Horizon Fitness SmartStacker User manual
*UM206030*
UM206030-10(000)
170107/HN,CF,AT,RN/IDCS5.5/ICS5/PXI
Sheet Cutter
SmartStacker
Important Information
-This manual is designed to help you to operate and maintain the Smart-
Stacker. Please read and understand this manual, and keep it in a safe and
convenient place.
-Do not operate the SmartStacker until you read and understand the in-
structions in this manual.
-Horizon International Inc. shall not be liable for incidental consequential
damages resulting from: improper or inadequate maintenance by the cus-
tomer, unauthorized modication or misuse, or operation outside of the
environmental specications for the product.
-Horizon International Inc. pursues a policy of continuing improvement in
design and performance of the product. Therefore, the product design and
specications are subject to change without prior notice and without our
legal obligation.
-All rights are reserved. No part of this manual may be photocopied, repro-
duced or translated to another language without the prior written consent
of Horizon International Inc.
User’s Manual
2SmartStacker User's Manual
Safety Precautions
Safety precautions are indicated in this manual as follows:
The term WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
The term CAUTION indicates a potentially hazardous situation which, if not avoided,
may result in serious injury, or damage to the machine.
This symbol indicates a note which includes important information. Follow the note to
operate the machine safely.
This symbol indicates a prohibited action. Do not perform any prohibited action.
This symbol indicates an essential procedure. Follow the procedure to operate the ma-
chine safely.
Important
This will help you to avoid an incorrect operation which may cause
problems with the machine, or make it necessary to go back to a
previous step.
Attention This explains functional limitations and restrictions on the operation
of the machine.
Note This indicates a helpful hint.
Additional Information This indicates additional information which will help you to operate
the machine efciently.
➡ This explains what the machine will do after you operate it as in-
structed.
- Horizon International Inc. cannot anticipate every possible situation that might involve a potential
hazard. Therefore, the instructions in this manual and warning labels on the machine are not all-
inclusive.
- All equipment shall be locked out or tagged out to protect against accidental or inadvertent operation
when such operation could cause injury to personnel. Do not attempt to operate any switch, valve,
or other energy isolating device when it has been locked or tagged out.
- Do not operate the machine when any covers are removed.
- Some of the drawings in this manual show the machine with the covers removed to help in
explaining the details inside the machine.
3SmartStacker User's Manual
26030
10101A1
Stack
Job
Page / Piece
Block
Sheet
Page
Glossary
The drawing below shows the terms we will use in this manual.
4SmartStacker User's Manual
Basic Safety Precautions
WARNINGS for Operation
Keep your hands and ngers outside of the safety cover and away from any moving parts
while the machine is running. Otherwise, moving parts can cause severe personal injury.
Work alone when you operate the machine. Letting someone else operate the machine
could cause it to start suddenly without warning, causing severe personal injury.
Do not remove or bypass any safety features. Without these protective features, moving
parts can cause severe personal injury.
Be sure all other operators are clear of the machine before turning the handwheel. If some-
one else has their hands in the machine, turning the handwheel could cause personal injury.
As the working condition may include exposure to high noise levels which can lead to hear-
ing damage, the employer and operator should ensure that any necessary hearing protec-
tion is provided and used by the operator and others in the work area.
Only for optional Sheet Feeder :
• Do not stare into beam of sheet edge indicator (class 1 laser product*1).
Otherwise, light beam can cause severe personal injury.
*1 This laser meets the IEC standards, 60825-1: 2007,class 1 LASER product.
• Use of controls or adjustments or performance of procedures other than these specied
here in may result in hazardous radiation exposure.
Sheet Edge Indicator
5SmartStacker User's Manual
WARNINGS for Operation
When you lower the feed table, do not place your feet under the table.
Press the Emergency Stop button before turning the drive handwheel. If the machine
accidentally starts suddenly, this can cause severe personal injury.
Turn off the power switch before adjusting the machine unless instructed otherwise. If the
Start button is pressed when the power is on, the machine may cause severe personal injury.
CAUTIONS for Operation
If you turn off the Power switch, wait about ten seconds before turning it on again. Other-
wise, a circuit board may be damaged.
If a jam occurs, remove all the jammed sheets before you start the operation again. Other-
wise the machine may be damaged.
Do not use the machine for any improper purpose. Otherwise, the performance of the ma-
chine cannot be guaranteed.
6SmartStacker User's Manual
Warning Label Locations and Meanings
Do not get into under the feed table. Otherwise, you may be injured
Do not approach your hands and ngers while the roller is rotating.
Otherwise your hands and ngers may be caught by the rotating roller.
Do not stare into beam of sheet edge indicator (class 1 laser product*1).
Otherwise light beam can cause severe personal injury.
*1 This laser meets the IEC standards, 60825-1: 2007, class 1 LASER product.
Laser Diode Wavelength: 625-640 nm
Maximum Power: 5 mW
Taiyo Seiki Co., Ltd.
Identification Label
Manufactured: 1.2014
1600 Aza-Shironoshita, Asahi, Shin-asahi-cho,
Takashima, Shiga 520-1501, Japan
Biwako Factory
Do not approach your hands and ngers to the suction head while the feed table is
moving. Otherwise your hands and ngers may be caught by the suction head.
There are electric parts inside. Take care when opening the cover.
Otherwise, high voltage can cause severe personal injury.
Taiyo Seiki Co., Ltd.
Identification Label
Manufactured: 1.2014
1600 Aza-Shironoshita, Asahi, Shin-asahi-cho,
Takashima, Shiga 520-1501, Japan
Biwako Factory
Sheet Feeder
1st Process
Unit
Feeder
1st Regist
Unit
7SmartStacker User's Manual
Keep your hands and ngers away from the rollers while they are turning.
Otherwise your hands and ngers may be caught by the moving rollers.
Do not approach your hands and ngers while the stack table of the Merge Stacker is
moving. Otherwise your hands and ngers may be caught by the stack table.
There are electric parts inside. Take care when opening the cover.
Otherwise, high voltage can cause severe personal injury.
Keep your hands and ngers away from the belts and rollers while the belts are
moving. Otherwise your hands and ngers may be caught by these parts.
Merge
Conveyor
90-degree
Turn Conveyor 2nd Process
Unit
Merge Stacker
Merge Stacker
8SmartStacker User's Manual
Contents
Important Information ........................................................................................................................1
Safety Precautions ............................................................................................................................2
Glossary ............................................................................................................................................3
Basic Safety Precautions...................................................................................................................4
Warning Label Locations and Meanings ...........................................................................................6
1 Machine Description
1-1 Features of the Machine .....................................................................................14
1-1-1 SmartStacker Conguration ................................................................................14
1-1-2 Directions described in this manual.....................................................................15
1-1-3 Sheet Flow...........................................................................................................16
1-1-4 Delivery................................................................................................................19
1-1-5 Supported Jobs ...................................................................................................22
1-1-6 Capability of Each Line........................................................................................26
1-1-7 The Role of Panels of the SmartStacker and the FLC ........................................27
1-2 SmartStacker Screen Descriptions.....................................................................28
1-2-1 Run - Main Screen - Part 1..................................................................................28
1-2-2 Run - Main Screen - Part 2..................................................................................29
1-2-3 Run - Main Screen - Part 3..................................................................................30
1-2-4 Run - Main Screen - Part 4..................................................................................31
1-2-5 Run - Main Screen - Part 5 (for Merge Stacker)..................................................32
1-2-6 Run - Main Screen - Part 6 (for B2 Stacker)........................................................33
1-2-7 Run - Setting Screen - Part 1 ..............................................................................34
1-2-8 Run - Setting Screen - Part 2 (for Merge Stacker) ..............................................35
1-2-9 Run - Setting Screen - Part 3 (for B2 Stacker)....................................................36
1-2-10 Run - Setting Screen - Part 4 (for B2 Stacker)....................................................37
1-2-11 Run - Fine Adjustment Screen - Part 1................................................................38
1-2-12 Run - Fine Adjustment Screen - Part 2................................................................39
1-2-13 Run - Fine Adjustment Screen - Part 3 (for B2 Stacker)......................................40
1-2-14 Run - Page Size Fine Adjustment Screen - Part 1 (for Merge Stacker) ....................41
1-2-15 Run - Page Size Fine Adjustment Screen - Part 2 (for B2 Stacker) ....................42
1-2-16 Run - Cutter Position Fine Adjustment - 1st Process Unit Fine Adjustment Screen..............43
1-2-17 Run - Cutter Position Fine Adjustment - 2nd Process Unit Fine Adjustment Screen.............44
1-2-18 Run - Scoring Position Fine Adjustment Screen (Optional).................................45
1-2-19 Setting - Size Setting Screen - Only for Ofine System- Part 1...........................46
1-2-20 Setting - Size Setting Screen - Only for Ofine System - Part 2..........................47
1-2-21 Setting - Size Setting Screen - Only for Ofine System - Part 3..........................48
1-2-22 Setting - Size Setting Screen - Only for Ofine System - Part 4 (for B2 Stacker) ..............49
1-2-23 Trim Guide Setting Screen ..................................................................................50
1-2-24 Memory - Main Screen - Part 1............................................................................51
1-2-25 Memory - Main Screen - Part 2............................................................................52
1-2-26 Information - Main Screen - Part 1 ......................................................................53
1-2-27 Information - Main Screen - Part 2 ......................................................................54
1-2-28 Information - Input Monitor Screen - Part 1.........................................................55
1-2-29 Information - Input Monitor Screen - Part 2.........................................................56
1-2-30 Information - Input Monitor Screen - Part 3.........................................................57
1-2-31 Information - Input Monitor Screen - Part 4.........................................................58
9SmartStacker User's Manual
1-2-32 Information - Input Monitor Screen - Part 5.........................................................59
1-2-33 Information - Input Monitor Screen - Part 6 (for B2 Stacker)...............................60
1-2-34 Information - Signal I/O Monitor Screen ..............................................................61
1-2-35 Information - Single Operation Screen - Part 1 ...................................................62
1-2-36 Information - Single Operation Screen - Part 2 ...................................................63
1-2-37 Information - Single Operation Screen - Part 3 ...................................................64
1-2-38 Information - Single Operation Screen - Part 4 ...................................................65
1-2-39 Information - Error History Screen.......................................................................66
1-2-40 Information - Administrator - Main Screen...........................................................67
1-2-41 Information - Administrator - Administrator Setting Screen - Part 1...........................68
1-2-42 Information - Administrator - Administrator Setting Screen - Part 2...........................69
1-2-43 Information - Administrator - Input Signal Enable Settings Screen - Part 1...........................70
1-2-44 Information - Administrator - Input Signal Enable Settings Screen - Part 2...........................71
1-2-45 Information - Administrator - Input Signal Enable Settings Screen - Part 3...........................72
1-2-46 Information - Administrator - Motor Enable Settings Screen - Part 1..............................................73
1-2-47 Information - Administrator - Motor Enable Settings Screen - Part 2..............................................74
1-2-48 Information - Administrator - Motor Enable Settings Screen - Part
3....................................75
1-2-49 Information - Administrator - Adjustment Mode Screen.......................................76
1-2-50 Information - Administrator - Network Conguration Screen ...............................77
1-2-51 Error - Main Screen .............................................................................................78
1-2-52 Error - Unit Screen...............................................................................................79
1-3 Finishing Line Controller Screen Descriptions....................................................80
1-3-1 Run - Main Screen - Part 1..................................................................................80
1-3-2 Run - Main Screen - Part 2..................................................................................81
1-3-3 Run - Main Screen - Part 3..................................................................................82
1-3-4 Run - Main Screen - Part 4..................................................................................83
1-3-5 Run - Main Screen - Part 5..................................................................................84
1-3-6 Run - Main Screen - Part 6..................................................................................85
1-3-7 Run - Main Screen - Part 7..................................................................................86
1-3-8 Run - Main Screen - Part 8..................................................................................87
1-3-9 Run - Main Screen - Part 9..................................................................................88
1-3-10 Run - Main Screen - Part 10................................................................................89
1-3-11 Run - Main Screen - Part 11................................................................................90
1-3-12 Run - Main Screen - Part 12................................................................................91
1-3-13 Run - Main Screen - Part 13................................................................................92
1-3-14 Run - Job Details Screen.....................................................................................93
1-3-15 Run - Diagnostic Tool Screen..............................................................................94
1-3-16 Setting - General(1) Screen - Part 1....................................................................95
1-3-17 Setting - General(1) Screen - Part 2....................................................................96
1-3-18 Setting - General(1) Screen - Part 3....................................................................97
1-3-19 Setting - General(1) Screen - Part 4....................................................................98
1-3-20 Setting - General(2) Screen - Part 1....................................................................99
1-3-21 Setting - General(2) Screen - Part 2..................................................................100
1-3-22 Setting - Job List Screen ...................................................................................101
1-3-23 Setting - Line Screen.........................................................................................102
1-3-24 Setting - Banner Screen Part 1..........................................................................103
1-3-25 Setting - Banner Screen Part 2..........................................................................104
1-3-26 Setting - About the FLC Screen.........................................................................105
10 SmartStacker User's Manual
2 Procedures for Near Line Operation
2-1 Daily Safety Check............................................................................................108
2-2 Changeover.......................................................................................................112
2-2-1 Before a Changeover ........................................................................................ 112
2-2-2 Starting the Changeover.................................................................................... 114
2-2-3 Setting the Trim Guides for the Gutter Trim....................................................... 116
2-2-4 Recalling Fine Adjustment Values ..................................................................... 117
2-3 Loading the Sheets on the Sheet Feeder ......................................................... 118
2-3-1 Loading the Sheets on the Feed Table.............................................................. 118
2-4 Starting a Job....................................................................................................122
2-5 Pausing and Resuming a Job...........................................................................123
2-5-1 Pausing and Resuming a Job Using the FLC....................................................123
2-5-2 Holding and Resuming a Job Using the FLC ....................................................124
2-5-3 Removing Any Blank Pages ..............................................................................126
2-6 Reprint - When using the Merge Stacker..........................................................127
2-6-1 Selecting the Reprint List Preparation Method..................................................127
2-6-2 Deciding How to Handle Reprinting...................................................................128
2-6-3 How the Stack is Delivered If a Jam Occurs .....................................................129
2-6-4 Reprinting the Whole Job from the Beginning...................................................131
2-6-5 Reprinting Only the Bad Stack ..........................................................................133
2-6-6 Reprinting Only the Bad Block...........................................................................137
2-6-7 Reprinting Only the Bad Sheet..........................................................................140
2-7 Error Recovery - When using the B2 Stacker ..........................................................143
2-7-1 How the Sheets are Delivered If a Jam Occurs.................................................143
2-7-2 Resuming the Job..............................................................................................144
2-8 Changing the Setting of Handy Scanner for FLC..............................................145
2-8-1 Turning down the beep sound...........................................................................145
2-8-2 Turning off the automatic scan mode ................................................................145
2-8-3 Returning to default settings..............................................................................145
3 ProceduresforOfineOperation
3-1 Setting the Control Panel - When using the Merge Stacker................................................148
3-1-1 Setting the Job...................................................................................................148
3-1-2 Setting the Delivery Action.................................................................................153
3-1-3 Starting a Job ....................................................................................................155
3-2 Setting the Control Panel - When using the B2 Stacker.........................................156
3-2-1 Setting the Job...................................................................................................156
3-2-2 Setting the Delivery Action.................................................................................159
3-2-3 Starting a Job ....................................................................................................162
3-3 Saving, Loading, and Deleting Jobs..................................................................163
3-3-1 Saving a Job......................................................................................................163
11SmartStacker User's Manual
3-3-2 Loading a Job....................................................................................................164
3-3-3 Deleting a Job....................................................................................................165
3-3-4 Protecting the Job Data.....................................................................................166
3-3-5 Exporting the Job Data......................................................................................167
3-3-6 Recalling Exported Jobs....................................................................................168
4 Procedures for Inline
Operation
4-1 Daily Safety Check............................................................................................172
4-2 Changeover.......................................................................................................175
4-2-1 Setting the Trim Guides for the Gutter Trim.......................................................175
4-3 Reprint - When using the Merge Stacker..........................................................176
4-3-1 How the Stack is Delivered If a Jam Occurs .....................................................176
4-3-2 Restarting the Operation ...................................................................................177
4-4 Post Processing................................................................................................178
4-4-1 Removing Any Blank Pages ..............................................................................178
5 Fine Adjustments
5-1 Adjusting the Sheet Feeder...............................................................................180
5-1-1 Adjusting the Position of the Suction Head .......................................................180
5-1-2 Adjusting the Feed Table Position .....................................................................180
5-1-3 Setting the Suction Head...................................................................................181
5-1-4 Setting the Side Air............................................................................................185
5-1-5 Adjusting the Table Guide and the Rear Guide .................................................187
5-1-6 Feed Rotor Adjustments....................................................................................188
5-2 Adjusting the Cutting Positions .........................................................................190
5-2-1 Adjusting the Length and Width of the Finished Size........................................190
5-2-2 Adjusting the Trim Width - Short Edge ..............................................................191
5-2-3 Adjusting the Trim Length - Long Edge.............................................................192
5-2-4 Adjusting Individual Trim Positions....................................................................193
5-3 Adjusting the Guide Positions...........................................................................196
5-3-1 Adjusting the Register Guide for the 1st Regist Unit.........................................196
5-3-2 Adjusting the Ejecting Gates on the 2nd Process Unit......................................198
5-3-3 Adjusting the Angle Adjusting Guides on the Merge Conveyor.........................199
5-3-4 Adjusting the Stopper on the Merge Stacker.....................................................200
5-3-5 Adjusting the Pressure of the Sheet Hold-Down Plates in the Merge Stacker........201
5-3-6 Adjusting the Stopper on the B2 Stacker...........................................................202
5-3-7 Adjusting the Pressure of the Sheet Hold-Down Plates in the B2 Stacker..............203
5-4 Adjusting the Optional Scoring Unit ..................................................................204
5-4-1 Adjusting the Scoring Positions.........................................................................204
5-4-2 Adjust the Scoring Depth...................................................................................205
6 Troubleshooting
6-1 If an Error Icon Appears....................................................................................208
12 SmartStacker User's Manual
6-2 If an Error Code Is Displayed on SmartStacker................................................ 211
6-3 If a Warning Screen is Displayed on SmartStacker ..........................................345
6-4 If an Error Code Is Displayed on FLC...............................................................349
6-5 If a Warning Message Is Displayed on FLC......................................................354
6-6 Pole Lamp and Up/Down Buttons.....................................................................355
6-6-1 Pole Lamp .........................................................................................................355
6-6-2 Up/Down Buttons...............................................................................................355
6-7 Problems with Cutting Quality...........................................................................356
6-7-1 Cutting is Skewed in the 1st Process Unit.........................................................356
6-8 Problems with the Sheet Feeder.......................................................................357
6-8-1 Misfeeding .........................................................................................................357
6-8-2 Double Feeding .................................................................................................360
6-9 If a Jam Occurs.................................................................................................363
6-9-1 Clearing the sheets after a jam..........................................................................363
6-9-2 Removing the jammed sheets...........................................................................364
7 Maintenance
7-1 SmartStacker ....................................................................................................370
7-1-1 Cleaning the Sensors ........................................................................................370
7-1-2 Cleaning the Air Filter ........................................................................................375
7-1-3 Cleaning the Belts .............................................................................................377
7-1-4 Lubrication.........................................................................................................380
7-1-5 Checking the Sheet Guide.................................................................................382
7-1-6 Checking the Rollers .........................................................................................386
7-2 Optional Sheet Feeder......................................................................................387
7-2-1 Cleaning the Vacuum Piston and Air Filter ........................................................387
7-2-2 Replacing the Separator and Suction Rubbers.................................................389
8 Appendix
8-1 Specications ....................................................................................................392
8-1-1 Specications of SmartStacker..........................................................................392
8-1-2 Specication Requirement on PC for FLC.........................................................395
8-2 Accessories.......................................................................................................396
8-2-1 SmartStacker Accessories.................................................................................396
8-2-2 Optional Sheet Feeder Accessories ..................................................................401
8-2-3 Component parts for FLC-H ..............................................................................404
8-2-4 Optional B2 Stacker Accessories ......................................................................405
1
This chapter explains the main features on
the machine, the touch panel screen on
the SmartStacker and the screen on the
Finishing Line Controller.
1 Machine Description
14 SmartStacker User's Manual
1-1 Features of the Machine
1-1-1 SmartStacker Configuration
62nd Process Unit (2Pro)
7Merge Conveyor (MC)
8Merge Stacker (MS)
9Output Shift Conveyor
10
1m Conveyor
11
B2 Stacker (BS)
1Sheet Feeder (SF) (Option)
21st Regist Unit (1Reg)
31st Process Unit (1Pro)
490-degree Turn Conveyor (TC)
52nd Regist Unit (2Reg)
1
2
3
4
5
6
7
8
9
10
11
Here are the sections included in a typical production line, along with the abbreviations we will use in this
manual.
15SmartStacker User's Manual
Features of the Machine
Delivery Side
Infeed
Side
Drive Side
Operator Side
Operator Side
Operator SideOperator Side
Operator Side
Operator Side
Drive Side
Drive Side
Infeed Side
Infeed Side
Infeed Side
Delivery
Side
Delivery
Side
Delivery Side
Operator SideOperator Side
Drive Side Infeed
Side
Delivery
Side
1-1-2 Directions described in this manual
16 SmartStacker User's Manual
Features of the Machine
1-1-3 Sheet Flow
12 11 10 912 11 10 9
11
20 19 18 1720 19 18 17
28 27 26 2528 27 26 25
87658765
4321
4321
16 15 14 1316 15 14 13
24 23 22 2124 23 22 21
GateGate
To
Top Tray
To
Top Tray
Gate
Gate
Gate
Gate
11
2pc2pc
22
3pc3pc
33
4pc4pc
MergeMerge
To B2
Stacker
To B2
Stacker
Scoring Unit
(Optional)
2nd Process
(9 Cutters)
2nd Regist
17SmartStacker User's Manual
Features of the Machine
4
8
12
16
20
24
28
4
8
12
16
20
24
28
3
7
11
15
19
23
27
3
7
11
15
19
23
27
2
6
10
14
18
22
26
2
6
10
14
18
22
26
1
5
9
13
17
21
25
1
5
9
13
17
21
25
4
8
12
16
20
24
28
4
8
12
16
20
24
28
3
7
11
15
19
23
27
3
7
11
15
19
23
27
2
6
10
14
18
22
26
2
6
10
14
18
22
26
1
5
9
13
17
21
25
1
5
9
13
17
21
25
4
8
12
16
20
24
28
4
8
12
16
20
24
28
3
7
11
15
19
23
27
3
7
11
15
19
23
27
2
6
10
14
18
22
26
2
6
10
14
18
22
26
1
5
9
13
17
21
25
1
5
9
13
17
21
25
43214321
8765
8765
12 11 10 9
12 11 10 9
16 15 14 13
16 15 14 13
20 19 18 17
20 19 18 17
24 23 22 21
24 23 22 21
28 27 26 25
28 27 26 25
4
8
12
16
20
24
28
4
8
12
16
20
24
28
3
7
11
15
19
23
27
3
7
11
15
19
23
27
2
6
10
14
18
22
26
2
6
10
14
18
22
26
1
5
9
13
17
21
25
1
5
9
13
17
21
25
22 2pc2pc
11
4pc4pc
4pc
4pc
33
4pc4pc
44
1st Process
(14 Cutters)
1st Regist
Double Feed Detect
Ultrasonic Sensor
18 SmartStacker User's Manual
Features of the Machine
GateGate
Gate
Gate
Eject
Eject
Stack
Stack
Gate
Gate
10 mm
Offset Guide
26030
10103C1
19SmartStacker User's Manual
Features of the Machine
1-1-4 Delivery
The processed stacks will be delivered to either of two destinations.
When Using in the Near Line or Inline System
To Completed Conveyor
The stack goes to the complete
conveyor in case that the stack is
reached to the planned number of
sheets.
To Uncompleted Conveyor
A stack which is less than the
planned number of sheets goes to the
uncompleted box in all cases.
For Example of 3 stacks in job
• A jam on middle of the rst stack
Completed Box
(Eoj = End of Job)
Uncompleted Box
• A jam on middle of the last stack
• The job end on middle of the last stack
20 SmartStacker User's Manual
Features of the Machine
• The job end on middle of the rst stack
Completed Box
Uncompleted Box
• If the “Offset” or “None” is selected for the operations after job processing on the FLC screen, the
previous job is not delivered, and the Line Clear button is pressed
• The user changes starting sheet number (from the Press UI)
• The user changes starting sheet number after the jam
• Break of a job with changeover
Table of contents
