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

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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

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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

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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 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.

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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.

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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

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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.

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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

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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

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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