Nagel Foldnak 80 User manual

Foldnak 80/100
Trimmer 100
Operations manual/
Service instruction
ENGLISH

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 2
Foldnak 80/100
Trimmer 100

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 3
Content
Safety precautions ............................................................................................................................................. 5
Important! Please pay attention......................................................................................................................... 5
Intended Use ..................................................................................................................................................... 6
Foldnak 80/100 .............................................................................................................................................. 6
Trimmer 100................................................................................................................................................... 6
Description and technical details ....................................................................................................................... 6
Foldnak 80/100 .............................................................................................................................................. 6
Trimmer 100................................................................................................................................................... 6
Technical data Foldnak 80/100...................................................................................................................... 7
Technical data Trimmer 100 .......................................................................................................................... 8
Installation and operation of Foldnak 80/100 .................................................................................................... 9
Sequence of switching on .............................................................................................................................. 9
Settings of the function keys............................................................................................................................ 10
Maintenance and cleaning............................................................................................................................... 10
Menu table of Foldnak 80/100 ......................................................................................................................... 11
Submenu 1 ...................................................................................................................................................... 12
Paper format ................................................................................................................................................ 12
Adjust ........................................................................................................................................................... 12
Reset Counter .............................................................................................................................................. 12
Operation mode ........................................................................................................................................... 12
Delivery ........................................................................................................................................................ 12
Trimmer........................................................................................................................................................ 12
Offset (of cutting width) ............................................................................................................................ 12
Trimmer modes ........................................................................................................................................ 12
STOP-Pos. ............................................................................................................................................... 12
Settings Foldnak 80/100 .............................................................................................................................. 13
Customized Formats (C-Formats)............................................................................................................ 13
Language.................................................................................................................................................. 13
Dimensions............................................................................................................................................... 13
Service...................................................................................................................................................... 13
Speed ....................................................................................................................................................... 13
Clearing .................................................................................................................................................... 13
Additional mechanical corrections at the Foldnak ....................................................................................... 13
Different stapling heads ................................................................................................................................... 14
Hohner.......................................................................................................................................................... 14
ISP Stitching & Bindery Products................................................................................................................. 15
Rapid............................................................................................................................................................ 15
Nagel............................................................................................................................................................ 15
Adjusting the stapling head.......................................................................................................................... 15
Clincher exchange (except at Rapid-SH)..................................................................................................... 15
Selection of staples and driver blade............................................................................................................... 16
Change from flat to loop staples...................................................................................................................... 16
Block stapling................................................................................................................................................... 16
Error messages ............................................................................................................................................... 17
Functional Errors / SH Exchange .................................................................................................................... 18
The wire uncoils too fast .............................................................................................................................. 18
Paper jam at the Foldnak infeed .................................................................................................................. 18
Paper jam..................................................................................................................................................... 18
Reset the over current fuse / also Trimmer.................................................................................................. 18
Reset to factory settings............................................................................................................................... 18
Exchange Nagel-stapling head / remove jammed staples........................................................................... 18
Nagel stapling head functional test .............................................................................................................. 18
Booklet shears at the stitching ..................................................................................................................... 18
Layout of Foldnak 80/100 ................................................................................................................................ 19
Sequence description of the Foldnak 80/100 .................................................................................................. 20

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 4
Operation of Trimmer 100................................................................................................................................ 21
Adjustments of the Trimmer in the Foldnak menu....................................................................................... 21
Setting up the cutting width ...................................................................................................................... 21
Trimmer modes ........................................................................................................................................ 21
Stop-Pos................................................................................................................................................... 21
Trimmer errors ................................................................................................................................................. 22
Waste drawer full ......................................................................................................................................... 22
Poor cutting quality....................................................................................................................................... 22
Booklets are not cut through ........................................................................................................................ 22
Knife doesn’t reach the TDC........................................................................................................................ 22
Knife doesn’t stop at the TDC (runs continuously) ...................................................................................... 22
Main motor doesn’t run ................................................................................................................................ 22
Further possible mechanical adjustments at the Trimmer 100........................................................................ 22
Layout of Trimmer 100..................................................................................................................................... 23
Sequence of Trimmer 100 ............................................................................................................................... 24
Service............................................................................................................................................................. 25
Submenu Foldnak Actuators........................................................................................................................ 25
Submenu Foldnak Sensors.......................................................................................................................... 26
Submenu Trimmer Actuators ....................................................................................................................... 27
Submenu Trimmer Sensors ......................................................................................................................... 27
Accessories ..................................................................................................................................................... 28
Layout of connectors on PCB.......................................................................................................................... 29
Adjustment data............................................................................................................................................... 29
Circuit diagram................................................................................................................................................. 30
DECLARATION OF CONFORMITY................................................................................................................ 34
Glossary/ abbreviations ................................................................................................................................... 35
History.............................................................................................................................................................. 35

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 5
Safety precautions
1. Please read this instruction carefully and completely before operating the machine.
2. Please make sure the mains voltage is suitable and the outlet has a proper earth connection.
3. Repairs have to be carried out by trained Nagel technicians only.
4. Disconnect the machine from the mains while servicing it.
5. Attention! The Trimmer comprises a razor sharp knife which could cause severe injury. When
removing a paper jam act with caution.
6. Use original Nagel consumables and spare parts only.
7. Lay the cables in a way that no dangers arise.
8. Install the machine in a dry room on leveled and solid ground. And within easy reach.
9. Block the breaks after putting the machines in place.
10. Safety precautions must not be removed or bypassed.
11. Replace fuses with the same type and rating.
12. Users with long hair need to keep safe distance to turning parts.
13. Close lids that they don’t fall.
14. Don’t open lid during operation this could cause paper jams.
15. Connect the machines with the provided screws. It is not allowed that they can be disconnected w/o
tools.
16. Allow at least 20 seconds to pass between attempts to switch on the unit, otherwise the software may be
damaged.
17. When changing plug connections, always switch off the machines!
18. Work careful at the leaf springs. They consist of thin sheet metal and could cause injury through
incautious contact.
Important! Please pay attention
- change of paper format: see „paper format“, page 12.
- small formats: see „paper format“, page 12.
- clincher exchange: page 15.

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 6
Intended Use
Foldnak 80/100
Intended use is the stapling and folding of booklets within the in “Technical data” documented limits.
Trimmer 100
Intended use is the inline face trimming of booklets within the in “Technical details” documented limits.
Description and technical details
Foldnak 80/100
The Foldnak 80/100 is designed to make booklets.
The sheets to be used for it can be supplied as a collated set by hand or through a collator. Another option is
to feed the Foldnak with single sheets through a RoboFeeder.
If you use thicker paper please keep in mind the physical limits. You might have to reduce the size of the
stack. 2.5 mm equals 25 sheets of 80 gsm paper.
The Foldnak has four different processing methods:
- saddle stitching and fold
- block stitching
- block stitching and fold
- fold only, also asymmetric
Trimmer 100
The Trimmer can trim the inline face of booklets.

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 7
Technical data Foldnak 80/100
Foldnak 100
Hohner
Foldnak 100 ISP Foldnak 100 M2 Foldnak 80 Rapid
Max. output (cuts) per
hour (depends on
format)
3,000 3,000 3,000 2,500
Paper format max. 364 x 521 mm
14.33 x 20.50 inch
364 x 521 mm
14.33 x20.50 inch
364 x 521 mm
14.33 x20.50 inch
364 x 461 mm
14.33 x 18.15 inch
Paper format min.
with 2 stapling heads
105 x 140 mm
4.14 x 5.5 inch
105 x 140 mm
4.14 x 5.5 inch
150 x 140 mm
5.90 x 5.5 inch
140 x 210 mm
5,5 x 8.27 inch
Max. height of stack
(booklet)
2,5 mm/ 0.10 inch 2,5 mm/ 0.10 inch 2,5 mm/ 0.10 inch 2,5 mm/ 0.10 inch
Max height of stack
(corner stitching)
3,0 mm/ 0.12 inch 3,0 mm/ 0.12 inch 3,0 mm/ 0.12 inch 3,0 mm/ 0.12 inch
Clincher yes yes yes yes
Possible stapling
head (=SH)
positions
any with 4 SH 88.5-
63-88.5 ; or with
2 SH 124 [mm]
any any
Number of SH,
standard (max.)
2 (4) 2 (4) 2 (4) 2 (4)
Staple types wire wire 26/6, 26/8 S,
loop staple 26/6
cartridge
Loop staples yes (optional) no yes no
Capacity of staples app. 65,000 app. 65,000 210 5,000
Delivery yes yes yes yes
Corner-/ block
stitching
yes yes yes yes
Infeed belts yes yes yes yes
Collator online yes yes yes yes
Integrated
accumulating station
yes yes yes yes
LCD Display yes yes yes yes
Trimmer online yes yes yes yes
Automatic jogger yes yes yes yes
Counter yes yes yes yes
Automatic triggering yes yes yes yes
Monitoring stock of
staples
yes yes yes yes
Power supply 230 V 50 Hz
0.8 kW
or 115 V 60 Hz 0.8
kW
230 V 50 Hz
0.8 kW
or 115 V 60 Hz
0.8 kW
230 V 50 Hz
0.8 kW
or 115 V 60 Hz
0.8 kW
230 V 50 Hz
0.8 kW
or 115 V 60 Hz
0.8 kW
Sound power level < 75 dB(A) ± 5%
with Trimmer
< 75 dB(A) ± 5%
with Trimmer
< 75 dB(A) ± 5%
with Trimmer
< 75 dB(A) ± 5%
with Trimmer
Operating conditions 10 to 35 degree
Celsius
35 to 85 % RH,
non condensing
10 to 35 degree
Celsius
35 to 85 % RH,
non condensing
10 to 35 degree
Celsius
35 to 85 % RH,
non condensing
10 to 35 degree
Celsius
35 to 85 % RH,
non condensing
HxWxD (cm) not
packed
without/with
delivery
115x72x118/186
without /with
delivery
115x72x118/186
without /with
delivery
115x72x118/186
without /with
delivery
115x72x118/186
Weight (kg) 230 not packed
260 packed
230 not packed
260 packed
230 not packed
260 packed
205 not packed
235 packed

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 8
Technical data Trimmer 100
Max. output (cuts) per hour: 3000/h
Max. booklet length, folded: 260.5 mm
Min. booklet length, folded: 74 mm
Max. cutting width (standard): 320 mm
Max. cutting width (longer knife): 364 mm
Max. height of stack: 60 sheets with 80 gsm
Max. trim margin: 15 mm
Adjustment of paper format: fully automatic
Delivery: yes
Waste monitoring: yes
Power supply: 115 Volt 60 Hz 650 Watt, or 230 Volt 50 Hz 650 Watt
Sound power level: < 75 dB(A) ± 5% with Foldnak
Operating conditions: 10 to 35 degree Celsius, 35 to 85 % RH, non condensing
HxWxD not packed (cm): 106 x 72 x 51/112 without/with delivery
Weight not packed: 160 kg
Weight packed: 180 kg

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 9
Main menu
0
Paper format
Paper format
0e
A3 420.0x297.0
Welcome !!!
FK xxx TR yyy
Installation and operation of Foldnak 80/100
Preparation of the stapling heads: to avoid uncoiling or tangling up of the wire during transport, the wire was
pinched off. That means only few stitches can be made until the wire is threaded again.
Both Foldnak and Trimmer have an additional mains switch close to the power inlet. If the machine is not in
use for a longer period of time, please switch it off with this switch.
Shortly after switching the Foldnak on the display shows the loaded S/W version:
xxx shows the Foldnak and yyy the Trimmer software version. This might be a
helpful piece of information for your service technician.
After power up the display shows in the upper line the operation mode, the finishing mode and the counter.
The lower line shows the name and the size of the selected format in inch or cm, e.g. A3 and 420.0 x 297.0.
Power switch Status
LED
Display Back
key
Control
keys
up/down
Enter
key
Function keys
F1, F2, F3
The Foldnak 80/100 and a possibly connected Trimmer are controlled via the four control keys and the three
function keys.
Please hit the enter key to go into the main menu. Scroll up and down with the
two direction keys. The upper line shows the higher menu level permanently.
The line underneath changes its contents and displays the submenus with
every hit of a direction key. If you have reached the desired submenu, please
hit the enter key again to select it. It is then displayed in the upper line.
The chapter “Menu table of Foldnak 80/100“ includes the complete structure, to make orientation within the
menu easier. With the back key you can arrive at a higher level. This equals one column to the left in the
menu table.
To ease repeated adjustments the Foldnak memorizes the last path in the menu. That means you can reach
the same submenu through repeated pressing of the enter key.
Terminating plug
Depending on the configuration, that means which machines are assembled, the fitting terminating plug must
be plugged in into the last element. For Foldnak and Trimmer plug with parts no. 2710198, for SP+ 2958571.
S8
Attention! S8 needs Software-Version 2.23 or higher to run at the Foldnak!
Sequence of switching on
First switch on the SP+ (if existing). Wait until the LED becomes green. Then the Trimmer can be switched
on, then the Foldnak. For the RoboFeeder it is unimportant when it is powered up.
Man. Saddle 0000
A3 420.0x297.0
F1 F2 F3

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 10
Settings of the function keys
The default settings of the function keys F1, F2, F3 are as follows:
F1 = Staple position
F2 = Fold position
F3 = Language
Each function key can be overwritten with a new function out of the menu table. In order to do this, go to the
desired submenu and hold the function key which is supposed to be overwritten for more than 3 seconds.
The LCD displays “function key stored”.
There is an option to replace the function key labels with customized ones. It should be done by trained
personnel.
Maintenance and cleaning
If the clinchers or stapling heads (=SH) are polluted visibly, they need to be cleaned. At least:
at every wire roller change the clinchers and SH are to be cleaned, see SH-manual.
When changing the wire roller all further jobs required by the maker need to be carried out, like greasing and
cleaning.
Remove regularly staple and paper remnants. They can cause troubles.

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 11
Menu table of Foldnak 80/100
0 1 2 3 4
Main Menu Paper Format ?
(e.g. after a change from inch
to cm) metric/inch:
CD | CD
A5 | Statement (5.5x8.5 in)
A4 | Executive (7.25x10.5 in)
A3 | Letter (8.5x11 in)
A3+ | Legal (8.5x14 in)
SRA3 | Tabloid (11x17 in)
C1-mm | C1-inch
… (C2 to C4)
C5-mm | C5-inch
Adjust Width +/-0.0 *
Length +/-0.0 *
Staple +/-0.0 *
Fold +/-0.0 *
Reset Counter Sure?
Mode S8
RoboFeeder
Manual-Start
Saddle
Block
Block+Fold
Fold only
Staple test
Delivery Delay +/-00
Trimmer Offset 00
Not connected
Bypass Mode
Trim Mode
SP+ in-line
Paper Stop 00
Settings C-Formats
(=Customized Formats)
C1-mm to C5-mm Length 000.0 *
Width 000.0 *
C1-inch to C5-inch
Length 00.00 **
Width 00.00 **
Language English
German
French
Spanish
Dutch
Italian
Dimension metric
inch
Service 0000 Paper stop offset T-Finger +/-0.0 *
Side guide +/-0.0 *
Staple Stop +/-0.0 *
Fold Stop +/-0.0 *
Staple Pos. +/-0.0 *
Fold Pos. +/-0.0 *
Total counter 0000000000
Staple head Wire
Staples
Rapid
Actuators FA1 to FA30
Sensors FS1 to FS41
Actuat. Trimmer TA1 to TA11
Sensors Trimmer TS1 to TS7
Speed Set: 0000
Clearing booklet
open side guides
drop out
* display in mm: 0.1 = 1/10 mm
display in inch: 01 = 1/256 inch ** 1.50 = 1 1/2 inch
display in inch:
see table below

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 12
Adjust
1a
Width
+/
-
0.0
-
+
-
+
Adjustment of fold position
Adjustment of staple position
Submenu 1
Paper format
Attention! Before every change of format check stapling head position. Danger of collision!
Small format: remove leaf springs from the side guides! Below a width of 152mm with a stapling head
distance of 75mm. After operating in small format reattach the leaf springs tight and parallel to the
side guides.
Smallest format (A6): install the kit for the smallest format (A6), see the manual enclosed the kit.
Remove support plate of S 8, mount attachment infeed funnel and infeed funnel left and right.
Use the special paper downholders.
Predefined formats like A5, A4, A3 or customized C-formats are selectable. Inch formats like Statement,
Executive, Letter, Legal and Tabloid are selectable after the dimensions have been changed from metric to
inch.
Adjust
If you notice during the jogging procedure that the paper seems to bee too
large or too small it is possible to adjust width and length of the format
setting.
Staple and fold position are also adjustable.
You have to enter the deviation from the basic setting.
Adjust the +/- first by using the up/down keys and confirm it with
the enter key. Search by using the up/down keys the correct value
(for each digit) and confirm it with the enter key. The enter key
moves the cursor one position to the right.
It is recommended first to adjust the position of the fold and then to
adjust the position of the staples.
Reset Counter
After having confirmed the question “sure?” you can reset the batch counter.
Operation mode
Here you can set if the paper is coming from a S8, a RoboFeeder or is fed manually. Also the finishing mode
of a booklet or a block is set in this submenu.
Delivery
In order to improve the booklet stream on the delivery the delay time of the delivery belts is adjustable.
The adjustment of the delivery in the menu is only possible, if the delivery is directly connected with the
Foldnak. At the Trimmer it is adjustable with the potentiometer, at the SP+ it is not adjustable.
Trimmer
Offset (of cutting width)
Offset defines the width of the waste.
Trimmer modes
You can set a tick mark to tell the Foldnak that a Trimmer is connected. You can tell the machine the same
way what is supposed to be done with the booklet. Not trimmed in the bypass mode or trimmed.
STOP-Pos.
The delay of the belts can be adjusted. This can be necessary if a booklet jumps back from the trim stop.

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 13
Settings Foldnak 80/100
Attention! Adjusting the Foldnak-parameter during operation may cause disruptions!
Customized Formats (C-Formats)
Definition of customized formats. Minimal: 105 x 140/ 4.14 x 5.50, Maximal: 364 x 521/ 14.33 x 20.50 resp.
461/ 18.15 [mm/inch]. Choose a C-Format and press enter twice. Search by using the up/down keys the
correct value (for each digit) and confirm it with the enter key. If the length is choosen, it jumps to the menu
item width. Finish it with the back key. To select a customized format it needs to be choosen in the paper
format menu. See paragraph “paper format”. Check stapling head position!
Language
The selection of different languages is possible.
Dimensions
Here you can change from metric to imperial dimensions. The display will show a question mark after a
change. It means you need to choose a paper format. There is a differentiation between fine and rough
adjustment. In the menutable it is marked with one * and two ** asterics. In the fine adjustment means
0.1 = 1/256 inch, rough adjustment means 01 = 1 inch. See little table below the menu table.
Service
This part is password protected and meant for the use of service technicians only. Attempting to perform
repair and replacement procedures w/o proper training may cause machine damage or operator injury.
Speed
The speed of the Foldnak can be set for S8-operation (sets per hour):
S8: continuous
with SP+: 1,000 compulsory (will be improved)
slow: 500-1,100 / 1,000 range / recommended initial value
medium: 1,200-1,800 / 1,600 range / recommended initial value
fast: 1,900-3,000 / 2,300 range FK100 / recommended initial value
2,000-2,500 / 2,300 range FK80/ recommended initial value
It is recommended to start e.g. in the medium speed with the initial value of 1,600 and than to increase it.
Speed of the Foldnak, RF-operation (sheets/hour):
slow and medium: up to 6,000
fast: above 6,000
The maximum of the FK depends on paper type and format and amout of pages of the booklets.
Clearing
There are three choices: a) booklet, that means stitch and fold, b) open the side guide and c) eject, that
means only folding.
If an error occurs, the Foldnak jumps automatically to this menu item.
Additional mechanical corrections at the Foldnak
The clearance between the fold rollers can be adjusted w/o tools. The
knurled screw needs to be loosened, see arrow in the picture. For
sensitive paper rather set a wider clearance, that means to turn the
screw in the direction of the infeed. It is important to set the lever on
both sides similar.
The pressure of the fold rollers can be reduced for sensitive paper. And
it can be set subtler by using a weaker spring. The pressure must not be
increased, because a thicker booklet may not pass the fold rollers.

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 14
Different stapling heads
The stapling heads (except ISP) can be put in in any position. But they can cause problems in the area of the
folding knife finger. That is in the range between 94 to 110 mm and 244 to 260 mm.
Please read the manufacturers handbook carefully. You get hints on feeding the stitch wire into the head,
preventive maintenance and repair. In the case of a malfunction, please call your Nagel dealer.
For small formats: remove leaf springs! Below a width of 152 mm with a stapling head distance of 75 mm.
Hohner
Please use wire #25, order no. 6170110. Stapling head: order no. 2660223.
The clinchers (lower arrow) can be adjusted with the alignment tool (upper arrow) to the stapling heads. For
this purpose turn the leaf spring sideways (left photo), take out the former and insert the alignment tool. Now
you can move the clincher sideways, until the marking in the middle aligns with the nose.
The stapling head can be aligned through lowering. The machine must be switched off. Disconnect
manually the stapling head clutch. For this purpose open the little lid and push at the place which is marked
with arrow 1 in the picture below. Put an Allen key 4 mm as shown with arrow 2 into the motor shaft and turn
the hexagon socket screw clockwise (arrow 3). After the adjustment turn it further until the stapling head
clutch opens again. The stapling heads are now at the top dead center.
2
3
1

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 15
ISP Stitching & Bindery Products
The stapling heads have fixed positions. The clincher can be easily
aligned to the stapling head by lowering them, see Hohner stapling
heads.
Please use wire #25, order no. 6170110.
Stapling head: order no. 2660225.
Rapid
For adjusting the distance unscrew the 4 hexagon socket screws
with SW 3 and move the stapling head to the required position.
Loosen the knurled screw of the clincher and align the clincher.
Please use only Nagel cartridges with the order no 2660800.
Stapling head: order no. 2660801.
Nagel
Alignment of the clinchers as described above with lowered
stapling heads.
For simple and precise adjustment of the 80 mm distance between
2 Nagel-SH’s it is recommended to use the alignment tool Nagel
SH. Also it can be used for aligning clincher to stapling head, for all
distances.
Alignment tool Nagel SH: 2660199.
Please use original Nagel staples with the order numbers:
26/6: 627 2060
26/8S: 627 2081
Ri 26/6: 627 4062
Stapling head (complete): order no. 2660100,
assembly stapling head without adapter FK 100: 2660106.
Adjusting the stapling head
For the adjustment of the SH also the wire rollers must be aligned with the stapling heads. It
can be enough to turn the wire guides.
Clincher exchange (except at Rapid-SH)
See SH-manual. Draw out the clincher pusher (4) downward, turn clincher (1) in clincher box
(3) up and draw out of the holding pin (2). Push new clincher in the holding pin and turn it to
the clincher box center. Reinsert clincher pusher.
Attention! When inserting the clincher pusher it must go into the slot of the clincher. If the
clincher pusher remains under the clincher it destroys the clincher during operation.

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 16
Selection of staples and driver blade
For very hard sheets or thick paper blocks (above 15 sheets 80 gsm) it is recommended to use 26/8S
staples and the flat driver blade.
Change from flat to loop staples
To change from flat staples to loop staples the driver needs to be exchanged, if the flat driver blade is
installed. See SH-change (Hohner: page 14, Nagel: page 18).
For a change from loop staples to flat staples the driver doesn’t need to be exchanged, unless very hard
sheets or thick paper blocks are processed (above 15 sheets 80 gsm).
Block stapling
The paper block is jogged against the staple stop when block stapling. That means the unstapled side of the
block is the leading edge. Please consider this orientation, when loading the collator.
A sheet metal ramp which guides the block into the transport belt after the fold rollers needs to be installed.
The side guides are opened automatically in order to allow the block to be deflected into the transport belt.
To insert the ramp remove the upper belt (fig. 2 and 3), then insert the ramp with both narrow guide fingers in
the table. Push the ends down (fig.4). After finishing, put the belt back in its place.
1
2
3
4

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 17
Error messages
In case of an error you have four options, described in the menu item ”clearing” in the chapter “Settings”
(p.13). Each error message has to be confirmed by pressing the Backspace key.
DOOR OPEN
Close the door.
CHECK --- >
See feeder e.g. S8 or RoboFeeder.
ERROR home position
Check if paper remainder is in the machine. Remove it. Check slotted optical sensor home position of
stitching and fold stops FS27 and FS8. Check if spindles of staple stop and fold stop run smoothly.
Check encoder FS32, FS33 and slotted optical sensor of the side guide.
ERROR pos. T.-Finger (=position transport finger)
Check Encoder FS30 and FS31 and slotted optical sensor FS25.
COLLISION S.H. change papersize! (collision stapling head - change paper format)
Decrease stapling head distance.
ERROR pos. staple stop
Check FS27, check if spindle runs smoothly.
ERROR pos. fold stop
Check FS28, check if spindle runs smoothly.
ERROR ref. T.-Finger (reference transport finger)
Check FS25, encoder FS30 and FS31. Check if delivery belt runs smoothly.
ERROR ref. side guide
Check FS26, encoder FS32 and FS33. Check if side guides run smoothly.
ERROR ref. staple stop
Check FS27. Check if spindle runs smoothly.
ERROR ref. fold stop
Check FS28. Check if spindle runs smoothly.
PAPER JAM infeed
Check speed of belt of S8 and RoboFeeder. The desired value amounts 60m/min.
Check the slotted optical sensor FS1.
PAPER JAM not at foldstop
The sheets didn’t leave sensor FS4. Check T-Finger.
ERROR Trimmer/ SP+
Paper jam at the Trimmer, or waste drawer is full.
STAPLES empty !!!
Refill it.
TRIMMER not connected!
Check connection.
ERROR folding
Sheets didn’t leave sensor FS4. Check clutch FA4.
ERROR feed slower!
Reduce the speed of S8/ RoboFeeder. Maybe in the Trimmer menu “SP+ in line” is choosen wrongly.
Paper too long for Block-mode
Not possible with this size.

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 18
Functional Errors / SH Exchange
The wire uncoils too fast
Tighten the spring with the adjusting ring (fig.1).
Paper jam at the Foldnak infeed
Possible reasons: The speed of the belt of the RF/S8 is too fast. The
desired value of the belt amounts 60 m/min.
The alignment of the machines is too inexact.
The lateral format rods in the RF/S8 are too wide open.
Paper jam
Attention! Don’t move the side guides by hand, they can be damaged.
In case of paper jam always empty via the menu (clearing).
Reset the over current fuse / also Trimmer
After a jam or a power outage it could be that the starting torque of the
main motor is insufficient to start against a closed wrap spring clutch. The
stapling heads and folding knife (Trimmer: knife bar) are not in their home
position.
The over current fuse could will interrupt the power in order to protect the
stalled motor.
First return the stapling heads and knife to their home positions (page 14,
fig. 2 & 3), use the provided long Allen key. Open the main cover. Then
reset the fuse (fig.2, arrow) through pushing it.
Reset to factory settings
Hold function key #3 for more than 3 seconds upon power up of the
machine. The memory of the Foldnak will be over written with the factory
settings.
Attention! You will lose your customized formats and settings. You have
to select language and type of stapling head again. Default language =
English. Default stapling head = Nagel.
Exchange Nagel-stapling head / remove jammed staples
Switch the machine off. Remove all staples. Disconnect the SH clutch
manually (page 14, fig.1). Put the long Allen key through the opening in the
front casing into the motor shaft (page 14, fig.2 & 3). Turn it clockwise until
the SH bar is approx. in the middle. Unfasten the SH from the back with
the long Allen key (fig.3). Remove jammed staples (fig.4).
Mounting of Stapling head (SH)
Attach the driver in the right direction: the number must be visible.
Assemble the SH from the back. Turn the SH bar to the top with the long
Allen key. Insert staples. Accomplish the stapling head functional test.
Nagel stapling head functional test
Push the spring of the SH down. Each time a staple must fall out.
Booklet shears at the stitching
If very thick booklets with glossy cover sheets shear at the staples, you can turn
the 2 knurled screws (a) anti-clockwise to reduce the pressure. If it doesn’t help
the 2 knurled screws (b) can be turned clockwise to lift the infeed belt.
The 2 knurled screws of each pair should be turned approximately the same.
2
1
2
4
3
a
b

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 19
Layout of Foldnak 80/100
Side view
Top view
FA23
FA24
FA25, FA26
FS26
FS28
FA4
FS4
FS27
FA1
FA2
FA
3
FA27
FA28
FS32, FS33
FS30
FS31
FS25
FA29
FA30
FS1

© Ernst Nagel GmbH 9965043 Operations manual Foldnak 80-100 Trimmer 100.doc Rev.1.3 23.10.2006 20
Sequence description of the Foldnak 80/100
After power up, the Foldnak references its stops and guides. Staple stop, fold stop and side guides are
moved to their outermost position until they reach the slotted optical sensors. The stepper motors are
reversed until the desired format is reached. The accurate position is controlled by encoders.
The main motor will be started via the solid state relays FA2 after the Foldnak has received a start signal.
The infeed rollers, fold rollers are turning. At the same time the solenoid of the staple stop is activated. The
stop is in its upper position.
As soon as the infeed sensor FS1 detects the trailing edge of an incoming stack of paper, the transport
finger is started. This will drive the stack against the staple stop. The exact position of the finger is controlled
by encoder FS32/33. Depending on the selected speed the set is jogged once or several times through
opening and closing of side guides and T-Finger. During folding the side guides are moving to the set width
of the format. The stapling stroke is triggered by wrap spring clutch FA3. The side guides are opened.
The staple stop is deactivated. The transport finger transports the stack from the stapling to the fold position.
The accuracy is controlled by encoder FS32/3. The side guides are closed. Wrap spring clutch FA4 triggers
a fold stroke, after the slotted optical sensor FS4 has detected that the fold position is reached.
To the RoboFeeder operation
In the accumulation mode the transport finger is in front of the stack and drives the sheets against the back
stop. After the last sheet has been accumulated the direction of the finger is reversed and the stack moved
towards the staple stop.