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 modication or misuse, or operation outside of the
environmental specications for the product.
-Horizon International Inc. pursues a policy of continuing improvement in
design and performance of the product. Therefore, the product design and
specications 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 efciently.
➡ 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 specied
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 Conguration ................................................................................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 Ofine System- Part 1...........................46
1-2-20 Setting - Size Setting Screen - Only for Ofine System - Part 2..........................47
1-2-21 Setting - Size Setting Screen - Only for Ofine System - Part 3..........................48
1-2-22 Setting - Size Setting Screen - Only for Ofine 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 Conguration 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 ProceduresforOfineOperation
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