Horizon Fitness VAC-100 User manual

IUM201050-09
020702/VAC100/09E/DV
Important Information
- This manual is designed to help you to install, operate and maintain Collator, VAC-100.
Read, understand and keep this manual in a safe and convenient place.
- Do not operate VAC-100 until you read and understand the instructions in this manual.
- Horizon International Inc. shall not be liable for incidental consequential damages
resulting from : improper or inadequate maintenance by customer; unauthorized modifica-
tion 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
translated to another language without the prior written consent of Horizon International Inc.
VAC-100
COLLATOR

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 Specifications ...................................................................................................... 2
1-1-1 VAC Series Specifications .............................................................................2
1-1-2 Receiving Tray (Option) Specifications .........................................................3
1-2 Machine Descriptions ........................................................................................ 4
1-2-1 Overview ........................................................................................................ 4
1-2-2 Feed Section ................................................................................................... 5
1-2-3 Operation Panel .............................................................................................. 6
[1] Main Page....................................................................................................... 6
[2] Set 1 Page ....................................................................................................... 8
[3] Set 2 Page ....................................................................................................... 9
[4] Program Page ................................................................................................. 10
[5] Memory Page ................................................................................................. 11
[6] Preset Input Page ............................................................................................ 12
1-2-4 Remote Controller .......................................................................................... 13
1-2-5 Receiving Tray (CCR).................................................................................... 14
1-2-6 Receiving Tray (CCR-DX) ............................................................................ 15
1-2-7 Stacker (ST-20) .............................................................................................. 16
1-2-8 Stacker (ST-20R)............................................................................................ 17
1-2-9 Stacker (ST-40) .............................................................................................. 18
1-2-10 Stacker (ST-60) ............................................................................................ 19
1-2-11 Hand Marry Unit (HMU-100) ...................................................................... 21
1-3 Accessories .......................................................................................................... 22
1-4 Consumables and Options ................................................................................ 24
2. Operation Procedures
2-1 Power ON ........................................................................................................... 26
2-2 Preparation for Operation ................................................................................ 27
2-2-1 Tower ON/OFF and Delivery Direction Setup .............................................. 27
2-2-2 Collating Sheet Preparation ............................................................................ 28
2-2-3 Small Size Sheet Setup ................................................................................... 30
2-2-4 Feed Height Adjustment ................................................................................. 32
2-2-5 Blower Adjustment......................................................................................... 32

IV
2-2-6 Double Feed Stop Plate Height Adjustment................................................... 33
2-2-7 Separate Nose Adjustments ............................................................................33
2-2-8 Delivery Section Setup ................................................................................... 34
[1] Bulging Nose and Delivery Roller Setup ....................................................... 34
[2] Weight Setup ..................................................................................................35
[3] Delivery Air Adjustment ................................................................................36
2-2-9 Tray Unit Setup ..............................................................................................37
[1] When CCR or CCR-DX Is Used ....................................................................37
[2] When ST-20/ST-20R Is Used ........................................................................40
2-2-10 Setup in Main Page....................................................................................... 41
2-2-11 Hand Marry Unit Setup (HMU-100: Accessary) ......................................... 42
2-3 Collating Operation ........................................................................................... 43
2-3-1 Sheet Thickness Calibration ........................................................................... 43
2-3-2 Collating Operation ........................................................................................44
2-4 Feed Error Indication and Remedy .................................................................45
2-5 Program Collation ............................................................................................. 47
2-5-1 Double Cycle ..................................................................................................47
2-5-2 Dual Cover Feed ............................................................................................. 49
2-5-3 Tab Insert ........................................................................................................51
2-6 Job Memory ....................................................................................................... 53
2-7 Right Side Delivery ............................................................................................54
2-8 Hand Marry ....................................................................................................... 55
3. Troubleshooting
3-1 Error Indication and Remedy ..........................................................................58
3-2 When Misfeeding Occurs ..................................................................................59
3-3 When Double Feeding Occurs ..........................................................................59
3-4 Sheets Are Fed on the Skew ..............................................................................60
3-5 Paper Jam in Transport Conveyor ..................................................................60
3-6 Sheet from Hand Marry Unit Is Jammed .......................................................61
3-7 Collating Operation Does Not Start Even If Pressing Start Buttom ............61
3-8 Fuse and Breaker Check ................................................................................... 62
3-9 Pump Does Not Work ........................................................................................ 65

V
4. Maintenance
4-1 Daily Cleaning ....................................................................................................68
4-1-1 Feed Ring .......................................................................................................68
4-1-2 Transport Belt .................................................................................................69
4-2 Monthly Cleaning ..............................................................................................70
4-2-1 Bin Sensor ......................................................................................................70
4-2-2 Delivery Sensor ..............................................................................................70
4-3 Double Feed Stop Plate Replacement ..............................................................71
4-4 Feed Error Sensor Cleaning .............................................................................72
5. Move and Installation
5-1 Collator Installation ...........................................................................................74
5-2 Blower Box Installation .....................................................................................75
5-3 System Switch Set Up ........................................................................................77
5-4 Cable Connection ...............................................................................................78
5-5 Receiving Tray Installation ...............................................................................79
5-5-1 CCR/CCR-DX ................................................................................................79
5-5-2 ST-20/ST20R..................................................................................................80
5-6 EAB-100 Extra Air Blower (Option) Installation ...........................................82
5-7 VAC-100a Right Side Unit (Option) Attachment ...........................................87
5-7-1 Accessories .....................................................................................................87
5-7-2 How to Attach ................................................................................................89
5-8 HMU-100 Hand Marry Unit (Option) Installation .........................................97
5-8-1 Accessories .....................................................................................................97
5-8-2 Hand Marry Unit (HMU-100) Installation .....................................................98
5-8-3 Cable Connection ...........................................................................................101

VI

1
1. Before You Begin
1. Before You Begin
1-1 Specifications ........................................................................................... 2
1-2 Machine Descriptions .............................................................................. 4
1-3 Accessories ............................................................................................... 22
1-4 Consumables and Options ...................................................................... 24

2
1. Before You Begin
Module Type VAC-100a (Main Module)
VAC-100m (Extension Module)
VAC-100c (Rear Delivery Module)
Number of Bins 10, 20, 30, 40, 50, 60
Sheet Size 148 x 148 mm to 350 x 500 mm
(5.8" x 5.8" to 13.8" x 19.7')
Bin Pile Height 55 mm (2.2")
Paper Weight Range 52 gsm to 208 gsm
Collating Speed 8,000 sets/hr (Single or 2 to 3 towers installation and Straight Receiving)
5,000 sets/hr (4 towers installation and Straight Receiving)
4,500 sets/hr (5 towers installation and Straight Receiving)
4,000 sets/hr (6 towers installation and Straight Receiving)
Error Detection Miss, Double and Jam detection system (Photocell)
Error Monitor Eight sets of Feed Error Monitors
Power 3-Phase 200 V 50/60 Hz
3-Phase 220 V 60 Hz 10.4A
Single Phase 230 V 50 Hz 10.4A
Power Consumption 200 V 1,500 W / 220 V 1,700 W / 230 V 1,800 W
Motors 1,200 W x 1 / 400 W x 1 / 200 W x 1 / 100 W x 1
60 W x 1 (only a, c towers)
Machine Weight VAC-100a : 290 kg (639.5 lb)
VAC-100m : 290 kg (639.5 lb)
VAC-100c : 290 kg (639.5 lb)
1-1 Specifications
1-1-1 VAC Series Specifications
The machine design and specifications are subject change without any notice.

3
1. Before You Begin
Model CCR CCR-DX ST-20 and ST-20R
Max. Sheet Size 318 x 470 mm (12.5" x 18.5") 320 x 450 mm (12.6" x 17.7")
Min. Sheet Size 148 x 210 mm (5.9" x 8.3") 128 x 185 mm (5.1" x 7.3")
Max. Pile Height A5 to A4 : 170 mm (6.7") 320 mm (12.6")
A4 to A3 : 100 mm (3.9")
Machine Weight 56 kg (123.5 lb) 64 kg (141.2 lb) 56 kg (123.5 lb)
1-1 Specifications
1-1-2 Receiving Tray (Option) Specifications
The machine design and specifications are subject change without any notice.
Model HMU-100
Max. Sheet Size 350 x 500 mm (14" x 20")
Min. Sheet Size 120 x 148 mm (4.7" x 5.8")
Max. Sheet Height 80 gsm (21.3 lb) 50 sheets (5 mm)
Min. Sheet Height 80 gsm (21.3 lb) 1 sheets (0.1 mm)
The HMU-100 can be used with maximum of two-tower VAC-100.
The HMU-100 can not be connected with c-tower VAC-100.

4
1. Before You Begin
1-2 Machine Descriptions
1-2-1 Overview
Transport Door
Belts, which transports sheets
from each bin, are provided
inside this door. This door can
be opened or removed.
Operation Panel (c-Tower)
Sheets can be delivered to the right by
setting with this panel. Feed errors and
troubles are indicated on this panel.
Remote Controller
Main operation can be performed
with this remote controller.
Bin
Sheets are loaded on this bin.
Stop Button
Power Switch
Accessories (Option)
Receiving tray can be connected
as finishing device.
Accessories
Receiving tray or stitcher & folder
(option) can be connected as
finishing device.
Delivery Section
Sheets are transported from this section to
the accessory.
Stool
This stool is used to load sheets on the upper
bin. This stool is equipped with blower.
Operation Panel (a-Tower)
This panel is used to operate or setup
collator. Feed errors and troubles are
indicated on this panel.
Hand Marry Unit (Option)
This unit is used to insert a sheet
on or under the collated sheets in
VAC-100. It can be attached to a -
tower or m-tower.

5
1. Before You Begin
1-2 Machine Descriptions
1-2-2 Feed Section
Feed Height Adjust Lever
(White)
This lever is used to adjust the
height of feed height sensor.
Separation air Adjust
Lever (Blue)
This lever is used to adjust
separation air.
Feed Rotor
This rotor sucks and feed sheets.
Separate Nose Knob
Feed Height Sensor
This sensor determines the
sheet feed height.
Side Guide
This guide is the rear register
when sheets are loaded on bin.
Bin
Sheets are loaded on this bin.
Double Feed Stop Plates
These plates prevent double feeding.
Front Plate
This plate is the left register when
sheets are loaded on bin.
Blower Nozzle
Blowing air comes out from this
blower nozzle.
Separate Nose
This separate nose supports to
separate sheets to prevent double
feeding.

6
1. Before You Begin
Delivery Air ON/OFF But-
ton
This button is used to turn on/
off delivery air.
Double Cycle Preset Counter
In case the double cycle mode is turned
on and the number of double cycle preset
is input in program screen with the
double cycle preset button, the collating
section is automatically switched over
when the number of collated sets reaches
the input number.
60 min.
60 min.
123
123
C
?
123
123
1-2 Machine Descriptions
1-2-3 Operation Panel
[1] Main Page
Tabs
These tabs are used to select the page
on the screen.
Total Counter
This counter counts sets of
collated sheets. This
counter can be reset with
clear button. When main
power is turned off, this
counter is reset.
Preset Counter
In case the required
number of collated sets is
input in this counter with
the right preset button, the
collation stops when the
number of collated sets
reaches the input number.
Tab Counter
This counter indicates the current
number of times of tab insert and
the preset number of tab insert.
Tab insertion must be set on the
program page.
Error Monitor Button
This button is used to indicate
feed error.
Hand Marry Mode Indica-
tion
These icon indicate the se-
lected mode on HMU-100.
: Sheet(s) from hand marry
unit is inserted under collated
sheets.
: Sheet(s) from hand marry
unit is inserted on collated
sheets.
: Hand marry unit is not
used.
Start Button
This button is used to start the operation. The
operation will not start before sheet calibra-
tion is performed.
Stop Button
This button is used to stop the operation.
This button must be pressed three times
to stop the collator completely and lower
bins. Refer to the chart below.
Stop Button Pressing Times
0
1
2
3
Feeding
ON
OFF
OFF
OFF
Motor and Blower
ON
ON
OFF
OFF
Bin
Up
UP
UP
DOWN
Feed Error Reject Function ON/OFF Button
This button is used to turn ON/OFF the function of
delivering errored sets, to the feed-error tray.

7
1. Before You Begin
60 min.
60 min.
123
123
C
?
123
123
1-2 Machine Descriptions
Program Indication
These icons indicate the setup
program function.
Automatic Setup Button
This button is used only when SPF-20A is
combined. When this button is pressed, the
collator speed is adjusted automatically to match
the SPF-20A speed.
Feed Speed Indication
Feed speed can be set with triangle buttons
below. The speed can be changed during opera-
tion.
Belt Speed Indication
The belt which transports collated sheets can be
adjusted on three scales with triangle buttons
below.
Overlap
The sheet overlap can be adjusted on four scales
with triangle buttons below.
Suction Air Indication
Suction air power can be adjusted on two scales
with triangle buttons below.

8
1. Before You Begin
1-2 Machine Descriptions
[2] Set 1 Page
Tower Indication
The current used towers (collators) are
highlighted.
Finishing Device Button
This button is used to select the
finishing device combined. When
CCR-DX is used, CCR-DX icon
must be selected. The standard
icon ( ) must be used for all the
other devices.
Finishing Device Button
This button is used to select
the finishing device combined.
When CCR-DX is used, CCR-
DX icon must be selected. The
standard icon ( ) must be used
for all the other devices.
Delivery Direction Button
This button is used to select delivery
direction. The c-tower is required to
deliver collated sheets to the right.
Tower Main Power Button
The tower which is not used must be turned off.
1 2 3 4 5 6

9
1. Before You Begin
Lamp Button
This button is used to adjust the light intensity
on two scales according to the sheet thickness
and print darkness.
: for Normal to Thin
: for Thick or Dark Print Image
1-2 Machine Descriptions
[3] Set 2 Page
Sensor Button
This button is used adjust feed
error sensor sensitivity on four
scales.
: High
: Middle
: Low
: Double Feed Detect OFF
Bin Power Button
This button is used to turn on/off bin. The bin
where sheets are loaded during a sheet calibra-
tion is on. If sheets on the particular bin do not
require to be fed, the bin must be turned off.
: ON
: OFF
Individual Calibration Buttons
These buttons are used to calibrate the sheet
thickness in the individual tower.
All Tower Calibration Button
This button is used to calibrate the
sheet thickness in all towers.
Page UP/DOWN Button
This button is used to see the rest
of tower indication when four
towers or more are combined.
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
123
1
2
3
4
5
6
7
8
9
10 12

10
1. Before You Begin
123 123
1
123
1-2 Machine Descriptions
[4] Program Page
Double Cycle Button
This button is used to turn
on/off the double cycle
mode.
Dual Cover Feed Button
This button is used to turn on/off the
dual cover feed mode.
Tab Insert Button
This button is used to turn on/off
the tab insert.
Double Cycle Select
Button
This button is used to select
which section is started in
the double cycle program.
Bin Select Button
This button is used to select
which bin is started in the
dual cover feed program.
Preset Button
This button is used to set where tab
sheets are inserted.
Stop Button
This button is used to input
number of tab insert to stop
operation when the number of
tab insert reaches the input
number.
Tab Sheet Button
This button is used to
select one tab sheet or
two to be used.
Dual Cover Feed : When one cover bin
empties, the VAC-100
automatically switches over
to the other cover bin.
A
B
AB
AB
BBAA
A
B
1
5
6
10
1
10
1
10
1
10
1
5
6
10
1
10
AB
A
B
1
10
A
1
10
1
5
6
10
1
10
B
1
10
1
10
1
10
1
10
1
10
BBAA
1
10
A
1
10
1
10
1
10
1
10
B
1
10
1 Tower
2 Towers
3 Towers
4 Towers
Cover Sheets
Collated Sets
Tab Insert : Up to two tab sheets can be
inserted between preset collated
sets.
Tab Sheets
Collated Sets
Collated Sets
Collated Sets
5 Towers
6 Towers
Collated Sets
Tab Sheets
Double Cycle :
The VAC-100 system is divided into two sections. When any bin empties, the
VAC-100 immediately switches over to the second section and continues collating.
NOTE
- Double cycle and dual cover feed programs can be operated together. The place of cover
sheets in the second section is the first two bins in the second section.
- Double cycle and tab insert programs can be operated together. The place of tab sheets in the
second section is the first bin in the second section.
Double Cycle Preset Button
In case the number of double
cycle preset is input, the
collating section is automati-
cally switched over when the
number of collated sets
reaches the input number.

11
1. Before You Begin
1-2 Machine Descriptions
[5] Memory Page
Current Setup Button
This button is used to indicate
the current setup condition of
collator.
Setup Indication
The setup condition is indicated when
current setup button or job No. button is
pressed.
Job No. Button
Up to nine collating setup patterns can be
stored with these buttons.
Write Button
This button is used to memo-
rize the collating setup pattern
in the selected job No.
Read Button
This button is used to read the memo-
rized setup for the selected job No.
1 2 3 4 5 6 7 8 9
hr.
hr.
123
123

12
1. Before You Begin
1-2 Machine Descriptions
[6] Preset Input Page
UP Key
This key is used to increase the number
indicated.
DOWN Key
This key is used to decrease the number
indicated.
10-number Keys
The required number can be input
with these keys.
Clear Key
The key is used to clear the input number.
Enter Key
This key is used to enter the number. The
page goes back after pressing this key.
1
71 81 9
1
41 51 6
1
11 21 3
1
C1 01 E
The preset input page is shown by pressing preset button on the main page or program page.

13
1. Before You Begin
1-2 Machine Descriptions
1-2-4 Remote Controller
Trouble Monitor
When collating operation stops, this monitor let
the operator know the cause with lamp lighting.
Speed Button
This button is used to adjust the collating speed.
The speed can be adjusted during the operation.
This button has the same function as the one on
the main page. While this button is being
pressed, the speed is increased rapidly.
Inching Button
This button is used to inch roller and belt in the
transport and delivery sections. They can inch
during being pressed this button.
Start Button
This button is used to start the operation. The
operation cannot be started before sheet calibra-
tion is performed. This button has the same
function as the one on the main page.
Stop Button
This button is used to stop the operation. This
button has the same function as the one on the
main page. When this button is pressed with
error page shown on the screen, the screen goes
back to the main page. This function is the same
as the OK button in the error page.
123

14
1. Before You Begin
1-2 Machine Descriptions
1-2-5 Receiving Tray (CCR)
Off-set Timing Knob
This knob is used to adjust the side
guide delay after sheets are delivered
to CCR.
Single Motion Button
Tray rotation can be actuated
with this button.
Off-set ON/OFF Switch
This switch is used to switch on/off
off-set.
(Operation Panel)
LS
Delivery Rollers
These rollers transport collated
sets to receiving tray. Weights
correct sheet skew.
Air Adjust Knob
This knob is used to adjust the
delivery air.
Connecting Cable
This cable must be connected
to the collator connector.
Operation Panel
Stopper
This stopper must be set according to
the sheet size.
Tray Lock Knob
This knob is used to lock tray.
Tray
Tray for A5 to A4 sheet size or
for B4 to A3 sheet size can be
selected.