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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