machine is secured, mount the front auxiliary table (13) and the
delivery table (7). When plugged in, the machine is ready to operate. When the electric switch (4) is
switched on, the touch screen (15) will light up. Setting the machine by means of the touch screen is
described in detail in Section 8.
Fig. 6: Machine installation on the table
7. SETTING THE MACHINE
7.1 Setting the Table
Use the side guides turning screw (10) to set the side guides (12) perpendicularly with the tool. The side
guides are set in the initial position (perpendicular to the tool) if the rear edge of the right side guide aligns
with the feeding table line (fig. 7).
Note: It is recommended to set the side guide perpendicularity in the position as shown in Fig. 7. Besides
the line parallel to the tools, the A2 position line may also be of assistance when identifying the correct side
guide position (the A2 position line must be parallel to the side guide).
36

Operating Instructions | AirSpeed 450
12
Fig. 7: Setting the Side Guides
Loosen the side guide lock (9). Set the side guides (12) approximately for the paper format size so that the
position of the sheet is symmetrical with the centre of the table. The rulers on the feeding table serve for
exact setting of the side guides (12). Place the levelling strips (14) on the feeding table between the front
side guides (12) – two or four strips according to the paper format.
Front stops (16) must be placed on the feeding table behind the paper for the feeding to run properly (Fig.
8).
Fig. 8: Levelling Strips and Front Stops
10
12
14
16

Operating Instructions | AirSpeed 450
13
7.1.1 Setting the Table Upper Position
Use the table position regulation screw (8) to set the table upper position. With default settings, the gauge
(37) is approximately in the centre of the hole (Fig. 9). The table upper position may need to be changed
when paper wave needs to be eliminated. Also, change the setting when you change paper thickness. For
thicker paper the table upper position will be closer to the feeding head. Consequently, use the regulation
screw to move the gauge in the direction of the UP position.
Fig. 9: Setting the Table Upper Position
7.2 Setting the Separator
Set the separator position regulation screw (3) in the maximum position (open gap). Put a sample of the
paper you wish to process in the gap between the separator (39) and the feeding head strips (38). Use your
hand to move the sample to and fro and, at the same time, use your other hand to tighten the separator
position regulation screw until the paper can no longer move freely and light resistance is felt. Now carefully
turn the screw back so that the paper can again move freely. This sets the optimum gap between the
separator and the feeding head strip. You may want to move the feeding table to the lower position to get
better access to the separator.
Fig. 10a: Regulation Screws of Separator Position and Front Air Blowers
37
8
3
41

Operating Instructions | AirSpeed 450
14
Fig. 10b: Setting the gap of Separator and Air Blowers
7.3 Setting Air Blowers Gap
Use the Front Air Blow Regulatory Adjustment Screw (41) to increase or decrease the amount of air fanning
out the pile of processed stock from the front side. The opening of the gap should be set according to the
paper weight/thickness, sheet size and extent of static electricity inside processed stock. The gap must be
open to the full extent for large, heavy or ‘glued’ paper. It might be reduced for small and light stock.
Our recommendation: Keep the blowers open to the full extent for the majority of processed stock, (not only
heavy and large sheets). If too much air has a negative effect on the feeding of light and small stock, then
reduce the gap of blowers.
7.4 Setting Rotary Perforating (Cutting) and Guiding Pulleys
Lift the rear upper cover (27) and use an Allen key to loosen the perforation pulley screws (25) in order to
adjust the perforating or cutting wheels (30). Set the pulleys on the lower shaft in the required position and
tighten up the screws. Then place the perforating wheel (30) in the required position and tighten up with the
screw.
Alternatively, you may remove the whole shaft (28) and add or remove pulleys as required. In order to
remove the shaft, use an Allen key to loosen the screw on the fixing sleeve (29 – Fig. 2) and push the
sleeve aside. Then move the whole shaft to the left (in the direction of the side of the machine) and remove
the shaft from the machine. Before you do so, make sure the perforating (cutting) wheels are placed in the
non-working position!!!
38
42
39

Operating Instructions | AirSpeed 450
15
Fig. 11: Setting Rotary Perforating and Cutting
For the machine to operate properly, the thrust pulleys (26) must always be put on the shafts correctly.
Once the setting is finished, tilt the cover (27) down because it operates as a stripper!
7.4.1 Setting Perforation or Cutting Thrust
Use an Allen key to turn the regulation screw of the perforating kit (30) to set perforation thrust.
Turn in the direction of +for higher thrust. Turn in the direction of -for lower thrust. It is recommended to set
the lowest possible thrust as this will prolong the service life of the perforating pulley.
7.5 Setting Delivery Table
The delivery table (7) is telescopic and can be set in three heights, or removed from the machine.
Fig. 12: Setting Delivery Table
25
30
26

Operating Instructions | AirSpeed 450
16
7.6 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 (23) can be moved down using the tool thrust regulation screws (20). The
screws should be loosened anticlockwise by approx. 30°,1/12 of the revolution (the bar moves downwards)
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 any more. When 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 (23) remains in the lower position, use the electric switch (2) to switch the
machine off and then wait for 20 seconds before you re-start the machine. Press (Manual control –
Section 8.10), then (tool backwards) under the field UPPER TOOL. The tool is now unlocked and the
thrust can be adjusted using the tool thrust regulation screws (20). Activate (tool forwards) to make a
trial stroke.

Operating Instructions | AirSpeed 450
17
8. SETTING THE MACHINE USING TOUCH SCREEN
8.1 Touch Screen Preview
Fig. 13: 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. 14: “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.

Operating Instructions | AirSpeed 450
18
8.2.2 Manual Control
Press to display the manual control screen, see Section 8.10.
8.2.3 Info
Press to display the information screen. The data are approximate. Press OK to go back to the
“SETTING” screen.
Fig. 15: “INFO” Screen
8.2.4 Language Selection
Press to display the language selection screen and choose the language.
Fig. 16: “LANGUAGES” Screen

Operating Instructions | AirSpeed 450
19
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
the “SETTING” screen (Fig. 17a). Entering the correct password and confirming by OK displays the
“SERVICE MENU” screen. Press OK to go back to the “SETTING” screen.
Fig. 17a: “SERVICE MENU” Screen – Password
Fig. 17b: “SERVICE MENU” Screen
Note: Description of service screen is not part of this document because this screen is not accessible to end
user.

Operating Instructions | AirSpeed 450
20
8.3 Setting the Feed
Press FEEDING on the “SETTING” screen (Fig. 14) to display the following menu.
Fig. 18: “FEEDING” Screen
Press the number icon next to SHEET LIFTING and SHEET FANNING fields to display a numerical keypad
in order to enter the values from 0 to 100, confirm by ENTER. Suggested values in these fields are 50 and
50. Generally, smaller paper formats and paper weights require a smaller amount of air and vice versa.
Notification: The amount of air coming from Front Air Blowers is strongly dependent on its opening. If
SHEET FANNING value is 50 the amount of air is different while the blowers are open and closed using the
regulatory adjustment screw (see Section 7.3).
The Numerical field next to FEEDING TABLE DROP serves for the setting and final ‘resting’ position of the
feed table before the feeding process, as it rises to the top (engages micro switch) then slightly ‘drops’ prior
to the start of a working cycle. Timespan adjustment for FEEDING TABLE DROP is 0 – 2 seconds of
movement. If the set value is 1 second, the feeding table terminates its upward movement after pressing
the micro switch of feeding head (Fig. 9) and then continues moving downwards for the time period set (1 s
= 8 mm). The value of this drop should be set with respect to the correspondence of levels of top layer of
processed paper and Front Air Blowers. Top sheets (6 – 12 pcs) must stop approximately in the middle of
blowers. Same as for SHEET FANNING values also FEED TABLE DROP must be set with respect to
extent of Front Air Blowers opening.
In summary the adjustment and setting of this final movement/position helps accurate separation of sheets
on feeding.
Now the machine is ready for test paper feed. Press LOAD PAPER (functions: press – table moves down;
press again – downward move stops). Then start the test by pressing . Use the numeric field over to