Formax 3950 Series User manual

3950
Series
Production Folders
OPERATOR MANUAL
First Edition
7
/2007

Operator's Manual 3950 Series
3
CONTENTS
1. GENERAL 5
2. SPECIFICATIONS 6
3. PROPER HANDLING OF THE MACHINE 7
4. SAFETY INSTRUCTIONS 9
5. SAFETY FEATURES 13
6. BASIC COMPONENTS OF THE MACHINE 14
7. SPACE REQUIREMENTS 15
8. OPERATING POSITIONS 15
9. ELECTRICAL CONNECTION 16
10. AIR FEEDER PBA 38 17
11. FLAT PILE FEEDER FSA 36 23
12. REGISTER TABLE 33
13. BUCKLE FOLD UNITS 35
14. ROLLER TABLE 37
15. DELIVERIES 39
Fanned Deliveries AM 52, AMS 52 39
Small Format Vertical Stacker SKM 36 40
16. AUTOMATIC SETTING 43
Operator Panel 43
Setting the Counter - Main Menu COUNTER 46
Clearing the Total Counter 46
Setting the Batch Counter 47
Set Kicker for Batch Counting 49
Paper Transport Control, Double Sheet Detection - Main Menu MONITORING 52
Paper Transport Control 52
Double Sheet Detection 53
Setting the Fold Length - Main Menu SET-UP 54
Standard Folds 54
Special Folds 61
Job Saved 72
Setting the Suction Length - Main Menu SET-UP 83
Saving of Job Data - Main Menu SAVING 86
Display of the Actual Job - Main Menu JOB 91
Correction of Fold Lengths - Menu FOLD LENGTH 92
Setting the Fold Rollers - Menu ROLLER GAP 93
Setting the Delivery Rollers - Menu DELIVERY 98
Choosing the Measuring System and the Language 100
Fold Plate Setting: Three Methods 101
Display of Malfunctions 104
Service Functions 105
17. OPERATION AND TRIAL FOLDS 109
18. FINE ADJUSTMENTS AND CORRECTIONS 111
19. PERFORATING-, SCORING- AND SLITTING TOOLS 115
20. POSSIBLE MALFUNCTIONS AND THEIR REMEDIES 121

Operator's Manual 3950 Series
4

Operator's Manual 3950 Series General
5
1. GENERAL
General Description The machines of the 3950 Series folder line are professional buckle folders
with an infeed width of up to 38 cm. They can be equipped with one or two fold units.
The fold units may be used in-line or at right angles.
There is a choice between suction- and flat pile feeders.
Folding Principle The infeed rollers (1) and (2) transport the
sheet to be folded into the fold plate (3).
As soon as it comes up against the adjustable
stop (4), the sheet forms a buckle (5) because
the infeed rollers keep on moving.
The loop gets bigger until the sheet is seized
by rollers (2) and (6); this is where the actual
fold occurs.
The rollers draw the folded sheet from the fold
plate and the infeed rollers and move it on.
4
1
2
3
5
6

Operator's Manual 3950 series General
6
2. SPECIFICATIONS
Paper size: Maximum Minimum
WxL WxL
Air feeder FD 3950: 38 x 65 cm 7* x 12 cm
*(less if paper is guided on one side only)
Flat pile feeder FD 3950 P 38 x 65 cm 10 x 12 cm
Fold length min.: 3.5 cm
1.8 cm with fold unit for small formats
Speed: 200 m/min
Paper weight: 40 - 250 GSM for single fold
Electrical: Voltage:3x400V/50Hz/N/PE or
3x208V/60Hz/PE
Current consumption: max. 10A
Power consumption:
- 1st fold unit with feeder: 0.9 kW
- 2nd fold unit with roller table: 0.9 kW
- Delivery: 0.1 kW
- Pump: 2 x 1.1 kW
Ambient conditions: Room temperature: 15 - 40°C
Air humidity: 50 - 90%
Weight (net): 1st fold unit with PBA 38, register table 270 kg
2nd fold unit, roller table 230 kg
Delivery A 38 25 kg
Delivery AM 52 60 kg
Small format vertical stacker SKM 36 60 kg
Pump 2 x 17 kg
Noise emission: Sound power level of the emission values
measured at specific sections of the machine
(machines with flat pile feeder):
- Feeder section: 83 dB (AI)
- Delivery section: 85 dB (AI)
Measured according to DIN 45 635, part 27

Operator's Manual 3950 Series General
7
3. PROPER HANDLING OF THE MACHINE
The machines of the 3950 Series folder line are built for folding paper.
They may also be used for perforating, scoring, slitting, cutting and counting paper
using the proper attachments.
They are unsuitable for handling other materials such as foil, plastics and textiles.
The manufacturer / distributor is not responsible for damages resulting from such
unsuitable applications. Responsibility lies alone with the user.
Reading the Operator's Manual and observing the conditions for inspection and
maintenance are part of the proper handling of the machine.
Installation of the machine, i.e. assembling as well as electrical and pneumatic work
should be carried out only by skilled personnel authorized by the manufacturer or his
representatives. Additional instructions are provided for this purpose.
Repairs and service should be carried out only by skilled personnel authorized by the
manufacturer or his representatives.
The interval between inspections including safety-related functions depend on the
machine usage.
For regular one-shift-operation, one inspection per year is recommended.
The machine needs a flat surface for installation.
The machine weight should be considered when choosing a location for the machine.
The levelling screws in the undercarriage of the machine can compensate for an
uneven floor to a certain degree.
To ensure stability during operation the machine should be secured by means
of the levelling screws.
The line voltage must correspond to the voltages on the serial plate.
No harmful emissions are produced.
Read the Operator's Manual before working with the machine.
We recommend to carry out all operations and settings in the sequence mentioned in
this manual.
The terms "right" and "left" in the following text always refer to the
direction of paper travel. Therefore the left side is the operator side.

Operator's Manual 3950 Series General
9
4. SAFETY INSTRUCTIONS
4.1 Safety Instructions for Transport and Set-Up
The following instructions and warnings are applied to the packing to ensure
appropriate and safe transport:
Top! - Transport in
upright position only!
Protect from humidity! Fragile! -
Handle with care!
Theses instructions and warnings must also be observed for transport within the
users premises.
For transport to other premises resp. for return shipment the machines must be
packed and provided with the same markings.
Warnings and Symbols
The following symbols and designations are used in the manual to identify
instructions of particular importance:
General instructions and special information how to use the machine
most efficiently.
!Instructions designed to prevent injury or extensive equipment damage.
4.2 Fundamental Safety Instructions
Basic Operation The machine has been built in accordance with state-of-the art standards and the
recognized safety rules.
Nevertheless, operators and third parties may get injured when working with the
machine, or damage to the machine and to other material property may result.
The machine must only be used in technically perfect condition in accordance
with its designated use and the instructions set out in the operator's manual.
Any malfunctions, especially those affecting the safety of the machine, should
therefore be rectified immediately.

Operator's Manual 3950 Series General
10
Organizational
Measures
The operator's manual must always be available near the machine.
In addition to reading the operator's manual, observe and instruct the user in all other
generally applicable legal and other mandatory regulations relevant to accident
prevention and environmental protection.
The operator's manual must be supplemented by instructions covering the duties
involved in supervising and notifying special organizational features, such as job
organization, working sequences or the personnel entrusted with the work.
Personnel entrusted with work on the machine must have read the operator's manual
and in particular the chapter on safety before beginning the work.
Reading the instructions after work has begun is too late.
This applies especially to persons working occasionally on the machine, e.g.
during setting up or maintenance.
Check, at least from time to time, whether the personnel is carrying out the work in
compliance with the operator's manual and paying attention to risks and safety factors.
For reasons of safety, long hair must be tied back or otherwise secured, garments must
be close-fitting and no jewelry - such as rings - may be worn.
Injury may result from being caught on moving parts.
Observe all safety instructions and warnings attached to the machine.
See to it that safety instructions and warnings attached to the machine are always
complete and perfectly legible.
In the event of safety-relevant modifications or changes in the performance of the
machine during operation, stop the machine immediately and report the malfunction
to the competent person.
Never make any modifications, additions or conversions which might affect safety
without the manufacturer's approval. Adhere to prescribed intervals or those specified
in the operator's manual for routine checks and inspections.
Selection of Per-
sonnel, Basic
Responsibilities
Employ only trained or instructed staff and set out clearly the individual responsibili-
ties of the personnel for operation, set-up, maintenance and repair.
Work on the electrical system and equipment of the machine must be carried out only
by a skilled electrician in accordance with electrical engineering rules and regulations.
Standard Operation Avoid any operational mode that might be detrimental to safety. Take the necessary
precautions to ensure that the machine is used only in a safe and reliable state.
Operate the machine only if all protective and safety-oriented devices, such as re-
movable safety devices, emergency stops, sound proofing elements, are in place and
fully functional. In the event of malfunctions stop the machine immediately and pre-
vent further use. Have any defects rectified immediately.
Before starting up or setting the machine in motion, make sure that nobody is in dan-
ger.
Special Work,
Maintenance,
Repair
Observe the adjusting, maintenance and inspection activities and intervals set out
in the operator's manual, including information on the replacement of parts and
equipment.
Pull the power plug for maintenance and repair work or before opening the control
box.
If the machine is completely shut down for maintenance and repair work, it must be
secured against inadvertent starting by attaching a warning sign to the main switch.
Always tighten any screw connections that have been loosened during maintenance
and repair.
Special Dangers The electric equipment of machines is to be inspected and checked at regular intervals.
Defects such as loose connections or scorched cables must be rectified immediately.

Operator's Manual 3950 Series General
11
Product-Specific Safety Instructions
!Exercise caution in the vicinity of the perforating- and slitting knives!
They have sharp edges for proper function!
SERIOUS INJURY MAY RESULT!
!Exercise caution in the vicinity of rotating shafts and rollers!
Hair, loose garments and jewellery may get caught!
SERIOUS INJURY MAY RESULT!
4.3 Cleaning and Maintenance
Regular and proper cleaning contributes to a long life of the machine and a consistent
quality. Therefore it is important to clean the machine in regular intervals and above
all to remove paper dust.
The interval between maintenance jobs depends on the workload.
It is recommended to clean the machine once a week.
!Before cleaning the machine always pull the power plug!
!Exercise caution in the vicinity of the perforating- and slitting knives!
They have sharp edges for proper function!
SERIOUS INJURY MAY RESULT!
Use only the special cleaning fluid from Formax for cleaning the fold rollers.
Do not use any solvents such as Acetone or Toluol. They would damage the non-
metal parts of the rollers.
Remove paper- or print powder dust from all fixed and moveable parts of the machine.
Clean the photodetector with a brush.
Use compressed air to clean the fold plates when paper with a high degree of powder
has been folded. Carefully remove deposits in the control box with a vacuum cleaner.
Clean the air filter of the compressor and the pump using brushes or air.
The maintenance-free flat belt drive needs no lubrication of any kind.

Operator's Manual 3950 Series General
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5. SAFETY FEATURES
The machines of the 3950 Series folder line are equipped with various
safety features. They ensure the safety of the persons working with the machine.
The following safety features are found on these machines:
1 Fixed cover at the fold roller infeed section
2 Swing-up noise covers
3 Safety handwheels
4 Emergency stop buttons
MATHIAS BÄUERLE
MATHIAS BÄUERLE
1
2
2
3
4
4
Possible remaining risks are pointed out in the respective paragraphs of this manual.

Operator's Manual 3950 Series General
14
6. BASIC COMPONENTS OF THE MACHINE
As a result of its modular design, the 3950 Series offers a wide range of
applications and configurations to suit the requirements of the user.
The following components are available:
-FD 3950PF Flat pile feeder - FSA
-FD 3950 & FD 3950 EX Bottom feed, top loading air feeder - PBA
- 1st buckle fold unit (automatic setting) with register table (CAS 38)
- 2nd buckle fold unit (automatic setting) with roller table (CAS 38)
- 3rd buckle fold unit (manual setting) with roller table (38) - separate operator's
manual
- Mobile knife fold unit MS 45 (manual setting) - separate operator's manual
- Fold unit for small formats KF 31 (manual setting)
- Fanned delivery AM 52
- Fanned delivery AMS 52
- Small format vertical stacker SKM 36
The model designations of the machines give an idea about the technical specifications
at a glance.
Examples:
FD 3950
38 Infeed width 38 cm
4 1st buckle fold unit with 4 fold plates
2 2nd buckle fold unit with 2 fold plates
PBA Suction feeder PBA 38
FD 3950PF
38 Infeed width 38 cm
4 1st buckle fold unit with 4 fold plates
4 2nd buckle fold unit with 4 fold plates
FSA Flat pile feeder FSA 38

Operator's Manual 3950 Series General
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7. SPACE REQUIREMENTS
When choosing a location for the machine, please bear in mind that additio-
nal space for the operator, for service and for pallets is needed in the feed-
and delivery areas.
2700
800
800
1900
2500
FD 3950 FD 3950 / FD 3950R
8. OPERATING POSITIONS
There is no fixed operator position at the machines.
The operator must move between the following
positions:
1 Feeder section for loading the unfolded paper
2 Operator panel for set-up
3 Delivery section for removing the folded paper
In addition, the machines should be accessible
from any other position for cleaning, resetting,
jam clearance, service jobs, etc.
1
2
3

Operator's Manual 3950 Series General
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9. ELECTRICAL CONNECTION
Operator panel, fold units and delivery are interconnected with cables.
Plugs and sockets allow variable connections.
!Do not bend or twist the cables sharply or place heavy objects on them -
they may get damaged!
!When making or breaking any electrical connection, always first turn
off the main switch or the safety switch on the folder. Non-compliance
may cause damage to electronic components!
At the rear of the base of each fold unit you will find the sockets for connecting
the various fold units and accessories.
Buckle fold unit 1
1 Socket for the connection cable to the
operator panel
2 Receptacle 230V for accessories
3 Socket for the connection cable of the
second fold unit or the delivery
4 Safety switch
5 Connection cable of the pump
6 Connection cable of the pump
7 Power cord 400V
123 4
567
Buckle fold unit 2
8 Connection cable for connection to the
socket at the first fold unit
9 Socket for the connection cable of the
delivery
Plug connections are easily pulled or inserted by holding the plug with one
hand and opening resp. closing the safety bracket with the other hand.
89

Operator's Manual 3950 Series FD 3950
17
10. AIR FEEDER PBA 38
Principle of
Operation
The air feeder PBA 38 consists of a feeder and a register table.
It is suitable for handling a wide variety of papers - uncoated papers as well as coated,
freshly printed or thin papers.
The sheets are separated by air and vacuum.
Air is supplied from the bottom of the stack both on the left and right side,
separating the paper in the stack which now floats in a cushion of air.
A rotating suction drum can then separate the sheets from the bottom of the paper
stack.
This principle has the advantage that paper can be continuously reloaded with the
machine running. There is no need to stop the machine.
On the register table, a transport belt, which runs at an angle, moves the sheets
against a register rail.
Description Components and operating elements of the air feeder PBA 38:
1
2
3
4
5
3
3
5
6
7
8
13
16
15 17 11 9
10
12
18
20
19
14
1 Feed table
2 Air guides left and right
3 Knobs for adjusting the air guides
4 Rear paper stop
5 Air adjustment valves
6 Suction drum with suction segment
7 Front paper stop
8 Guide rollers
9 Lever for adjusting the suction
segment
10 Lock screw
11 Window for adjustment of suction
segment
12 Vacuum adjustment valve
13 Register table
14 Ball cage
15 Handwheel
16 Lock screw
17 Lever for adjustment of sheet gap
18 Hold-down bars
19 Alignment rail
20 Adjustment wheel for changing
the infeed angle

Operator's Manual 3950 Series FD 3950
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Setting the Format When setting the format, care should be taken that the sheets are fed
approximately from the center.
Ł Loosen the handles (1) by turning them
counter-clockwise.
Ł Set the left feed guide to half sheet width
with the help of the scales (2).
Ł Tighten the handles (1) again.
Ł Place a stack of about 50 sheets on the
feed table.
Ł Slide the right feed guide (3) against the edge of the stack.
1
2
1
2
34
4
Make sure that the sheet does not actually touch the guide. There should be
a gap of approx. 0.5 mm. The right and left feed guide should be parallel.
Ł Tighten the handles (4) at the right feed guide.
Setting the Sheet
Separation Sheet separation is achieved by the combined action of the rotating suction drum,
the paper stop and the air.
Paper weight and type of paper have an influence on the setting.
Setting the Air
A suction drum (5) separates the sheets from the
bottom of the stack.
This is achieved by the suction segment (6)
inside the suction drum.
The angle of the suction segment
with respect to the paper stop
can be changed to suit different
types of paper.
5
6
Basic setting
Ł Loosen the lock screw (7).
Ł Turn the knob (8) until the figure "6" on a red
background appears in the window (9).
Ł Tighten the lock screw (7).
Now the suction segment is in its zero position (10).
7
8
9
10
If the width of the paper is less than 7 cm, only one paper guide can be used.

Operator's Manual 3950 Series FD 3950
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Most types of paper with a weight of 80 to 90 GSM can be separated in this position.
For different paper grades, other figures must be set in the window:
- Paper grades below 80 GSM: 7 - 9
- Paper grades above 90 GSM: 1 - 5
Setting for light paper grades:
For running light-weight paper, first try the suction segment setting as
described under "Basic Setting".
A steeper inclination is only necessary for special types of paper.
Light paper grades easily cling to the curve of the suction drum.
Therefore the suction segment must be tilted in direction of the paper stop.
The inclination of the suction segment in this direction
has the effect that the paper is wrapped around the
suction drum (1).
The sheets are easily separated from the stack and
double sheets occur very rarely.
1
In the batch counting mode it may happen occasionally that a single sheet is fed
during the interval time.
This is caused by the fact that the suction drum continues to turn during the interval
time (although without vacuum). For light paper grades the friction between paper
and suction drum may be sufficient for detaching a sheet.
To prevent this, a special plate (2) can be placed
over the suction drum. This plate, which is pulled
out of the feed table, can cover the suction drum
to its highest point (3).
Sheets are no longer affected by the friction
of the suction drum.
Proceed as follows to pull out the plate:
Ł Loosen the screw (4).
Ł Insert a screwdriver in the hole (5).
Ł Pull out the plate.
Ł Tighten the screw (4).
2
3
54

Operator's Manual 3950 Series FD 3950
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Setting for heavy paper grades
Heavy paper grades do not easily cling to the curve
of the suction drum.
For this reason the suction segment must be tilted
in direction of the paper stack.
The inclination of the suction segment in this
direction has the effect that the paper is barely
wrapped around the suction drum (1).
This is sufficient because heavier paper grades
are more easily separated from the stack.
1
2
Vacuum:
Vacuum can be modified by means of a regulating
valve (2). This is necessary because heavy paper
grades require more vacuum than light paper grades.
The vacuum can be modified by turning knob (2).
Setting the vacuum:
For setting the vacuum, the machine must be turned on.
!
Exercise caution in the vicinity of rotating shafts and rollers!
Hair, loose garments and jewellery may get caught!
SERIOUS INJURY MAY RESULT!
!
Do not get close to rotating shafts and rollers while the machine is
running and the noise-absorbing cover is open!
SERIOUS INJURY MAY RESULT!
!
Exercise caution in the vicinity of the perforating- and slitting knives!
They have sharp edges for proper function!
SERIOUS INJURY MAY RESULT!
Ł Close the valve (2) for setting the minimum effect.
Ł Start the machine.
Ł Slowly open the valve (2) by turning the knob clockwise.
Observe the sheet separation while doing this.
At first no sheets are pulled off the stack or they are pulled off irregularily.
The more the valve is opened, the smoother is the paper transport.
Make sure that much vacuum does not cause feeding of double sheets.
Ł Switch off the machine.

Operator's Manual 3950 Series FD 3950
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Air
Ł Open the valves (1) at both air brackets.
1
In most cases it is sufficient to open the second
and the last valve (with respect to the format
length).
closed open
Front Paper Stop
2
3
4
5
6
7
The position of the front paper stop (2) can be
adjusted in a horizontal and vertical direction.
Adjusting the horizontal position:
The horizontal position of the front paper stop
determines the suction point on the paper and
in turn depends on the position of the suction
segment in the suction drum.
The inclination of the suction segment
must be set correctly before making
the horizontal adjustment.
When the suction segment is adjusted,
the horizontal position must also be
changed accordingly.
Ł Turn the handwheel until the openings of the suction drum (3)
are exactly above the openings of the suction segment (4).
Ł Adjust the horizontal position of the front paper stop in such a way that it forms
a vertical line (5) with the leading edge of the suction openings.
To achieve this, turn the knurled screw (6) counter-clockwise or clockwise.
Adjusting the vertical position:
The respective paper thickness is set by adjusting the vertical position of the front
paper stop. Proceed as follows:
Ł Place a stack of about 50 sheets on the feed table.
Ł Start the machine.
Ł By turning the knurled screw (7), adjust the vertical position of the paper stop
in such a way that only one sheet is pulled off the stack.
!
Exercise caution in the vicinity of rotating shafts and rollers!
Hair, loose garments and jewellery may get caught!
SERIOUS INJURY MAY RESULT!
!
Do not get close to rotating shafts and rollers while the machine is
running and the noise-absorbing cover is open!
SERIOUS INJURY MAY RESULT!
!
Exercise caution in the vicinity of the perforating- and slitting knives!
They have sharp edges for proper function!
SERIOUS INJURY MAY RESULT!

Operator's Manual 3950 Series FD 3950
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Sheet Gap For normal folds the sheet gap should be set only via the potentiometer (1) on
the operator panel.
555
1
However, if small formats with a length
below 20 cm are to be folded, the sheet
gap can also be adjusted by means of
a lever (2).
The adjustment changes the speed of the
suction drum, i.e. different speeds of
feeder and fold rollers result in different
sheet gaps.
A smaller sheet gap increases the speed
of the folder, independent of the cycle
frequency.
Lever in right position:
Adjustment of small formats below a length of 20 cm.
Lever in center position:
Setting for all "normal" folds.
2
The adjustment can be made with the machine
running.
To increase the sheet gap, always use the potentiometer (1) on the
operator panel, do not use the lever.
Positioning the
Paper Stack
Ł Fan the paper stack well to avoid double sheets.
Ł Place the stack on the feed table.
Ł Position the rear paper stop. It prevents the paper from sliding off the table.

Operator's Manual 3950 Series FD 3950PF
23
11. FD 3950PF - FLAT PILE FEEDER FSA 38
Principle of
Operation
The flat pile feeder FSA 38 with rear edge separator is suitable for separating different
kinds of paper, uncoated as well as coated, freshly printed or thin paper.
Sheet separation is done by vacuum and air from the top of the paper stack.
Air blowers separate the top sheets at the rear edge of the stack.
Sheet separators lift the uppermost sheet by approx. 2 cm.
This opens the rear air nozzles and an uninterrupted stream of air is blown
under the separated sheet.
The suction drum at the front edge of the stack grips the sheet and leads it
onto the register table.
Description Components and operating elements
of the flat pile feeder FSA 38:
1 Pile table
2 Stacking stops
3 Carrier arm for rear edge separator
4 Rear edge separator
5 Operator panel
6 Valves for regulating the air flow
7 Sheet separator height adjustment
8 Knurled knob for rear edge separator
9 Knurled knob for stripper springs
10 Rear separator nozzles
11 Front separator nozzles
12 Hold-down rods
13 2 sucker cups
14 Suction drum with suction segment
15 Lever for adjustment of suction segment
16 Rear edge separator lock lever
1
2
4
5
3
16
67
8
9
10
11
1213
15
14