Intimus 2051 User manual

Model 2051 Folder
Installation & Operating Instructions
Specifications
Folder Speed.............................................3,000-15,000 SPH Paper Weight...............................18# Bond (67.72 gsm) min.
Folder Capacity................................500 Sheets of 20# Bond 90# Index (161.78 gsm) max.
(2.25” Stack Height) Fold Length (both tables).............................2.3” (5.8cm) min.
Paper Size...............................................2.5” W X 5.2” L Min. 14.75” (37.5 cm) max.
(Half Fold Only) Feed Method ............................................... Top feed, friction
12” W X 18” L Max. Muli-Sheet Bypass.......................4 Sheets of 20# Bond max.
Programmed Sizes..............................8 ½” X 11”, 8 ½” X 14” (stapled sets ok)
11” X 17”, A4, A3 Electrical................................. 115 VAC, 1.4 Amps, 50/60 Hz
Programmed Folds..............Letter, Zee, Half, Double Parallel 220/230 VAC, .8 Amps, 50/60 Hz
Gate, Engineering, Church Dimensions (assembled)........... 43.2” W X 17.8” H X 22.2” D
Memory Capacity.......................................... 10 custom folds 110cm W X 452cm H X 564cm D
Storage of speed, quantity Shipping Weight...................................................102 Pounds
and Batch quantity optional
Introduction
Thank you for selecting the intimus® Model 2051 AutoFolder. All components have been thoroughly
inspected and performance tested to provide you with the best folder value in its class. Before each
machine is packed for shipment, it must pass a critical performance test. This folder can execute Letter,
Zee, Half, Double Parallel, Gate, Engineering, Church and custom folds within its paper size capacity.
Please review this publication in its entirety before attempting to operate your folder. Thorough
understanding of this information will help eliminate most operator-associated errors and ensure years
of trouble-free performance.
WARNING! Never connect power to the machine until you are ready to set up and operate the folder. This
machine contains moving parts. During setup, operation, and maintenance keep hands, hair, loose clothing,
and jewelry away from all moving parts. Serious bodily injury could result.
Notice: This folder contains NO USER SERVICALBE COMPONENTS. Service or disassembly should only
be completed by a qualified technician, and with the power disconnected and locked out. The AC outlet for this
(2051.11.02.09.15.00)
machine must be near by, and access to the outlet must not be blocked.
intimu9
A MAR IN YALE IBRAND
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intimus®2051 Folder (2051.11.02.09.15.00)
Revision 1.0 Martin Yale Industries, Wabash, Indiana, USA 260-563-0641 Page 2 of 29
Extension
Fold Types
Fold
Select
Display
Incremental
Adjust
Size Quantity
Select Custom Paper
Length
Dejam Handle
Storage
Extension
1st Fold
Table
V.-HI--I-_ Folder
Speed
.............. -Run
11&"tI--+--Stop
Display
Contrast
Enter
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intimus®2051 Folder (2051.11.02.09.15.00)
Table of Content
5.4 Storing a Program 12
Getting Started 5 5.5 Recalling a Program 12
1.1 List of Components 5 6 Multi-Sheet Bypass 12
1.2 Setting Up Your New Folder 5 6.1 Introduction 12
1.3 Power Connection 5 6.2 Software Rev. 1.00 to 1.23 12
1.4 Fold Tables 5 6.3 Software Rev. 1.24 and Greater 13
1.4.1 First Fold Table Installation 5 6.4 Multi-Sheet Best Practices 13
1.4.2 Second Fold Table Installation 5 7 Limp Mode 13
1.5 Feed Table Extension 6 8 Diagnostics and Setup 13
2 Using Your Folder 6 8.1 General 13
2.1 Power Up 6 8.2 Option 1 – Configure System 13
2.2 Loading Paper 7 8.2.1 Languages 13
2.3 Setting a Paper Size 7 8.2.2 Units 13
2.4 Setting a Fold Type 7 8.2.3 Save Speed 14
2.5 Setting the Paper Guides 7 8.2.4 Save Quantity 14
2.6 Running a Test Fold 8 8.2.5 Save Batch 14
2.7 Fold Skew Adjustment 8 8.3 Option 2 – Input Sensor Mode 14
2.7.1 Old Style Skew Adjustment 8 8.4 Option 3 – Keypad Input Mode 15
2.7.2 New Style Skew Adjustment 8 8.5 Option 4 – Feed Mode 15
2.8 Ready to Fold 9 8.6 Option 5 – Output Mode 16
2.9 Stopping the Folder 9 8.6.1 Fold Tables Drives 16
3 Adjusting and Counting 9 8.6.2 Exercising the Drives 16
3.1 Incremental Adjustment Buttons 9 8.6.3 Stack Wheels 16
3.2 Fold Table Adjustment 9 8.7 Option 6 – Fold Counters 16
3.3 Stack Wheel Position 10 8.7.1 CLTCH CNT (Clutch Count) 17
3.4 Folder Speed 10 8.7.2 Age Count 17
3.5 Display Contrast 10 8.8 Option 7 – Output Limits Mode 17
3.6 Quantity and Batch Mode 10 8.8.1 Fold Table #1 Home 17
3.6.1 Quantity 10
8.8.2 Fold Table #2 Home 17
3.6.2 Batch Mode 10 8.8.3 Diverter Offset 18
3.6.3 Stacking Problems 11 8.8.4 Stack Wheel Home 18
4 Manual Mode 11 8.8.5 Fold Position Center 18
5 Custom Folding Jobs 11 8.9 Option 8 – LED Test 19
5.1 Custom Paper Lengths 11 9 Error Codes 19
5.2 Custom Fold Table Settings 11 9.1 Error 100 – Bypass Sensor Failure 19
5.3 Custom Fold Programs 12
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intimus®2051 Folder (2051.11.02.09.15.00)
9.2 Error 101 – Feed Error 19
9.3 Error 102 – Exit Sensor Failure (on)19
9.4 Error 103 – Exit Sensor Failure (off)20
9.5 Error 104 – Motor Controller Failure20
9.6 Error 105 – Fold Table #1 Drive
Encoder Fault 20
9.7 Error 106 – Fold Table #1 Drive Wires
Reversed 20
9.8 Error 107 – Fold Table #2 Drive
Encoder Fault 20
9.9 Error 108 – Fold Table #2 Drive Wires
Reversed 20
9.10 Error 109 – Clutch Error 20
9.11 Error 110 – RPM Sensor Failure 20
9.12 Error 111 – Feed Error 20
10 Trouble Shooting
10.1 Folder will not start when the “Run”
button is pressed. 21
10.2 Folder will not start when paper is
inserted into the multi-Sheet Bypass. 21
10.3 The LCD Display is blank 21
10.4 There is a loud clicking noise… 21
10.4.1 …Only when the Fold Table is
trying to Home. 21
10.4.2 …Anytime the Fold Table is
trying to move. 21
10.5 The Fold Table pointer does not
match the LCD display. 22
10.6 The location of the fold is not correct.
22
10.7 The Stack Wheels are not moving
when they should be. 22
10.7.1 There is a clicking noise. 22
10.7.2 There is no sound coming from
the Stack Wheels. 22
10.8 Paper is piling up between the Stack
Wheels and the rollers. 22
10.9 One line of the LCD display is blank,
and the other is all black. 22
10.10 The folder is having feeding
problems… 22
10.10.1 …It’s feeding intermittently. 22
10.10.2 …It’s feeding more than one
sheet at a time. 23
10.11 The fold is not square… 23
10.11.1 The folds are all off in the
same direction. 23
10.11.2 …The folds are off in both
directions. 23
11 Debugging 23
11.1 Electrical 23
11.1.1 Sensors 23
11.1.2 Switches 23
11.1.3 Motors 23
21 11.2 Mechanical 23
11.2.1 Fold Table 23
11.2.2 Stack Wheels 24
12 Appendix 25
12.1 Fold Chart 25
12.2 Exploded View Drawing 26
12.3 Part List 27
12.4 110 Volt Wiring Layout 28
12.5 220/230 Volt Wiring Layout 29
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intimus®2051 Folder (2051.11.02.09.15.00)
Getting Started
1.1 List of Components
Your shipping container comes complete with
the following items;
Qty 1 – 2051 Folder
Qty 2 – Fold Table Assembly
Qty 2 – Feed Table Extension
Qty 1 – Power Cord
Qty 1 – Dejam Handle
Qty 1 – 9/64” Hex Key
The Fold Table Assemblies are shipped in their
own box and included within the folder
container. The Feed Table Extensions and the
Dejam Handle are in their own box as well.
1.2 Setting Up Your New Folder
Place your folder on a sturdy, flat surface such
as a table, desk, or bench. Inspect your folder
for signs of damage. If damage is apparent, call
the freight carrier immediately, then call Martin
Yale for instructions.
1.3 Power Connection
The Power Cord for the folder is a standard
computer power cord. Plug the female end of
the power cord plug into the folder’s power
connection (Figure 1).
The power switch is located on the same
surface as the power connection, nearest the
front of the folder.
Figure 1
1.4 Fold Tables
Both fold tables are the same, and can be
installed into either the first (upper, right) or
second (lower, left) fold table positions. The
fold table is locked into position by 4 (four) pins
located in the folder.
1.4.1 First Fold Table Installation
To install the first fold table, refer to Figure 2.
Step 1: slide the front slot opening of the fold
table onto the inner set of pins (closest to the
folding rollers).
Step 2: lower the fold table onto the outer set of
pins with a light amount of downward pressure
as shown. There will be a slight snapping
action as the fold table drops into the detent
position.
Figure 2
1.4.2 Second Fold Table Installation
To install the second fold table, refer to Figure
3.
Step 1: slide the front slot opening of the fold
table onto the inner set of pins (closest to the
folding rollers) with a light to moderate amount
of pressure.
Step 2: lower the fold table onto the outer set of
pins with a light amount of downward pressure
as shown. There will be a slight snapping
action as the fold table drops into the detent
position.
Figure 3
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intimus®2051 Folder (2051.11.02.09.15.00)
1.5 Feed Table Extension
Your folder comes with 2 Feed Table
Extensions. One of the Extensions is used on
the Exit Conveyor, and the other extension is
used on the Feed Table. Both extensions are
identical and can be used on either the Feed
Table or the Exit Conveyor.
To install the Extension onto the Feed Table,
align the locking tabs of the Extension with the
slots in the Feed Table as shown in Figure 4.
Figure 4
Squeeze the Feed Table and Extension
together nearest the tabs and slots until the 2
pieces snap together.
To install the Extension onto the Exit Conveyor,
align the tabs on the Extension with the slots
provided in the Exit Conveyor as shown in
Figure 5. No force is required to install the
Extension onto the Exit Conveyor – gravity will
hold the Extension in place.
Figure 5
2 Using Your Folder
After performing all of the steps in section 0
(Getting Started), you’re ready to turn on the
folder.
2.1 Power Up
With your left hand, reach under the second
(left) fold table and turn on the power. When
the power switch is turned on, the display will
read as follows;
Intimus 2051 Folder
By Martin Yale Ind.
Figure 6
This message will display for a short time, then
the display will read;
Model 2051
Revision XX.XX
Figure 7
This is the software revision level.
In the event that you must call Martin Yale
Support for help, please have the software
revision number available.
After a few seconds, the display will change
again and read as follows;
Homing Fold Tables
Please Stand By
Figure 8
At this time, both fold tables will begin to move
to their respective home positions.
Homing of the fold tables is required to
insure a proper and accurate fold. This
operation may take several seconds. Allow the
folder to continue without interruption until the
display indicates that it’s ready.
Once the Fold Tables have been homed, the
display will toggle between 2 different
messages;
Bypass Ready
Qty Done = 0
Figure 9
And…
Custom Fold Set
Qty Done = 0
Figure 10
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intimus®2051 Folder (2051.11.02.09.15.00)
You will see the “Custom Fold Set” message
displayed when none of the “Fold Type” lights
are illuminated. This is to tell you that the folder
does not recognize the Fold Table positions as
a standard fold type. This is typically referred to
a “Manual Mode”.
2.2 Loading Paper
To load paper into the Feed Table, firmly push
the Feed Table down as show in Figure 11,
until it locks into the “load” position as shown in
Figure 12.
Figure 11
The Feed Table is capable of holding 500
sheets of 20# bond paper, or a stack of paper 2
1/8 inches high, up to the maximum rated
weight of paper for this folder.
Load the paper into the Feed Table as shown in
Figure 12, making sure that the paper is fully
within the folder, and that the leading edge of
the stack is resting against the face indicated.
Figure 12
Once the Feed Table has been loaded with
paper, depress the Feed Table Release to
unlocked the Feed Table, allowing it to return to
the raised position (Figure 13).
Figure 13
2.3 Setting a Paper Size
To change paper sizes, depress the “SIZE
SELECT” button located on the folder keypad.
Each time the “SIZE SELECT”
button is depressed, the lights
indicating the paper size will
sequence through all of the paper
sizes.
You must specify the paper size that you
intend to fold prior to running the folder.
2.4 Setting a Fold Type
To change the fold type, depress the “FOLD
SELECT” button located on the folder keypad.
Each time the “FOLD SELECT”
button is depressed, the lights
indicating the fold type will
sequence through all of the fold
types.
Once you have selected a fold type, the
folder will wait for 8 seconds, for any additional
settings that you may want to set, such as a
quantity of folds to run. To bypass this time
delay, depress the “ENTER” button.
Additionally, pressing either the “Test” or “Run”
buttons will bypass this time delay and then
perform either “Test” or “Run”, whichever was
pressed.
2.5 Setting the Paper Guides
Your 2051 folder comes factory set to 8½ X 11
paper. To adjust the paper guides, loosen the
thumb knobs of the Paper Guides by rotating
the knobs counter-clockwise (top to the left)
approximately 1 full turn (Figure 14). Move the
Paper Guides to the desired location, and then
retighten the thumb knobs.
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Fully insert paper to
surface indicated
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intimus®2051 Folder (2051.11.02.09.15.00)
Do not over tighten the thumb knobs.
Tighten the thumb knobs just enough to hold
the Paper Guides in place. Do not use any
tools to tighten the thumb knobs as this will
damage the knobs and the Paper Guides.
Figure 14
When setting the Paper Guides, it is easier
to have the correct paper in the Feed Table
between the guides as you adjust them. Also, it
is easier to move the Paper Guides with your
left hand from under the Feed Table, rather
then from the top.
It’s important to note that for best folding
results, the paper should be as close to
centered on the Feed Table as possible.
2.6 Running a Test Fold
The Test button provides the
ability to check the folder settings
by feeding a single piece of paper
from the Feed Table. Pressing the
Test button once will turn on the
main motor, feed two sheets of paper, and then
main motor will stop.
Folders with older revisions of software will
only feed a single sheet of paper when the Test
button is depressed.
Holding the Test button down will cause the
folder to continuously feed paper. Once the
Test button is released, to folder will stop
normally.
If the location of the fold is incorrect,
adjustment of the Fold Tables is required. See
section 3.2 - Fold Table Adjustment.
If the fold is not square (skewed fold),
adjustment to the paper guides is required.
See section 2.7 - Fold Skew Adjustment for
more information.
2.7 Fold Skew Adjustment
Skew adjust of the fold is done by changing the
angle of the Paper Guides in the Feed Table.
There are 2 styles of Skew Adjustment on the
2051 folder.
2.7.1 Old Style Skew Adjustment
With the Feed Table depressed into the load
position, push or pull the adjustment lever
located in the Feed Table (Figure 15) until the
desired amount of skew adjustment has been
made.
Figure 15
2.7.2 New Style Skew Adjustment
With the new style of Skew Adjustment,
adjustments can be made at anytime,
regardless of paper load in Feed Table, or if the
folder is running.
To adjust, rotate the Skew Adjustment Knob
located on the side of the Feed Table, closest
to the front on the folder (Figure 16).
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intimus®2051 Folder (2051.11.02.09.15.00)
Figure 16
2.8 Ready to Fold
Pressing the Run button will
initiate folding – the main motor
will start and paper feeding will
begin.
Feeding will continue until one of the follow
conditions is met; 1. the Stop button is
depressed, 2. The Feed Table becomes empty
of paper, 3. a folding error is encountered, 4. or
the programmed quantity reaches 0 (zero).
To program the quantity of sheets to be
folded, see section 3.6 - Quantity and Batch
Mode.
Your folder is equipped with a “Limp” mode.
In the event that either Fold Table Drive
malfunctions (see error codes 105, 106, 107, or
108), you can still move the fold table manually
and run the folder. For more information
regarding “Limp” mode, see section 7 - Limp
Mode.
2.9 Stopping the Folder
Pressing the Stop button once
instructs the folder to perform a
normal shut down, allowing all
paper to clear the folder prior to
the main motor stopping.
Depressing the Stop button twice in quick
succession causes an immediate stop of the
main motor. This is to be used in the event that
there is a paper jam that the folder did not
detect, or other condition where an
instantaneous stop is necessary.
Double pressing of the Stop button is
reserved for emergency stopping only, and
should not be used for normal stopping
when the folder is running.
3 Adjusting and Counting
Pressing any of the following buttons will place
you into the respective adjustment mode. If you
do not press any other buttons for 8 seconds,
the folder will revert to its previous mode.
Pressing the Enter button will bypass the 8
second time delay and will instantly proceed.
3.1 Incremental Adjustment Buttons
The Incremental Adjustment Buttons are used
for the fine adjustment of various items on your
folder.
These buttons work for all of the functions that
have the matching light-blue background color
only. These buttons will auto-repeat if held
down for more than one second.
This button will
increase a number
value by one count.
This button will
decrease a number
value by one count.
3.2 Fold Table Adjustment
To manually adjust a fold table, press the
corresponding fold table adjustment button as
shown below, and then press either the
increase or decrease button (as described in
section 3.1 - Incremental Adjustment Buttons).
Second Fold Table First Fold Table
In addition to the Incremental Adjustment
buttons, the fold tables can be positioned to a
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intimus®2051 Folder (2051.11.02.09.15.00)
specific location by entering a value with the
number buttons on the keypad. To do so,
simply type in a value and press the enter
button.
The keypad is disabled when the folder
is in Limp mode. Only the Incremental
Adjustment buttons are functional when in
Limp mode. Also when in Limp mode, the
LCD displays shown below in Figure 17 and
Figure 18 may be disabled. See section 7 -
Limp Mode for more information.
Fold Table 1
XX.XX IN
Figure 17
Fold Table 2
XX.XX IN
Figure 18
If you find it necessary to make an
adjustment to either fold table when you have a
standard fold type specified, changing the fold
table by more than 1/4 of an inch will place the
folder into “manual” mode, as indicated by the
illumination of the “Other” LED. Moving the fold
table back to within 1/4 of an inch will turn off
the “Other” LED and the standard fold type LED
will again by illuminated.
Your folder is equipped with a “Limp” mode.
In the event that either Fold Table Drive
malfunctions (see error codes 105, 106, 107, or
108), you can still move the fold table manually
and run the folder. For more information
regarding “Limp” mode, see section 7 - Limp
Mode.
3.3 Stack Wheel Position
To manually adjust the position of
the Stack Wheels, press the Stack
Wheel button (shown on the left),
and then press either the increase
or decrease button (as described
in section 3.1 - Incremental Adjustment
Buttons).
The correct position of the Stack Wheels is
automatically calculated based on the length of
the paper and the position of the fold tables.
Manual adjustment of the Stack Wheels is not
normally required when performing a standard,
pre-programmed fold.
3.4 Folder Speed
To adjust the speed of your folder,
press the Speed button (shown on
the left), and then press either the
increase or decrease button (as
described in section 3.1 -
Incremental Adjustment Buttons).
Folder speed can be adjusted while the folder is
running. For most all folding jobs, the folder
can be run at full speed (100%).
3.5 Display Contrast
To adjust the display contrast of
the LCD display, press the Display
Contrast button (shown on the
left), and then press either the
increase or decrease button (as
described in section 3.1 - Incremental
Adjustment Buttons).
3.6 Quantity and Batch Mode
The Quantity (#) is used to specify
the total number of sheets to be
folded, and to specify a Batch
quantity.
3.6.1 Quantity
To program a specific number of pages to be
folded, press the Quantity (#) button once.
Pressing the Quantity (#) button twice will
skip the Quantity screen and place you directly
into Batch Mode.
Using the numbers on the keypad, enter the
quantity of sheets to fold, and press the enter
key. After entering a quantity, you will
automatically enter Batch Mode.
ENTER QUANTITY TO GO
Qty To Go= 0
Figure 19
3.6.2 Batch Mode
The Batch Mode function gives you the ability to
fold and deliver a specified number of sheets as
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intimus®2051 Folder (2051.11.02.09.15.00)
a “batch”, and automatically places a gap
between batches. A batch quantity of 0 (zero)
will turn off Batch Mode, and all of the folded
sheets will be delivered without a delay.
To enable Batch Mode, enter a Batch quantity
value greater than 0 (zero). This quantity is the
number of sheets that will be folded and
delivered as a “batch”. When the entered
quantity of sheets has been folded, the folder
will suspend feeding until the Exit Conveyor has
become clear of paper, then folding will resume.
This run/pause/run sequence will continue until
the Stop button is depressed, the Feed Table
becomes empty of paper, a folding error is
encountered, or the programmed quantity
reaches 0 (zero) (see section 3.6.1 - Quantity).
3.6.3 Stacking Problems
Occasionally, you may find that the folded
paper is not stacking cleanly because of a
particular type of fold or paper weight. A
condition such as this can result in a paper jam
because paper piles up between the Stack
Wheels and the fold rollers, allowing paper to
be drawn back into the spinning rollers.
To eliminate the possibility of this occurring, as
an extension of the Batch Mode, folded sheets
can be delivered one at a time with a slight
delay between pages to insure that the folded
sheets have become captured by the Stack
Wheels.
Setting the Batch quantity to “1” instructs the
folder to feed one sheet at a time, and to wait
for the Exit Conveyor sensor to become clear,
before feeding the next sheet. This insures that
the Stack Wheels have a firm grasp of the
previously folded sheet before the next sheet is
fed into the folder.
4 Manual Mode
The folder is in “Manual Mode” if none of the
Fold Type lights are illuminated. Manual Mode
is entered if the position of either Fold Tables is
manually change by a more than 1/4 of an inch
from a Standard Fold position. Doing so will
turn off all Standard Fold lights, indicating that
the folder has been placed into “Manual Mode”.
Also, the top line of the LCD Display will state
“Custom Fold Set”.
Custom Fold Set
Qty Done = 0
Figure 20
When in Manual Mode, the folder assumes that
the operator knows what they want for a
desired fold, and therefore, it is completely up
to the operator to specify the paper length and
set both Fold Table positions. The position of
the Stack Wheels will still automatically adjust
based on the paper size and Fold Table
positions.
When in Manual Mode, it is still important to set
the proper paper length as this helps to control
feeding, and insures maximum operating
efficiency.
5 Custom Folding Jobs
5.1 Custom Paper Lengths
Your folder has the necessary
intelligence to calculate the proper
settings for the Fold Tables and
the Stack Wheels for all of the pre-
programmed fold types for any
given paper length. If a pre-programmed fold
type is selected, and you enter a custom paper
length, the fold tables and stack wheels will
automatically be configured to produce that
fold.
To specify a custom paper length, press the
Paper Length button. Using the number
buttons, enter a valid paper size value (see the
folder specifications on the cover of this
document for valid paper sizes), and press the
Enter button to save this value.
5.2 Custom Fold Table Settings
When a custom Fold Table setting is entered,
the folder enters a “manual” mode where you
must specify everything manually. You may
use the pre-programmed paper sizes, if you
wish.
When the folder is in manual mode, the “Other”
light will be illuminated, indicating that you are
creating a fold “Other” than the standard, pre-
program fold types.
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intimus®2051 Folder (2051.11.02.09.15.00)
5.3 Custom Fold Programs
The folder can store up to 10 different custom
fold configurations. Custom programs store
both Fold Table locations, Paper Length, Folder
Speed, Quantity, and Batch Quantity.
The location of the Stack Wheels is calculated
automatically when the program is recalled, and
therefore, are not part of Custom Fold
Programs.
This button will “store”
the current folder
configuration into a
memory location.
This button will
“recall” a previously
stored folder
configuration.
See sections 8.2.3 - 8.2.5 for information
regarding storing Folder Speed, Quantity, and
Batch Quantity.
Programs are maintained in memory even if
the power is turned off or power is removed.
Once a program is stored into a memory
location, it can not be deleted. Programs can
only be overwritten with another program.
5.4 Storing a Program
To store a program, press the “Store” button,
then press one of the number buttons (0-9) to
specify a storage location.
Each number button is a separate program
storage location.
5.5 Recalling a Program
To recall a stored program, press the “Recall”
button, and press a number button where a
program is stored. If there is a stored program
in the number pressed, the folder will
immediately begin to configure itself per the
stored program. All of the standard Fold Table
and Stack Wheel messages will be displayed.
If there is no program stored in the number
pressed, the following message will be
displayed;
Storage Location
Empty
Figure 21
Once a program is stored into a specific
memory location, this message will not be
displayed again.
6 Multi-Sheet Bypass
6.1 Introduction
Your folder can fold up to 4 sheets of 20# Bond
paper through the multi-sheet Bypass. The 4
sheets may be stapled together. However, the
location of the staple is restricted to the top
edge of the pages. The staple can be located
in either corner so long as it is along the top of
the document.
When placing the multiple sheets into
the Bypass slot, the stapled edge must enter
the slot first! Failure to do so will cause
wrinkling of the sheets.
It is not necessary to empty the Feed Table
when using the Multi-Sheet Bypass. Nor does
the Feed Table need to be in any particular
position.
There are 2 different software versions
controlling the multi sheet bypass function.
6.2 Software Rev. 1.00 to 1.23
On all folders with a software revision of 1.23
and less, the Main Motor of the folder will start
automatically.
When paper is introduced into the Multi-Sheet
Bypass, the top line of the display will show the
following message;
Bypass Paper Detectd
Figure 22
After a 5 second delay, the Main Motor will start
running and the display will show the following;
Bypass Paper Detectd
Running Main Motor
Figure 23
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intimus®2051 Folder (2051.11.02.09.15.00)
6.3 Software Rev. 1.24 and Greater
On folders with a software revision of 1.24 and
greater, you must depress the “Run” button to
start the folder. The folder will not automatically
start.
6.4 Multi-Sheet Best Practices
For best results, insure that all of the pages are
aligned with each other before placing them into
the Bypass. For best possible results, place all
of the sheets into the Multi-Sheet Bypass slot in
the following manner;
1. With your left hand, palm facing down, hold
the multi-sheet document at the bottom and
allow the paper to hang with the top of the
document below your hand.
2. Lower the top edge of the document into the
Multi-Sheet Bypass slot located in the Top
Cover, and allow the document to drop the
last half inch or so.
3. Without grasping, support the document so
that the document is not bent so when the
folder starts running, the document will feed
straight into the folder.
4. Before the folder begins to run, apply a
small amount of downward pressure to help
feed the document into the slot.
7 Limp Mode
Limp mode allows you to manually set the
position of the fold tables and run the folder at a
reduced speed.
Limp mode is entered automatically in the event
that the folder encounters one of the following
error codes; 105, 106, 107, or 108.
Positioning of the fold tables is done in the
normal manner as described in section 3.2 -
Fold Table Adjustment.
Since the LCD display for either fold table may
be disabled when in Limp mode, use of the
scales on the fold table is required when
positioning. A fold chart is provided in the
Appendix of this manual showing the positions
of both paper stops in the Fold Tables to
produce a particular fold for a given paper size..
8 Diagnostics and Setup
8.1 General
To enter any of the diagnostics options listed
below, from the main diagnostics screen, press
the corresponding diagnostics option number
on the keypad. Figure 24 shows the Main
diagnostics screen.
Diagnostics Setup
Press 1-8 or STOP
Figure 24
To exit any of the following diagnostics screens,
press the “Stop” button.
To exit diagnostics altogether, from the Main
diagnostics screen, press the “Stop” button.
8.2 Option 1 – Configure System
This option is used for basic setup of the folder.
Using the “+” or “-“ button on the keypad, scroll
through the list of parameters. When you reach
the parameter that you which to change, press
the “Enter” button once. This will put you into
an edit mode. When in edit mode, the bottom
line of the display will show arrows at the
extreme right and left.
If you have accidentally entered edit mode,
to exit edit mode and abort changing the
parameter, press the “Stop” button.
8.2.1 Languages
To change the display language, once you are
in edit mode, use the “+” and “-“ buttons to
scroll through the list of languages. Once you
have found the language you want, press the
“Enter” button once to save this language and
exit edit mode. The display will now read in the
language selected.
8.2.2 Units
There are only 2 units programmed into the
folder – Inches and Centimeters. To change
between units, once you are in edit mode,
pressing the “+” will set units to “Inches”, and
pressing the “-“ button will set units to
“Centimeters”. Once you have selected the
units, press the “Enter” button once to save and
exit edit mode.
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intimus®2051 Folder (2051.11.02.09.15.00)
8.2.3 Save Speed
This parameter enables or disables saving of
the folder speed setting (see section 3.4 -
Folder Speed) as part of a custom fold program
(see section 5.3 - Custom Fold Programs).
To change this parameter, once you are in edit
mode, pressing the “+” will set this parameter to
“Yes”, and pressing the “-“ button will set this
parameter to “No”. Once you have set this
parameter, press the “Enter” button once to
save and exit edit mode.
With this parameter set to “Yes”, when a
Custom Fold Program is stored, the current
folder speed will also be stored. When the
Custom Fold Program is recalled, the Folder
Speed will be set to the previously stored
Folder Speed.
If this parameter is set to “No”, Folder Speed
will remain unchanged by Custom Fold
Programs.
8.2.4 Save Quantity
This parameter enables or disables saving of a
fold Quantity (see section 3.6.1 - Quantity) as
part of a custom fold program (see section 5.3 -
Custom Fold Programs).
To change this parameter, once you are in edit
mode, pressing the “+” will set this parameter to
“Yes”, and pressing the “-“ button will set this
parameter to “No”. Once you have set this
parameter, press the “Enter” button once to
save and exit edit mode.
With this parameter set to “Yes”, when a
Custom Fold Program is stored, the current fold
Quantity value will also be stored. When the
Custom Fold Program is recalled, the fold
Quantity will be set to the previously stored
value.
If this parameter is set to “No”, fold Quantity will
remain unchanged by Custom Fold Programs.
8.2.5 Save Batch
This parameter enables or disables saving of a
Batch quantity (see section 10 - Figure 19
Batch Mode) as part of a custom fold program
(see section 5.3 - Custom Fold Programs).
To change this parameter, once you are in edit
mode, pressing the “+” will set this parameter to
“Yes”, and pressing the “-“ button will set this
parameter to “No”. Once you have set this
parameter, press the “Enter” button once to
save and exit edit mode.
With this parameter set to “Yes”, when a
Custom Fold Program is stored, the current
Batch quantity value will also be stored. When
the Custom Fold Program is recalled, the Batch
quantity will be set to the previously stored
value.
If this parameter is set to “No”, Batch quantity
will remain unchanged by Custom Fold
Programs.
8.3 Option 2 – Input Sensor Mode
This option shows the current state of all sensor
inputs.
The display will look similar to the example in
Figure 25 below. The letters along the top of
the display represent the input channel on the
folders Main Controller. The numbers along the
bottom of the display shows if the input is on or
off for that specific input channel, with “1” being
on and “0” being off.
ABCDEFGHJKLMNOPQ
1111000110100101
Figure 25
A list of all input channels can be found in Table
1 - Input Channel List below.
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intimus®2051 Folder (2051.11.02.09.15.00)
Table 1 - Input Channel List
where “B” is the second row down on the
keypad, and “3” is the third column from the left.
ABCD 1234567
0100 0010000
A Feed Table Load Position Switch
B Paper Present In Feed Table Sensor
C Paper Being Fed Sensor
D Paper In ByPass Sensor
E Top Cover Switch
F Fold Table #1 Present Switch
G Home Sensor #1
H Quad Sensor #1, Channel A
J Quad Sensor #1, Channel B
K Fold Table #2 Present Switch
L Home Sensor #2
M Quad Sensor #2, Channel A
N Quad Sensor #2, Channel B
O Exit Conveyor Sensor
P RPM Sensor
Q Spare
8.4 Option 3 – Keypad Input Mode
This mode is for verifying the function of the
keypad. The display will look like the example
below in Figure 26. On the top line of the
display, the letters represent the “row” position
of the button, and the numbers represent the
“column” position. When one of the buttons on
the keypad is pressed, the corresponding “0”
below the row and column values will a change
to “1”.
ABCD 1234567
0000 0000000
Figure 26
For example, pressing button “5” will change
the display to the example shown in Figure 27,
Figure 27
Pressing the “Stop” button will briefly show
a “1” in row “D” column “7”, then you will exit
this diagnostics mode.
8.5 Option 4 – Feed Mode
This mode allows running of the folder, moving
of the fold tables and firing of the feed clutch.
While in the mode, the Multi-Sheet Bypass
sensor is disabled and the Feed Table Load
Position switch is disabled.
In this mode, all safety interlock
switches (fold table present switches and
top cover closed switch) are disabled. The
main motor can be run and the fold table
drives can be run. Do not place any loose
items such as hair or hanging jewelry into or
near the rubber rollers. Also keep hands
and fingers clear of the rollers at all times.
Entanglement and injury will occur.
The buttons listed below are enabled and
perform the following functions;
• Run – Toggles main motor on and off
• Speed – Allows changing of speed in
normal manner
• Stop – If the Main Motor is running, this
button will stop the Main Motor. If the Main
Motor is not running, pressing the “Stop”
button will exit this diagnostics mode.
• Test button – If Main Motor is not running,
the “Test” button toggles the Feed Clutch
solenoid on and off. If Main Motor is
running, the Feed Clutch fires in one-shot
manner, normal timing. Note: If Feed
Clutch solenoid is on, pressing the “Run”
button will turn off the Feed Clutch solenoid
prior to the Main Motor starting.
The display will show the following
information;
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intimus®2051 Folder (2051.11.02.09.15.00)
CLT=0 MOTOR=0 L=0
FT=0 PBF=0 RPM=0 X=0
Figure 28
• CLT – Shows output signal for the Feed
Clutch solenoid (1=on, 0=off)
• MOTOR – Shows the output signal for the
Main Motor (1=on, 0=off)
• L – (Length) This is not a calibrated paper
length measurement. This value shows
how many counts are seen on the RPM
sensor while the Paper Being Fed sensor is
covered. Resets to zero when the Main
Motor is on and the Clutch is fired. Counts
on the raising and falling edge of RPM
sensor signal.
• FT – State of Paper In Feed Table sensor
• PBF – State of Paper Being Fed sensor
• RPM – State of RPM sensor
• X – State of Exit Conveyor sensor
8.6 Option 5 – Output Mode
This mode allows the manual movement of both
fold tables and the stack wheels.
8.6.1 Fold Tables Drives
This mode is intended to manually move the
fold tables and operate the fold table drives.
To move one of the Fold Tables, press the
corresponding Fold Table button, then press
either the “+” or “-“ button. Running of the Fold
Table Drives can be done regardless if the fold
tables are installed or not. The display will
show the current encoder count and where it
assumes the fold table to be in either inches or
centimeters (depending on the current units
set).
Fold Table 1
XX.XX XX,XXX CNTS
Figure 29
Fold Table 2
XX.XX XX,XXX CNTS
Figure 30
Removal and reinstallation of the Fold Table
will NOT force the Fold Table to return to its
“home” position, which will cause the position
on the display to be different than the pointer on
the fold table.
8.6.2 Exercising the Drives
The Fold Table Drives can be “exercised”
automatically while in this mode. Exercising of
the drives consists of moving the Fold Table
between 13” and 3” inches repeatedly.
Exercising of the Fold Table Drives is used to
confirm the function and accuracy of the Fold
Table Drives and the position encoders in the
drives.
To exercise a specific Fold Table Drive, with the
Fold Table installed, press and release the
corresponding Fold Table button, and then
press the “Run” button. The Fold Table will
then go to Home. Once the Fold Table has
been “Homed”, the Fold Table will go to 13”,
stay in that position for a few seconds, then it
will move to 3”, stay there for a few second, and
then will move back to 13”.
Exercising of the Fold Table Drives will continue
until the “Stop” button is pressed.
8.6.3 Stack Wheels
To move the Stack Wheels, press the Stack
Wheel button, and then press either the “+” or “-
“ button. The display will show the analog
sensor reading (A/D) from the Stack Wheels,
and it will show the position of the Stack
Wheels in either inches or centimeters
(depending on the current units set).
8.7 Option 6 – Fold Counters
This mode will display an age reference of the
folder. There are 2 different values displayed in
this mode; Clutch Count and Age Count. These
counters provided a means of tracking the age
and the amount of use that the folder receives.
CLTCH CNT:
AGE COUNT:
Figure 31
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intimus®2051 Folder (2051.11.02.09.15.00)
In the event that a Tech Support call is
required to Martin Yale, the Clutch Count and
Age Count of the folder will be required.
8.7.1 CLTCH CNT (Clutch Count)
This value shows the number of times that the
clutch has fired since it has last been serviced.
In this case, “serviced” means either R&R or
maintenance performed in the field by a
qualified technician, such as a clutch
replacement, or a fold table drive replacement.
The Clutch Count is meant to be reset anytime
work is performed on the folder.
To reset the Clutch Counter, depress and
release the following buttons in sequence; “CE”,
“0”, “STORE”.
8.7.2 Age Count
This value shows the number of clutch firings
that have occurred since the machine has been
built and first shipped from the factory. This
value can not be reset in the field, and is not
meant to be reset.
8.8 Option 7 – Output Limits Mode
This mode is used to fine tune the folder and
teach the folder various required operating
parameters. There are 5 different parameters
that must be “taught” to the folder; Fold Table
#1 Home, Fold Table #2 Home, Paper Diverter
Engagement Distance, Stack Wheel Home, and
Fold Position Center.
To teach the folder where the home positions
are, you must have a sheet of paper folded with
the fold tables at their minimum position (home
position).
To fold a sheet of paper with the fold tables in
their respective home positions, first perform
the following steps;
1. Turn on the folder power and allow the
folder to home both fold tables normally. Do
not enter diagnostics and do not specify a
fold type!
2. With the Feed Table loaded with a few
sheets of paper, press the test button to fold
one sheet.
3. Re-enter diagnostics by pressing and
holding the “Stop” button for several
seconds.
4. Press button “7” to enter Offset Limits Mode
Figure 32
It is very important to make all Offset
measurements using either dial or digital
calipers. A line gage, pica stick, ruler, tape
measure, etc., is not accurate enough.
Typical Fold Table offset values are between
2.20 and 2.35 inches. If your measurement
is outside of this range, contact Martin Yale
Technical Support for assistance.
8.8.1 Fold Table #1 Home
To set the home offset position for Fold Table
#1, do the following;
1. Press the Fold Table #1 button. The display
will look like the example below (Figure 33).
Fold Tbl 1 Home Pos.
Len.=[X.XX]: . IN
Figure 33
2. Using a pair of digital calipers, measure the
distance from the leading edge of the paper
to the first crease (see Figure 32 – 1st
Fold), and using the keypad, enter this
distance into the folder, and press “Enter”
when done.
8.8.2 Fold Table #2 Home
To set the home offset position for Fold Table
#2, do the following;
1. Press the Fold Table #2 button. The display
will look like the example below (Figure 34).
Fold Tbl 2 Home Pos.
Len.=[X.XX]: . IN
Figure 34
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intimus®2051 Folder (2051.11.02.09.15.00)
2. Using a pair of digital calipers, measure the
distance between the first and second
creases (see Figure 32 – 2nd Fold), and
using the keypad, enter this distance into
the folder, and press “Enter” when done.
8.8.3 Diverter Offset
This is a continuation of Fold Table #2
Home. To change this value, you must follow
the direction starting at section 8.8.2 - Fold
Table #2 Home. The Diverter Offset value tells
the folder how far Fold Table #2 must move
inward to engage the Paper Diverter.
Diverter Offset
Len.=[.XX]: . IN
Figure 35
3. The folder will then ask/show the distance
that the fold table must be driven to engage
the paper diverter. The default value for this
setting is .37 inches. To change this value,
use the keypad to enter a new value and
press “Enter” to save.
The Diverter Offset value does not
normally need to be changed for any
reason, except when there are problems
performing a Half fold, or the fold table is
making a loud clicking noise when moving
into Half fold. Improperly setting this value
can cause damage to the fold table. This
value should ONLY be changed as a last
resort!
8.8.4 Stack Wheel Home
Press '-' A/D=XXX
Press Enter to Teach
Figure 36
To teach the home position for the Stack
Wheels,
1. Press the Stack Wheel button.
2. Press and hold the “-“ button until you hear
the Stack Wheel make a clicking noise.
This is the home position.
The A/D value should read greater than
zero.
3. Press the “enter” button.
4. The display will now ask for the maximum
travel distance. The default value is 10.5.
There should not be any reason to change
this value. Simply press “Enter” to accept
this value.
8.8.5 Fold Position Center
Fold Position Center.
Len.=[.XX]: . IN
Figure 37
This value is used to better balance fold table
positions. Slight folding errors occur depending
on how many layers of paper there are in the
fold table. This also occurs depending on the
weight of the paper being folded. The more
layers there are, the shorter the fold length.
Same goes for heavy paper, and conversely for
fewer sheets and lighter paper.
You first must have a single sheet of 11 X 17
paper Half folded by the folder to set the Fold
Position Center. To do this, perform the
following steps, otherwise skip to step 7;
1. Turn on the folder power and allow the
folder to home both fold tables normally. Do
not enter diagnostics.
2. Press the Fold Select button and specify
Half fold.
3. Press the Size Select button and specify 11
X 17.
4. With the Feed Table loaded with a few
sheets of 11 X 17 paper, press the test
button to fold two sheets.
5. Reenter diagnostics by pressing and
holding the “Stop” button for several
seconds.
6. Press button “7” to enter Offset Limits Mode
7. Press the “Paper Length” button. This will
display the current center position.
Using a pair of digital calipers, on the Half
folded paper, measure the distance that the 2
edges of paper overhang. Enter this value
using the keypad and press “Enter” to save.
It is very important to make this
measurement using either dial or digital
calipers. A line gage, pica stick, ruler, tape
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intimus®2051 Folder (2051.11.02.09.15.00)
measure, etc., is not accurate enough. If
your measurement is greater than .10
inches, contact Martin Yale Technical
Support for assistance.
Exit diagnostics and Half fold another sheet of
11 X 17 paper to confirm the setting.
The factory settings for all offsets can be
found on the underside of the Access Panel,
located under the 2nd Fold Table. A Phillips
screwdriver will be required to remove the
Access Panel.
8.9 Option 8 – LED Test
This option will cycle the LED in a Race Track
manner and will continue until the “Stop” button
is pressed.
9 Error Codes
9.1 Error 100 – Bypass Sensor Failure
1. This error can be caused if paper is
detected in the Multi-Sheet Bypass for
longer than the allotted time. For more
information regarding the use of the Multi-
Sheet Bypass, please see section 6 - Multi-
Sheet Bypass.
2. If no paper has been placed into the Multi-
Sheet Bypass, then the controller assumed
there was a sensor failure. Verify proper
function of sensor through diagnostics #2,
and see section 11 - Debugging.
9.2 Error 101 – Feed Error
Caused when the folder tries to feed a sheet of
paper from the Feed Table, but was unable to.
This is the most common error and is caused
by one of the following;
1. The Paper Guides are adjusted too tight
against the paper and are holding the paper
back from feeding.
2. Coated stocks are very heavy and if the
Feed Table is loaded to its maximum
capacity, it’s possible that the Feed Table is
not able to lift the full stack. Reduce the
number of sheets in the Feed Table.
3. Feeding of some coated stocks will cause a
build up of static in the last few sheets of
paper (less than 10) in the Feed Table,
causing the paper to stick to the Feed Table
and not feed. Use of Martin Yale Anti-Static
Spray on the Feed Table may remedy this
problem.
4. The Feed Wheel is dirty. Clean the Feed
Wheel with an approved Martin Yale brand
roller cleaner.
5. The Retarder is adjusted too tight, not
allowing the paper to pass under the Feed
Wheel. Using the supplied 9/64” Hex key,
adjust the Retarder down (clockwise = down
= loosen) 1/4 of a turn. Repeat if
necessary. With the Feed Table down (in
the load position), turn the Feed Wheel by
hand. There should be a small amount of
drag on the Feed Wheel caused by contact
with the Retarder. If not, raise the Retarder
(counter-clockwise).
Retarder adjustments can be made with the
folder running. In most cases, it is easier to
adjust the retarder with the folder running.
6. If there are only a few sheets of paper
remaining in the Feed Table (typically, less
than 20 sheets), the Paper Lift Spring may
not be applying enough force against the
Feed Wheel. Bending the Paper Lift Spring
up a small amount (less than 1/4 of an inch)
usually remedies this problem.
7. The Feed Table isn’t rising up as it should.
This can be caused by the Feed Table Lift
Spring being out of adjustment, a lack of
lubrication on the moving parts, or a
mechanical problem caused by shipping
damage. Field service is required.
8. The clutch didn’t fire like it should have.
Field service is required.
9. This error can also be caused by a Paper
Present sensor failure because the
controller still thinks there is paper in Feed
Table when none exists. Verify proper
function of sensor through diagnostics #2,
and see section 11 - Debugging.
9.3 Error 102 – Exit Sensor Failure (on)
This error occurs when the sensor is seeing
paper all of the time. There are two possible
causes for this error to occur;
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intimus®2051 Folder (2051.11.02.09.15.00)
1. Possible paper jam at exit conveyor and the
sensor is covered. Clear paper jam at Exit
Conveyor.
2. May be caused if the Exit Sensor has failed
and the sensor acts as if it’s always sensing
paper when none exists. Verify proper
function of the sensor through diagnostics
#2 and see section 11 - Debugging.
9.4 Error 103 – Exit Sensor Failure (off)
This error occurs when the sensor did not
detect paper in the exit conveyor when it should
have. There are two possible causes for this
error to occur;
1. A paper jam in either fold table can cause
this error. Clear the paper jam from the
Fold Table(s).
2. The sensor has failed and can not sense
paper in the Exit Conveyor. Verify proper
function of the sensor through diagnostics
#2 and see section 11 - Debugging.
9.5 Error 104 – Motor Controller Failure
Caused when power is turned on and the Main
Motor starts running when it should not. The
Main Motor drive circuitry has failed and the
Main Controller PCB requires replacement.
Service required.
9.6 Error 105 – Fold Table #1 Drive
Encoder Fault
The position encoder on the #1 drive is not
functioning correctly. Replacement of the drive
is required. Verify proper function of the sensor
through diagnostics #5.
9.7 Error 106 – Fold Table #1 Drive Wires
Reversed
The motor wires on the fold table #1 drive have
been reversed. In rare occasions, this error can
be caused by an encoder fault. Verify proper
function of the position encoder through
diagnostics #5.
9.8 Error 107 – Fold Table #2 Drive
Encoder Fault
The position encoder on the #2 drive is not
functioning correctly. Replacement of the drive
is required. Verify proper function of the
position encoder through diagnostics #5.
9.9 Error 108 – Fold Table #2 Drive Wires
Reversed
The motor wires on the fold table #2 drive have
been reversed. In rare occasions, this error can
be caused by an encoder fault. Verify proper
function of the position encoder through
diagnostics #5.
9.10 Error 109 – Clutch Error
This error occurs when the clutch is engaging
the Feed Wheel when it should not. In most
cases, an adjustment to the clutch will remedy
this problem. Service is required.
9.11 Error 110 – RPM Sensor Failure
1. Caused by a serious paper jam, where the
rollers can not rotate freely. Using the
Dejam Handle, insure that the Rollers are
free to rotate.
2. Can be caused by a serious failure of one or
more mechanical components. Using the
Dejam Handle, insure that the Rollers are
free to rotate.
3. Can be caused if the RPM Sensor has
failed. Verify proper function of the RPM
sensor through diagnostics #2 and see
section 11 - Debugging.
4. If the folder does not start running and the
rollers are free, the Main Motor drive
circuitry has failed and the Main Controller
PCB requires replacement.
5. If the Main Controller PCB has been
recently replaced, make sure the red 24 volt
jumper wire has been installed correctly on
the Main Controller PCB.
9.12 Error 111 – Feed Error
The Retarder is adjusted too loose, and is not
holding the lower sheets of the paper back.
Using the supplied 9/64” Hex key, adjust the
Retarder up (counter-clockwise = up = tighten)
1/4 of a turn. Repeat if necessary. With the
Feed Table down (in the load position), turn the
Feed Wheel by hand. There should be a small
amount of drag on the Feed Wheel caused by
contact with the Retarder.
You WILL experience this error while
feeding coated or glossy paper if the folder was
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