Nagel Foldnak 100, Operation Manual

Page 1: ...Foldnak 80 100 Trimmer 100 Operations manual Service instruction ENGLISH ...

Page 2: ... Ernst Nagel GmbH 9965043 Operations manual Foldnak 80 100 Trimmer 100 doc Rev 1 3 23 10 2006 2 Foldnak 80 100 Trimmer 100 ...

Page 3: ... 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...

Page 4: ...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 ...

Page 5: ...olid 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 sc...

Page 6: ... 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 ...

Page 7: ... 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 s...

Page 8: ...x 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 ...

Page 9: ...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 i...

Page 10: ...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 S...

Page 11: ...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 ...

Page 12: ...o 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 A...

Page 13: ...nd 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 50...

Page 14: ...rder 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...

Page 15: ...gel 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 ...

Page 16: ...ed 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 ne...

Page 17: ...ng 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 run...

Page 18: ... 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...

Page 19: ...5043 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 FA3 FA27 FA28 FS32 FS33 FS30 FS31 FS25 FA29 FA30 FS1 ...

Page 20: ...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 guid...

Page 21: ...d off at the back of the Trimmer Adjustments of the Trimmer in the Foldnak menu Setting up the cutting width The width of cutting can be chosen Trimmer modes Through ticking off in the menu the Foldnak receives the information whether a Trimmer is present whether the booklet should only pass through or if it should be trimmed Stop Pos The delay of the belts can be adjusted This can become necessar...

Page 22: ...sert an Allen key 4 mm from the back into the motor shaft Turn it clockwise until the booklet is cut through and the knife is again in the top dead center position Remove the Allen key Toggle the service switch Knife doesn t reach the TDC The reason can be a dull knife a power failure or another disruption Let a technician bring the knife to the TDC as described above Knife doesn t stop at the TDC...

Page 23: ... Ernst Nagel GmbH 9965043 Operations manual Foldnak 80 100 Trimmer 100 doc Rev 1 3 23 10 2006 23 Layout of Trimmer 100 Side view TA1 TA2 TA3 TA4 TS7 TS2 TS6 TA1 TA10 11 TS4 TS3 TS5 ...

Page 24: ...olid state relays TA2 after the Trimmer has received a start signal from the Foldnak The infeed belts are turning At the same time the solenoid TA1 of the booklet stop is activated The stop is now in its upper position The clutch TA3 of the out feed belt is started as well As soon as both switches TS2 at the booklet stop are closed the out feed belt TA3 is stopped and a knife stroke is triggered v...

Page 25: ...8 J19 3 GND 11 24 V FA8 AUX4 J19 FA9 AUX5 J19 FA10 AUX6 J19 FA11 AUX7 J19 FA12 DELIVERY Delivery J19 8 GND 16 24 V FA13 RELAY 1 FA14 RELAY 2 FA15 ERROR LED Error LED J20 1 GND 2 3 V FA16 GREEN LED Error LED J20 3 GND 4 3 V FA17 LED3 Error LED J20 5 GND 6 3 V FA18 LED4 Error LED J20 7 GND 8 3 V FA19 LED5 Error LED J20 9 GND 10 3 V FA20 LED6 Error LED J20 11 GND 12 3 V FA21 LED7 Error LED J20 13 GND...

Page 26: ...10 GND FS18 BUTTON 6 J21 11 Make contact to pin 12 GND FS19 BUTTON 7 J21 13 Make contact to pin 14 GND FS20 BUTTON 8 J21 15 Make contact to pin 16 GND FS21 STAPLE 1 Staples empty J26 1 Make contact to pin 5 GND FS22 STAPLE 2 Staples empty J26 2 Make contact to pin 6 GND FS23 STAPLE 3 Staples empty J26 3 Make contact to pin 7 GND FS24 STAPLE 4 Staples empty J26 4 Make contact to pin 8 GND FS25 REF ...

Page 27: ...ND TA7 ERROR RELAY 2 J9 2 Make contact to pin 6 GND TA8 ERROR LED J20 1 GND 2 3 V TA9 GREEN LED J20 3 GND 4 3 V TA10 PAPERSTOP large Gear motor J9 3 24 V 7 24 V TA11 PAPERSTOP small Gear motor J9 3 24 V 7 24 V Submenu Trimmer Sensors Description Connector on PCB Pins Signal TS1 OFFLINE START J22 7 24 V 8 GND TS2 PAPER STOP J27 22 Make contact to pin 20 GND TS3 OUTPUT IR LED J27 1 Collector IR Tran...

Page 28: ...taples Recommendable for very hard sheets and thick paper blocks above 15 sheets 80 gsm Parts no 2660256 Stapling heads and staples Hohner wire 25 Order no 6170110 Stapling head order no 2660223 ISP Stitching Bindery Products wire 25 Order no 6170110 Stapling head order no 2660225 Rapid Nagel cartridge Order no 2660800 Stapling head order no 2660801 Nagel staples order no s 26 6 627 2060 26 8S 627...

Page 29: ...doc Rev 1 3 23 10 2006 29 Layout of connectors on PCB Adjustment data Format Staple position Fold position Transport finger Side guide Staple stop Fold stop J25 J11 J12 J10 J17 J13 J14 J15 J16 J29 J30 J26 J21 J20 J28 J23 J24 J32 J7 JP1 JP6 JP7 J8 J9 J18 J19 JP2 JP3 JP4 JP5 ...

Page 30: ... Ernst Nagel GmbH 9965043 Operations manual Foldnak 80 100 Trimmer 100 doc Rev 1 3 23 10 2006 30 Circuit diagram ...

Page 31: ... Ernst Nagel GmbH 9965043 Operations manual Foldnak 80 100 Trimmer 100 doc Rev 1 3 23 10 2006 31 ...

Page 32: ... Ernst Nagel GmbH 9965043 Operations manual Foldnak 80 100 Trimmer 100 doc Rev 1 3 23 10 2006 32 ...

Page 33: ... Ernst Nagel GmbH 9965043 Operations manual Foldnak 80 100 Trimmer 100 doc Rev 1 3 23 10 2006 33 ...

Page 34: ...ves auquel se réfère cette déclaration est en conformité avec les exigences essentielles des directives de la communauté européenne 89 336 EEC und Änderungen and amendments et amendements 89 392 EEC und Änderungen and amendments et amendements 73 23 EEC und Änderungen and amendments et amendements unter Anwendung der folgenden harmonisierten Normen by applying the following harmonized standards en...

Page 35: ...Trimmer new many changes and additions adjusted to layout of German Operations manual software version FK 4 43 Rev 1 05 09 2006 pages 25 27 tables completed p 7 13 paper format min software version FK 5 xx p 10 Maintenance and cleaning Rev 1 1 11 09 06 p 18 booklet shears p 15 28 alignment tool SH Clincher exchange p 9 Sequence of switching on p 5 Safety precautions 8 16 17 18 Rev 1 2 28 09 06 p 1...

Page 36: ...Ernst Nagel GmbH D 70565 Stuttgart Germany Inland 0711 78078 11 Export 49 711 78078 21 Telefax 49 711 78078 10 www ernstnagel com ...