Rhin-O-Tuff HD7700 User manual

Instruction Book
for APES System

The APES System is an attachment for the HD7700, HD7000 or HD6500 punches. This manual
discusses all of the necessary steps to transform the punch into an utomatic aper jecting and
tacking punch machine. The paper specifications for punching, ejecting, and stacking are
between 14” x 14” (maximum) down to 8-1/2” x 5-1/2” A5 (minimum). It will also punch mixed
stock including tabs and acetate cover material.
APE
S
APES System Operators Training Manual
Please see the HD7700, HD7000 or HD6500 Manual for die setup and machine use.

APES System Contents
Reception Assembly (1)
Ejector Assembly (1)
Paper Reception Guide (1)
Tall Paper Deflector (1)
Tall Paper Deflector w/ Paper Stop (1)
Shipping Kit (1)
Instruction Book (1)
HD7000/HD6500/HD7650 Adaptor Kit (1)
a) Adaptor Bar (1)
b) Bolt 8-32 x 3/4 (2)
c) Hex Wrench 9/64 (1)
Serial Number:______________ Inspected by:______
APES System Shipping Kit Contents
Power Cord (1)
Mate Blocks (2)
Reception Paper Guide Stop w/ Knob (1)
Palm Switch Mount (1)
Knob Kit (1)
a)Three arm 1/4-20 Knob (4)
b) Quick Release Pin (2)
c) 1/4-20 Socket Head Bolt (4)
d) Star Wrench T-30 (1)
e) Hex Wrench 3/16 (1)

Table of Contents
Topic: Page Number:
Important safety notice! 4
Placing the APES System in the proper location. 6
Preparing your HD7000 or HD6500 for the APES System. 7
Mounting the APES System to a punch. 8
Preparing your HD7700 for the APES System. 10
Mounting the APES System to a HD7700 punch. 12
Mounting continued for all setups. 13
Plugging in the APES System for the first time. 15
Operating the APES System.
1. Control Center and Power Overview. 16
2. Reception Setup. 17
3. Accessing the Die with an HD7000. 17
4. Ejector Setup 6” and larger paper. 18
5. Ejector Setup 5-1/2” and smaller paper. 20
6. Ready to Operate. 21
Setup and Use of the AccuSet Index Paper Guide. 22
Troubleshooting Guide. 23
Electrical Diagram for APES System 115VAC 24
Electrical Diagram for APES System 230VAC 25
NOTICE: This manual covers both the APES System for the HD7000 and HD6500 Punches and also the
APES System for the HD7700 Punch. The following symbols will head sections related to those machines.
You may skip ahead to the next section if your machine is not designated within the
heading of the section. In most cases both designators will appear.
= APES System and the HD7700 Punch.
= APES System and the HD7000 or HD6500 Punch.
6500/7000
7700
3

Safety Alert Symbols
uAPES SystemThe needs to be plugged into a wall outlet that provides
a 15-amp, 120 volt service (16-amp, 220 volt for European
installations) and is protected by a fuse or circuit breaker at the main
electrical panel.
uIf machine cycles on its own, turn off power switch, unplug machine
from the wall outlet and call your dealer immediately for service.
uMake sure you read this section very carefully! Learn to recognize
these The APES System has been designed
to provide a high level of protection to an operator. Follow the
guidelines below while installing, operating and maintaining your
machine.
Safety Alert Symbols.
!DANGER
!WARNING
Safe Operating Guidelines
!CAUTION CAUTION: Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury. It may also be used without the safety alert symbol as
an alternative to "Notice".
WARNING: Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
DANGER: Indicates a hazardous situation which, if not avoided, will result in
death or serious injury. This signal word is to be limited to the most extreme
situations.
Trip Hazard
Two Person Lift
Electric Shock
Crushing Hazard
uAlways replace any fuse with the same type and
amperage as indicated on the machine.
Hazardous voltage
inside.
Disconnect power
before servicing.
!WARNING
uAlways keep this instruction manual with the machine for reference to
safe operating guidelines and correct operation of the machine.
Cutting Hazard
Hint or Suggestion
4

Placing your machine in the proper location:
uBefore lifting machine, turn power off and remove
the power cord from the wall outlet. The machine
is very heavy! Never attempt to lift the machine
by yourself. Two people will be needed to lift the
machine.
uPlace the machine on a hard level surface, place the foot pedal on the
floor in front of the machine. Ensure the placement of machine allows
for ergonomic work flow (separate locations for un-punched books and
a punched books).
Lifting Hazard
Single person
lift could result
in injury.
Two person lift required.
!CAUTION
uTurn power switch off before maintaining
machine or changing die assembly.
!WARNING
Crush hazard.
Keep hands away
from moving parts.
Lockout and disconnect
power before servicing.
uUse of appropriate hand protection should be
utilized to avoid injury from handling of materials.
!CAUTION
Cutting Hazard
Injury to fingers
and hands.
Use hand protection
uFollow all recommended workplace procedures for repetitive activities.
5

Providing power to the machine:
uPower cord shall be certified for the country
where the machine will be installed. Plug
one end of the power cord into the power cord
receptacle on the back of the machine. The
other end goes into the wall outlet.
!DANGER
Hazardous voltage.
Use only approved
power cord
assemblies.
Locate a clear work area 48” wide X 30” deep with a duplex outlet within
5 feet that provides a 15-amp service (16-amp European). The work area
must be a solid and firm cabinet or a heavy duty table with a flat level
surface.
Locate your punch on the right side of a 48” wide work area with the chip
tray near the front edge of the work area.
Never attempt to move the HD punch with one person!
Always move your HD punch with two people, one on each side.
Placing the APES System in the proper location:
6500/7000 7700
6

Preparing your HD-7000 or HD-6500 for the APES System:
Unplug HD-7000 or HD-6500 from outlet! Hazardous voltage inside! Crush hazard! Keep
hands away from moving parts!
Unplug foot pedal and store (The APES System has a foot pedal attached). See Figure B.
Using a Philips screwdriver rotate counter clockwise. See Figure A. Only ¼ turn
is needed. Newer ONYX punches have two hex screws that need to be removed, one is located
in the same location as the safety screw shown in Figure A, the other is located on the left side of
the top cover.
the Safety Screw
Raise the lid on your HD punch and remove the Paper Stop Assembly by first, removing the
nylock nut (use 7/16” wrench, not included) and then the paper stop nut located under the cover.
The paper stop and knob can now be removed from the front of the cover. See Figure B.
Re-assemble the Paper Stop into one piece and Store.
Close the lid and REPLACE the SAFETY SCREW to its locked position.
Your APES System came with two required Interface Blocks (Figure C page 8) that are 9” long by
¾” square, and four ¼-20 X 1-1/4” socket head cap screws and an allen wrench and torx wrench.
On each side of the punch, locate the two top most allen screws (or torx screws) and remove
(use the short side of the wrench for leverage) by turning counter clockwise.
6500/7000
7
Figure A
Figure B

Orient the Interface Block with the (as shown in figure C) toward the
and the round hole toward the rear of machine. Make sure the in the
blocks face outward. (See counter bore example in Figure D)
oval hole forward front of
the punch
.
counter bores
Attach the rear Allen screws first; use the provided longer screws to attach the block securely
and repeat for the other side of machine.
Mounting the APES System to a punch.
Check your HD-7000 or HD-6500 for front cover warping. Warping must be corrected before
proceeding. See FiguresE&F.
If your machine has any warping, open the machine top cover as described earlier Take a pair of
pliers and gently bend down the warped areas back flush to the machine front. Replace the cover
and safety screw.
.
6500/7000
8
Figure D
Figure F
Figure E
Figure C

Attention users mounting the APES System to a HD7000,
HD6500, HD7650, HD7100
Please locate the adaptor packaged with the APES System and install the adaptor as
shown in the diagrams below.
9

Place the APES System Ejector Base Plate Assembly on top of the punch. Avoid colliding the
APES System and the Assembly with the punch while setting it
down. Keep control cable clear. See Figure G.
Front Paper Guides Drive Motor
Adjust the APES System Ejector Base Plate Assembly back against the front of the punch and
install and tighten the two 3-winged provided. See Figure G.mounting knobs
Preparing your HD7700 for the APES System:
Unplug HD7700 from outlet! DO NOT OPEN COVER!! Hazardous voltage inside! Crush
hazard! Keep hands away from moving parts!
Unplug foot pedal and store (the APES System has a foot pedal attached). See Figure H. If the
palm switch is being used; unplug palm switch and remove palm switch from machine.
See Figure H Remove Knob (1) by rotating counter-clockwise; remove Paper Pointer Guide (2).
Store these Items, they will not be needed while the APES System is installed.
7700
10
Figure G

Your APES System came with two required Interface Blocks (Figure I page 9) that are 9” long by
¾” Square, and four ¼-20 X 1-1/4” socket head cap screws, and an allen wrench.
On each side of the punch locate the top most and two forward most Allen screws and remove
them (use the short side of the allen wrench for leverage and turn counter clockwise). See Figure I
for location.
Orient the Interface Block with the oval hole forward (shown in figure I), and round hole to the rear
of machine. Make sure the counter bores in the blocks face outward. See the counter bore
example in Figure J.
Attach the rear Allen screws first; use the provided longer screws to attach the block securely
and repeat for the other side of machine.
11
Figure H
Figure I
Figure J

Mounting the APES System to a HD7700 punch.
Place the APES System Ejector Top Plate Assembly on top of the punch. Avoid colliding the APES
System Front Paper Guides and the Drive Motor Assembly into the punch while setting the APES
System down. Keep control cable clear. See Figure K.
7700
12
Figure K

Adjust the APES System Ejector Base Plate Assembly back against the front of the punch.
Notice the Rear Paper Guide on each side of the machine in Figure L & M;
The Rear Paper Guide should be centered between both HD-7700 side plates and rest against
the front of the HD-7700 top front cover. Locate the APES System into this position without
bending the Rear Paper Guide forward.
Install and tighten the two 3-winged mounting knobs provided into the last (rear) mounting slots.
See Figure N.
Mounting Continued.....
Move the APES System Reception Assembly next to the punch. See Figure N. Note that the
Reception Pivot Block will align centered about the Ejector Base Plate Reception Mounting Bar as
shown. See Figure O.
6500/7000 7700
13
Figure L
Figure M
Figure N Figure O

If the reception fails to align with the Ejector Top Plate (on older HD punches with shorter feet) you
will need to adjust the Reception Pivot Block with two adjustment screws at the base of the Pivot
Block Mount just under the lid on the inside of the Reception. See figure P.
Mount the APES System reception to the APES System Ejector Base Plate with the two supplied
large 2-winged mounting push pins thru assembly holes in both the reception and Ejector Plate.
Mount the Reception Paper Stop to the Reception Paper Guide. See Figure Q.
14
Figure P
Figure Q

Mount the Reception Paper Guide to the APES System Reception top with the 2 supplied 3-
winged knobs. Push the assembly to its back-most setting. This is the standard location for the
Paper Guide. The Paper Stop adjustment is covered later in this manual. See Figure R.
Plugging in the APES System for the first time:
See Figure S. Attach the Reception cable to the back of the punch. Attach the APES System
Ejector Control Cable from the Ejector Top Plate Assembly to the back of the Reception Assembly
by inserting the keyed connector and tightening the collar. Attach the power cord for the punch
and the APES System to the power cord receptacles on the back side of each device and plug
each cord into a protected AC outlet as outlined earlier in the Safe Operating Guidelines section.
6500/7000 7700
15
Figure R
Figure S

Operating the APES System.
Control Center and Power Overview;
APES-14 Paper Exit INACTIVE – Switching to this position puts the
APES-14 in idle status. Your punch will still operate normally but the
APES-14 will not eject and stack.
Normal setting for this switch is down.
APES-14 Paper Exit ACTIVE – Puts the APES-14 in the active status.
Your punch and APES-14 will work together punching, ejecting, and
stacking.
Paper Stop ACTIVE – When selected, the optional Paper Stop will
override the foot pedal. When correctly installed the paper will activate the
switch, cycling the machine in the same manner as the foot pedal. (See
assembly instructions within the Paper Stop package)
Normal setting for this switch is down.
Foot Pedal ACTIVE – When selected, it allows for normal activation with
the attached foot pedal. The optional Paper Stop Switch can be installed
without removing the foot pedal. Only one is active at a time.
Portrait – Changes APES-14 machine timing to better accommodate
stacking portrait paper.
Landscape – Changes APES-14 machine timing to better accommodate
stacking landscape paper.
Normal setting for this switch is down.
APES-14 POWER ON I/0 – Turns the APES-14 off. It is recommended you
turn the APES-14 off when you're done for the day. The punch has its own
independent power switch that should be powered off also.
6500/7000 7700
16

Reception setup:
Loosen Paper Stop (shown in Figure T) then turn and move so that the Paper Stop Arm is aligned
with or above the center of page and width of page matches or exceeds the mark on the
horizontal guide, tighten Paper Stop. Loosen Drawer Screws (see Figure U) and pull out reception
drawer until sheet's top edge aligns with LINE “A” yellow label and bar edge (see graphics inside
drawer). tighten screws.Lightly
Accessing the Die in the Punch.
Turn both power switches off before removing a die or performing maintenance. See Figure
V. To change the die on a punch, pull the forward APES System Reception mounting pin and pivot
the Reception away from the punch. This will allow access to the left die locking handle. Unlock
both handles, replace die, lock both handles, then swing the APES System Reception back in
place and replace forward mounting pin. The HD-6500 uses forward mounted die locking screws
and will not require this action.
17
Figure T Figure U
Figure V

Ejector Setup 6” and larger paper.
Your APES System came without the Paper Deflectors installed. The machine came with a large
Top Front Paper Deflector with an Adjustable Edge Guide attached to it and a large Top Front
Paper Deflector without an Edge Guide, see Figure X. These guides are used in the locations
shown in Figure W.
Adjustable Paper Stop Knob: This adjustment knob is used to center the holes within your
sheet. Move the Adjustable Edge Guide to the most right position so it will not conflict with the
Paper Stop adjusting process. Rotating the knob clockwise will in essence move the holes to the
left on your paper and rotating the knob counter-clockwise will move the holes to the right.
18
Figure W
Figure X