Horizon Fitness MC-80 User manual

I
COLLATOR
000928/MC80/02E/DV UM201006-02
MC-80
Important Information
- This manual is designed to help you to install, operate and maintain Automatic Collator,
MC-80. Read, understand and keep this manual in a safe and convenient place.
- Do not operate MC-80 until you read and understand the instructions in this manual.
- Horizon International Inc. shall not be liable for incidental consequential damages result-
ing from : improper or inadequate maintenance by customer; unauthorized modification or
misuse; operation outside of the environmental specifications for the product.
- Horizon International Inc. pursues a policy of continuing improvement in design and
performance of the product. Therefore, the product design and specifications are subject to
change without prior notice and without our legal obligation.
- All rights are reserved. No part of the manual may be photocopied, reproduced or trans-
lated to another language without the prior written consent of Horizon International Inc.

II
Safety Precautions
- The signal word WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
- The signal word CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in damage on machines. It may also be used to alert against unsafe
practices.
- Read and understand all safety instructions with signal word such as WARNING and
CAUTION. If safety instructions are ignored, personal injury may result.
- Horizon International Inc. cannot anticipate every possible situation that might involve
a potential hazard. The instructions in this manual and warning labels on the machine are
therefore not all inclusive.
- All equipment shall be locked out or tagged out to protect against accidental or inad-
vertent operation when such operation could cause injury to personnel. Do not attempt to
operate any switch, valve, or other energy isolating device where it is locked or tagged out.
- Do not operate the machines when any covers are removed.
- Some of the drawings in this manual show the machine uncovered for explaining the
detail or inside of machine.

III
CONTENTS
Important Information ............................................................................................I
Safety Precautions....................................................................................................II
1. Before You Begin.....................................................................1
1-1 Specifications......................................................................................................2
1-2 Machine Descriptions ........................................................................................3
1-2-1 Collator Module .............................................................................................3
1-2-2 Sucker Bar Assembly .....................................................................................4
1-2-3 Monitor Panel .................................................................................................5
1-2-4 Remote Controller [1] ....................................................................................6
1-2-5 Remote Controller [2] ....................................................................................7
1-3 Accessories..........................................................................................................8
2. Setting & Operation ................................................................11
2-1 Setting Up MC-80 ..............................................................................................12
2-1-1 Loading Sheets On Bins ................................................................................12
2-1-2 Sucker Stopper and Valve Setting.................................................................13
2-1-3 Delivery Roller Unit Setting...........................................................................14
2-1-4 Receiving Accessory Setting..........................................................................15
2-2 Operation Procedure .........................................................................................16
2-3 Right-side Delivery Function ............................................................................19
2-4 Hand Marrying Operation (HMU-80 : Option) .............................................21
2-5 Feed Error Indication........................................................................................23
2-6 Programming Collating.....................................................................................25
2-6-1 Double Cycle Collation ..................................................................................25
2-6-2 Dual Cover Feeding........................................................................................27
2-6-3 Mixed Modes of Collation. ............................................................................28
2-7 Tab Insertion Mode & Preset Stop Mode........................................................29
2-7-1 Tab Insertion Mode ........................................................................................29
2-7-2 Preset Stop Mode............................................................................................30

IV
2-8 For Efficient Operation.....................................................................................31
2-8-1 Detector Sensitivity Setting............................................................................31
2-8-2 Paper Condition..............................................................................................31
2-8-3 Folded Sheets .................................................................................................31
2-8-4 Wet Ink ...........................................................................................................31
2-8-5 Correct Loading..............................................................................................31
2-8-6 Roller Pressure ..............................................................................................31
3. Maintenance.............................................................................33
3-1 Cleaning ..............................................................................................................34
3-1-1 Detector Cleaning...........................................................................................34
3-1-2 Delivery Sensor Cleaning...............................................................................35
3-1-3 Nip Roller and Transport Belt Cleaning.........................................................35
3-1-4 Replacement of Fuses.....................................................................................36
3-1-5 Replacement of Double Sheet Prevent Brush ................................................36
3-1-6 Filter on Air Pump.........................................................................................36
4. Installation Instructions..........................................................37
4-1 Installation of Collator Module ........................................................................38
4-1-1 Installation Location.......................................................................................38
4-1-2 Installing MC-80 ............................................................................................38
4-2 Installation of Kit CTK-80 (Option) ................................................................44
4-2-1 Parts ................................................................................................................44
4-2-2 Installation Procedure.....................................................................................44
4-3 Installation of DDM-80 (Option)......................................................................49
4-3-1 Parts ................................................................................................................49
4-3-2 Installation Procedure.....................................................................................49
4-4 Installation of DDA-80 (Option).......................................................................51
4-4-1 Parts ................................................................................................................51
4-4-2 Installation Procedure.....................................................................................52

1
1. Before You Begin
1. Before You Begin
1-1 Specifications ........................................................................................... 2
1-2 Machine Descriptions.............................................................................. 3
1-3 Accessories ............................................................................................... 8

2
1. Before You Begin
Module Type MC-80a (Main Module)
MC-80m (Extension Module)
MC-80c (Right-side Delivery Module)
Number of Bins 8, 16, 24, 32, 40 and 48
Sheet Size 148 x 210 mm to 318 x 470 mm
(5.8" x 8.3" to 12.5" x 18.5")
Bin Pile Height 50 mm (2")
Stock Weight 52 gsm to 260 gsm
Collating Speed (A4) 3,500 sets/hr (8 bins)
2,500 sets/hr (16 bins)
2,400 sets/hr (24 bins)
2,300 sets/hr (32 bins)
2,050 sets/hr (40 bins)
2,050 sets/hr (48 bins)
Power 200 V 50/60 Hz 400 V 50 Hz
Machine Weight MC-80a ... 229 kg (505 lb)
MC-80m ... 223 kg (492 lb)
MC-80c ... 229 kg (505 lb)
1-1 Specifications
Machine Dimensions
The machine design and specifications are subject to change without any notice.
MC-80aST-20 MC-80m MC-80m MC-80m MC-80m MC-80c PJ-77
Pump Pump Pump
Pump Pump
Conveyor FC-10II SPF-10II MC-80a MC-80c PJ-77
575
(22.6")
400
(15.7")
Height=1,640(64.5")
500(19.6") 780(30.7") 780(30.7") 780(30.7") 780(30.7") 780(30.7") 780(30.7") 500(19.6")
590
(23.2")
580(22.8") 580(22.8")580(22.8")
580(22.8") 580(22.8")
590
(23.2")
610
(24")
600(25.9") 570(22.4") 1,470(57.8")
4,760(187.4") 780(30.7") 780(30.7") 500(19.6")
5,680(144.3")
:mm(inch)

3
1. Before You Begin
1-2 Machine Descriptions
1-2-1 Collator Module
Stop Button
Used to shut down whole system in case
of emergency.
Transport Belt Section
Transport belts carry fed sheet to
delivery section.
Roller Pressure Selector Lever
Used to select pressure of support
roller to hold sheets when collating
NCR.
Down Position : Normal
Up Position : Weak
Remote Controller
Major operation switches are
provided on remote controller.
Accessories (Option)
Six different accessories can be
combined. (CCR(DX), ST-20,
PJ-77, SPF-11, SPF-20, SP-10 or
SP-1) Refer to each accessory
operation or instruction manual.
Monitor Panel
Monitor panel is equipped with
two sets error monitor system.
Bin
Sheets will be piled on
these bins for collating.
Right-side delivery Acces-
sory (Option)
Optional receiving tray for
right-side delivery operation.
Delivery Speed Control Knob
Two different speed "Turtle" or
"Rabbit" (fast or slow) can be
selected.
Power Switch
Used to turn on/off main power of module.
Delivery Unit
Used to adjust angle of delivery
unit according to connected
accessory.
Receptacle for Accessories
Accessory connectors will be connected
on these receptacles.
Delivery Speed Control Knob
Two different speed "Turtle" or "Rabbit"
(fast or slow) can be selected.

4
1. Before You Begin
1-2 Machine Descriptions
1-2-2 Sucker Bar Assembly
Sucker Stopper A
Sucker stopper A is provided on each sucker
bracket and used to provide a clearance between
sucker rubber and sheets.
- Stopper A should be set at fully DOWN
position when collating less than around 130
gsm sheets; fully UP position when collating
more then around 130 gsm sheets.
NOTE :
- Use sucker stopper A either fully
DOWN position or fully Up position.
Suction Air Valve
Used to select suction air open
or close. Open suction air valve
according to size of sheets.
Sucker Stopper B
Used to provide a clearance be-
tween suckers and sheets when
double sheet feeding often happens
to collate heavier paper with sucker
stopper A being Up position.
Sucker Stopper C
Used to adjust angle of sucker brackets.
Use sucker stopper C when sucker stopper
A can not eliminate double sheet feeding.
Sucker Rubber
Two types of sucker rubbers are supplied with
machine.
Small Sucker Normal to Heavy Stock
(Installed on MC-80)
Large Sucker Very Heavy Stock
(Packed in accessory box.)
Suction Adjusting Ring
Used to adjust the vacuum air power.

5
1. Before You Begin
Preset Mode Switch (Only for MC-80a and
MC-80c)
Used to select function of preset counter
: Tab Insertion Mode
: Preset Stop Mode
Both Off : Continuous Collating
COLLATOR a
1
123
123
6
7
8
2
3
4
5
1
2
MC-80
1-2 Machine Descriptions
1-2-3 Monitor Panel
Total Counter
(Only for MC-80a and MC-80c)
This counter shows total amount of
collated sets.
Memorizing Sheet Caliper Button
- Used to check and memorize sheet
caliper of sheet to be collated.
- When lamp in memorizing sheet
caliper button is flashing, incorrect
communication from tower to
tower may occur. Turn off main
power and check system switch
and system cable connection.
(Refer to Page 39 and 40.)
Module ON/OFF Button
Used to turn on/off module.
Jam Lamp
When jamming occurs on each
bin, this lamp comes on.
Miss Feed Lamp
When miss feed occurs on each
bin, this lamp comes on.
Double Feed Lamp
When double sheet feeding
occurs on each bin, this lamp
comes on.
Error Monitor 2
Error monitor 2 shows feeding
errors in second set from top
on receiving tray.
Error Monitor 1
Error monitor 1 shows feeding
errors in first set from top on
receiving tray.
Preset Counter (Only for
MC-80a and MC-80c)
Detector Sensitivity Monitor
Button
Used to check detector sensi-
tivity on all bins.
Bin ON/OFF Button
Used to turn on/off each bin.
Detector Switch
Used to select brightness of
detector lamp.
OFF : for Normal Sheet
ON : for Dark Printed Sheet
Detector Lamp (Green)
Used to check dust on detec-
tor. When detector is contami-
nated with paper dust or pro-
jector lamp burned out, this
lamp goes off.
Stop Button
Inching Button
Used to operate feed roller,
transport belt and sucker
intermittently.

6
1. Before You Begin
Double Cycle Selector
Used to select double cycle mode.
First section feeds sheets.
Second section feeds sheets.
Double cycle mode OFF.
123 123
1
2
!
?
1
2
!
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1
2
!
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1
2
!
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1
2
!
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1
2
!
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342156
1-2 Machine Descriptions
1-2-4 Remote Controller [1]
Preset Counter Lamp
When collating stops with preset counter, this lamp comes on.
Receiving Tray Lamp
(1) When receiving tray becomes full, this lamp comes on.
(2) When jamming occurs on delivery unit, this lamp flashes.
(3) When delivery sensor is contaminated with paper dust or
alike, main motor won't start and this lamp flashes.
Module Lamp
(1) When module(s) is (are) turned on, this lamp comes on.
(2) When stop button is depressed, this lamp flashes.
(3) When delivery sensor on 2nd, 3rd, 4th, 5th or 6th module
continues to detect sheets, this lamp flashes.
Hand Marrying Indicator
- When hand marrying function is selected, this lamp comes on.
- When sensor on hand marrying unit is covered with paper or
alike, this lamp flashes.
Overlap Indicator
Indicates overlap mode; minimum, middle, maximum or 100%.
Stop/Bin Down Button
First Depression : Collating stops.
Second Depression : Transport belts stop rotating, pump
stops and bins descend.
Double Cycle Lamps
Indicate double cycle working block.
Start/Bin Up Button
First Depression : Transport belts start rotating, pump
starts and bins raise up.
Second Depression : Collating starts.
Speed Indicator
Indicates collating speed (interval) in 13 steps.
Speed Button
Collating speed (interval) can be selected with those button.

7
1. Before You Begin
Dual Cover Feeding Selector
Used to select dual cover feeding mode.
Upper cover feed bin works.
Lower cover feed bin works.
Dual cover feeding mode OFF.
Overlap Button
Four overlapping can be selected.
Maximum Overlap
Middle Overlap
Minimum Overlap
All ON 100 % Overlap
123 123
1
2
!
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1
2
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1
2
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1
2
!
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1
2
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1
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342156
1-2 Machine Descriptions
1-2-5 Remote Controller [2]
Feeding Error Lamp
(1) Error lamp ! shows feeding errors in first set on receiving
tray.
(2) Error lamp " shows feeding error in second set from top
on receiving tray.
(3) Error lamp " flashes when three sets of collated sheets
transported at same time. (6 modules operation).
Operation Error Lamp
Operation error lamp comes on;
(1) when sheet is not existing on bin which is turned on,
(2) when all sheets are fed and collating stops,
(3) when bin is not raised,
(4) when memorizing sheet caliper has not been performed.
Right-side delivery Indicator
Indicate right-side delivery function is selected.
Right-side delivery Selector Button
Used to select right-side delivery mode on MC-80c or MC-
80a with C Tower Kit (CTK-80). This button can be used on
above two modules which installed at right end of system or
single tower with C Tower Kit (CTK-80).
Dual Cover Feeding Lamps
Indicate dual cover feeding working bin.

8
1. Before You Begin
1-3 Accessories
Hose Clamp a-4 pcs, m-2 pcs, c-4 pcs
Connecting Plate (Upper) m-1 pc
Sheet Guide a-8 pcs, m-8 pcs, c-8 pcs
Bulging Nose a-3 pcs, c-3 pcs
Connecting Plate (Lower) m-1 pc Detector Cleaning Kit a-1 pc, c-1 pc
Setting Plate a-3 pcs, m-3 pcs, c-3 pcs Detector a-2 pcs, m-2 pcs, c-2 pcs
Double Sheet Prevent Brush
(a-3 pcs, m-2 pcs, c-2 pcs)
Tool Set a-1 pc, c-1 pc

9
1. Before You Begin
1-3 Accessories
Grease a-1 pc, c-1 pc Sucker Rubber (Small)
(a-8 pcs, m-8 pcs, c-8 pcs)
Sucker Rubber (Large)
(a-8 pcs, m-8 pcs, c-8 pcs)

10
1. Before You Begin

11
2. Setting & Operation
2. Setting & Operation
2-1 Setting Up MC-80.................................................................................... 12
2-2 Operation Procedure............................................................................... 16
2-3 Right-side Delivery Function ................................................................. 19
2-4 Hand Marrying Operation (HMU-80 : Option)................................... 21
2-5 Feed Error Indication ............................................................................. 23
2-6 Programming Collating .......................................................................... 25
2-7 Tab Insertion Mode & Preset Stop Mode ............................................. 29
2-8 For Efficient Operation .......................................................................... 31

12
2. Setting & Operation
7
NOTE (Before loading sheets)
- Fan well sheets to be collated to minimize
double sheets feeding.
- Press firmly at folded edge when 4-page
signature will be collated to minimize miss
feed or jamming.
- Dry printed ink on sheets before piling to
minimize trouble on feed roller or transport
belt.
1. Turn on main power of all modules.
2. Lower bins.
- Depress stop/bin-down button on remote
controller to lower all bins.
3. Load sheets on each bin.
- Page No. in each set should be coincide
with sequence of sheet delivery.
- Sheets should be placed firmly against
side resister and front guide.
- Maximum pile height is 5 cm (2").
(In case right-side delivery function is used.)
Please refer to "2-3 Right-side Delivery
Function" in Page 18.
4. Place sheet guide.
- Place sheet guide tightly to right end of
operation side of sheet.
NOTE
- Use lower position bins for productive
collating in case pages are less than 8.
2-1 Setting Up MC-80
2-1-1 Loading Sheets On Bins
Side Resister
Front Guide
Sheet Guide
Sheets

13
2. Setting & Operation
Close position :
Open position :
1. Set sucker stoppers according to quality
and condition of sheets.
A: Sucker Stopper A
Turn all four sucker stopper A fully
clockwise to set them at DOWN
position when collating less than 130
gsm sheets. Turn fully counterclockwise to
set at UP position when collating more
than 130 gsm sheets.
NOTE
- Sucker stopper A can be used only UP or
DOWN position.
B: Sucker Stopper B
Use sucker stopper B when double sheet
feeding often happens with sucker
stopper A being UP position. Sucker
stopper B can be moved down to
provide gap between suckers and sheet
by tuning clockwise.
C: Sucker Stopper C
1. Turn sucker stopper C clockwise to
provide gap between suckers and sheet
when double sheet feeding often
happens even if sucker stopper A set at
DOWN position.
2. Turn sucker stopper C clockwise to
provide gap between suckers and sheet
when NCR paper is collated.
2. Close or open suction valve.
- Close or open suction valve according to
sheet size.
Sucker Stopper B
Sucker Stopper C
Sucker Stopper A
Suction Valve
Sucker Stopper A
2-1 Setting Up MC-80
2-1-2 Sucker Stopper and Valve Setting

14
2. Setting & Operation
Weight
Push down this part to
install delivery sheet
bulging nose.
Push down this part to remove
delivery sheet bulging nose.
Bulging Nose
Lock Knobs
2-1 Setting Up MC-80
2-1-3 Delivery Roller Unit Setting
CAUTION
- Be sure to turn main power off when-
ever weight rollers and/or bulging nose
position are adjusted.
1. Set bulging nose and weight roller
- Set bulging nose and weight roller accord-
ing to sheet weight and size to perform
smooth and neat delivery of sheets.
- Loosen lock knob and position weight
roller unit.
(Patterns of setting bulging nose and
weight rollers.)
- When collating heavy-weight stocks or
folded sheets.
- When collating thin and less stiff paper
(More bulging).
Install three nosed when running large
size sheets.
2. Set weight position.
- Turn weight counterclockwise and slide it
forward or backward to increase or de-
crease roller pressure.

15
2. Setting & Operation
Air Nozzle
Delivery Air Knob
Delivery Air Switch
Up Down
Lever Knob
OFF
Max Pressure
(Delivery Air Knob)
2-1 Setting Up MC-80
2-1-4 Receiving Accessory Setting
3. Use delivery air.
- Use delivery air when collating thin stock
or when statistic causes difficulty in
transporting and jogging sheets.
- Turn switch up to start delivery air and
adjust air pressure with delivery air knob.
CAUTION
- Be sure to turn main power off when-
ever receiving accessory is installed.
1. Set delivery unit.
- Delivery roller position should be ad-
justed according to type of receiving
accessory to be connected.
UP... ST-20, SPF-11, SPF-20, SP-10
Down... CCR(DX), PJ-77/75, SP-1
- Loosen lock knob pull up lever or push
down lever to change delivery roller
position.
2. Install and set receiving accessories.
- Install and set receiving accessory accord-
ing to instructions in each receiving
accessory operation or instruction manual.
Lever Knob

16
2. Setting & Operation
1
123
1
2
1. Turn on power switch on each module.
2. Turn on module.
- Turn on module with module ON/OFF
button on each module.
3. Select detector mode with detector
switch on monitor panel.
Lamp OFF : for Normal sheet
Lamp ON : for ark Printed sheet
4. Raise bin with start/bin-up button on
remote controller.
- All bins are raised and transport belts start
rotating.
5. Memorize sheet caliper on each bin.
- epress memorizing sheet caliper button
on monitor panel to check and memorize
sheet caliper on all bins.
NOTE
- When SPF-11/SPF-20 is connected, turn on
motor on SPF-11/SPF-20 efore depressing
memory utton.
- Press memory utton from right side mod-
ule in case more than two modules are used.
etector Switch
Module ON/OFF Button
Start/Bin-Up Button
Memorizing Sheet
Caliper Button
Power Switch
2-2 Operation Procedure