TABLE OF CONTENTS

2094 DESCRIPTION / SPECIFICATIONS

COUNTER OPERATION

2084 DESCRIPTION / SPECIFICATIONS

Programming the Batch Counter

Burster Unpacking & Set-Up

Resetting the Batch Counter

Feed Table Assembly Installation (2094)

Start/Stop - Drive Motor

Transfer Table Assembly Installation (2084)

Shutting Off Jam Detectors

CONTROL PANELS

OPERATION - 2094

Feed Table Side Guide Adjustment

Vacuum Feed Sheet Separator

Checking Squareness of Fold

Set-Up with Optional Slitter

Output Conveyor Stacker Adjustment

OPERATION - 2084

Form Set-Up with Optional Imprinter

JOB SET-UP & PROGRAMMING

DAILY MAINTENANCE

Cleaning Fold Stop Guides

DISPLAY MESSAGES

LANGUAGE SELECTION

BASIC THEORY OF BUCKLE FOLDING

SAFETY COVERS

FAULT DETECTORS

Powering Up the Folder

Setting a Standard Fold

JAM CLEARING &

FAULT INDICATOR RESET

Saving Non-Standard Fold into Memory

DETERMINING FOLD TYPE

Recalling a Saved Fold from Memory

TROUBLESHOOTING

2094 DESCRIPTION

Folder Transport Table & Ball Deck

Upper Fold Plate Cover

Air Blow Adjustment Knobs

Side Guide Adjustment Knobs

Folder Air and Vacuum Hoses

Pump Access Panel

Lower Fold Plate Cover

FUNCTION

The 2094 folds and seals pressure sensitive forms with pre-applied glue lines into mail ready pieces. Numerous folds using several different paper sizes can be processed to meet your needs. For confi gurations and paper sizes see specifi cations.

SPECIFICATIONS

Dimensions Paper thickness Fold styles Paper loading capacity Processing speed Duty cycle Paper size Weight Power

76” L x 27” W x 51” H (193 L x 69 W x 130 H cm) Up to 65# cover stock Half, Letter “C”, Accordion “Z”, Double Parallel, Gate, Engineering & custom folds Up to 500 sheets (20# paper) Up to 27,600 sheets per hour (8.5” x 11”), up to 41,000 sheets per hour (3” x 5”) Up to 400,000 per month 3” - 12” W x 5” - 20” L (76 - 300 W x 127 - 508 L mm) Approx. 950 lbs. 125V, 60Hz, 30 Amp (NEMA L5-30R Receptacle required)

2084 DESCRIPTION

PRESSURE SEALER

Upper Fold Plate Cover

BURSTER

TRANSPORT TABLE

BURSTER

Power ower Switch

Lower Fold Plate Cover

Pump Access Panel

BURSTER BASE

FUNCTION

The 2084 separates, folds, and seals continuous pressure sensitive forms with pre-applied glue lines into mail ready pieces. Numerous folds using several different paper sizes can be processed to meet your needs. For confi gurations and paper sizes see specifi cations. Options include an imprinter and various slitting features.

SPECIFICATIONS

Dimensions Paper thickness Fold Styles Processing speed Duty Cycle Paper Size Weight Power

146” L x 41” W x 56” H (Sealer, Burster, Transport Table) 20-110# index Half, Letter “C”, Accordion “Z”, Double Parallel, Gate, Engineering & custom folds Up to 27,600 sheets per hour (8.5” x 11”), up to 41,000 sheets per hour (3” x 5”) Up to 400,000 per month 3” - 12” W x 5” - 20” L (76 - 300 W x 127 - 508 L mm) Approx. 1,403 lbs. 125V, 60Hz, 30 Amp (NEMA L5-30R Receptacle required)

ASSEMBLY

UNPACKING & INSPECTION

The 2094 is shipped in two cartons - Folder/Sealer (Fig. 1a) Feed Table and Accessories (Fig. 1b)

The 2084 is shipped in four cartons - Folder/Sealer (Fig. 1a) Transfer Table and Accessories (Fig. 1b) Burster (Fig. 2a) Burster Base (Fig. 2b)

NOTE: Immediately upon unpacking, carefully inspect each unit for shipping damage. If any damage is found, be sure to contact the delivery freight carrier to fi le a damage claim. Save all packaging material for the claims adjuster to inspect.

WARNING

Do not plug the power cord into an AC outlet until the 2094/2084 is fully assembled, adjusted and ready to use. Unplug the 2094/2084 any time assembly is required.

BURSTER ASSEMBLY - 2084

UNPACKING AND SET-UP

1. Remove bands which hold cardboard box to wooden pallet. Remove top of box.
2. Remove (4) carriage bolts: (2) on infeed end of burster and (2) outfeed end (Fig. 3a & 3b). Hint: Leave carriage bolts in place on center burster support.
3. Remove (4) foam blocks.
4. With Allen wrench supplied, remove four retaining bolts which hold machine to the board immediately below it. NOTE: Center burster support is not fastened to burster.
5. Add burster feet to burster. (Fig. 4)
6. Remove burster base from its carton.
7. Set burster on base. NOTE: Burster will line up evenly on all sides of the base.

Once the unit and its components have been carefully removed from the packaging begin by attaching the Output Conveyor, next install Fold Plates and then the Feed Table (2094) or Transfer Table & Burster (2084).

OUTPUT CONVEYOR INSTALLATION

1. Insert the output conveyor with the drive wheel toward the seal rollers.
2. Slide the output conveyor over both sets of locating pins. The fi rst notch in the front part of the output table should rest on the pins (Fig. 5a).
3. Drop the rear notch down on the rear dowel pins (Fig. 5b).
4. Plug the output conveyor into the table receptacle on the input/output power assembly. (Fig. 6)

NOTE: Do not operate machine without output conveyor in place.

Conveyor connector

FOLD PLATE INSTALLATION

WARNING: Unplug the AC power cord when installing or removing fold plates.

The fold plates are interchangeable. Each fold plate has an open end which faces toward the fold rolls.

1. To install the fold plates, pivot the fold plate holddowns (Fig. 7) out of the way and slide the fold plate in position so the slots in the leading edge of the fold plate engage the two locating pins in the side frames.

The center notches should seat on the second set of locating pins.

2. Pivot the fold plate hold-downs back into position to secure the fold plates.
3. Turn the hand wheel (Fig. 10) to be sure that the fold plates are properly installed and not rubbing on the fold rolls.
4. Plug the fold plate connectors into the side frame.

(Fig. 8a & 8b)

NOTE: Do not operate machine without fold plates in place.

Fold plate hold down

FEED TABLE ASSEMBLY INSTALLATION - 2094

(NOTE: For 2084, skip this process and go to page 8.)

1. Insert the feed table with the feed wheel toward the fold rolls.
2. Slide the paper feed table over both sets of locating pins. The fi rst notch in the front part of the feed table should rest on the pins (Fig. 9a).
3. Drop the rear notch down on the upper dowel pins (Fig. 9b).

USE OF THE HAND WHEEL: The hand wheel is used to help clear jams and for setup. To use the hand wheel, shut off the folder, pull out the hand wheel and turn it in either direction.

4. Rotate the hand wheel to check that the gears are properly meshed (Fig. 10).
5. Connect the feed table hoses. Push the fi ttings into the holes in the manifold block (Fig. 11).

Feed Table Hoses

6. Plug the feed table into the side of the frame. (Fig.

12)

NOTE: Do not operate machine without feed table in place.

Pump Hoses

Locating Pins

Locating Pins

PUMP HOSE CONNECTIONS: Two sets of hoses are included with your 2094, two (2) for t the feed table and two (2) for the pump.

TRANSFER TABLE ASSEMBLY INSTALLATION - 2084

1. Install the transfer table for the 2084. Insert the table between the folder side frames (Fig. 13) and set the notches on to the locating pins (Fig. 9a).

3. Plug burster power cable & interlock cable into folder (Fig. 15). Remove lower fold plate to access the receptacles.

4. Place ball deck onto the burster transfer table (Fig. 16).

2. Align the outfeed of the burster with the transfer table and push the burster forward until the mounting holes of the transfer table and the burster line up.

Slide mounting pins into holes to lock the table in place (Fig. 14).

CONTROL PANELS

Folder Control Panel

NAME

MEMORY #2 SET

SHEET MODE SELECT (2094 Only)

PUMP START/STOP (2094 Only)

MEMORY #3 SET

SHEET FEED (2094 Only)

FOLDER DRIVE START/STOP

SHEET JAM SELECT

INCHES/METRIC UNIT SET

LETTER FOLD SELECT

SPEED ADJUST

FUNCTION RESET

Z-FOLD SELECT

UPPER FOLD PLATE ADJUST

COUNT SELECT

DOUBLE HALF-FOLD SELECT

LOWER FOLD PLATE ADJUST

INCREMENT

HALF-FOLD SELECT

STACKER ADJUST

DECREMENT

GATE FOLD SELECT

BATCH COUNT SET

RATE SELECT

ENGINEERING FOLD SELECT

DATA ENTER

TIME SELECT

MEMORY #1 SET

LCD ALPHANUMERIC DISPLAY

Burster control panel (2084)

NAME

FUNCTION

Counts number of forms processed

Press to stop the burster at infeed or outfeed

Select the speed to run the burster

Press to start the burster at infeed and outfeed

Indicates cover open, jam grill in up position, folder not running

Advances forms forward or backward at infeed and outfeed

Sets the length of the form to be burst apart

Turns Burster on and off

OPERATION - 2094

MAIN POWER/RESET SWITCH

The main power/reset switch (Fig. 17) will completely shut off all power to the operating system. This will stop everything immediately.

Side guide locking knobs

Side guides

Main power switch

Side guide adjustment knob

VACUUM FEED SHEET SEPARATOR

FEED TABLE SIDE GUIDE ADJUSTMENT

The sheet separator will have to be adjusted for the weight of paper you are folding. Ideal adjustment will feed only one sheet without marking the paper or feeding doubles. Use the following procedure to get started. Fine tune these adjustments according to the condition of the paper and the environmental conditions of your particular work area.

In order for your machine to fold squarely, it must be fed into the rollers square. On the paper feed table there are two guides which keep the stack of paper properly aligned for feeding into the folder. (Fig. 18). Adjust these guides to correspond with the different widths of paper being processed.

GAP ADJUSTMENT

1. To adjust the paper feed guides, loosen the two side guide locking knobs on each guide.

1. With the machine running, insert two sheets of paper between the tab and the sucker wheel. (Fig. 19)

2. Slide the guides from side to side until the inside edge of each guide is aligned with the number corresponding to the width of the paper being folded. Example: For a 10cm wide sheet, move the side guides until the inside edges align with the “10” on the feed table.

2. Turn the gap knob counterclockwise until there is a slight drag on the paper.

3. Remove the paper. The correct gap is now set.

3. An additional check is to lay a sheet of paper on the feeder, close to but not touching the side guides. Push the sheet down into the nip of the fold rolls.

4. Next, loosen the adjusting knobs and align the guide so it’s parallel to the edge of the paper. When one side is square, the other side can be moved into position.

5. Tighten the locking knobs to secure the paper guides in position.

NOTE: When loading an actual job, you may have to move these guides slightly to accommodate variations in sheet size. To feed properly, the paper must slide freely between these guides.

AIR BLOW ADJUSTMENT

CHECK SQUARENESS OF FOLD

1. Turn the air blow adjustment on the vacuum/air control panel fully clockwise to the (-) position (Fig.

20a). Adjust the air blow to fl oat the sheet stack using the air blow adjustment, this is to separate the bottom 4 or 5 sheets.

Examine the folded sheets on the stacker to be sure you are getting an even and square fold. A skew adjustment is located on each plate to adjust for a square fold on paper that is not cut square. (Fig. 21)

2. The feeder valve knob may be used to balance the air between the left and right side of the feed table.

Turn the knob to the right to obtain more blow on the right side and front of the feed table. Turn the knob to the left to obtain more blow on the left side and lessen the front blow.

3. With the folder and pump running, press the “SHEET START” button. Gradually increase the vacuum setting until the sheet is pulled from the feeder.

Fold plate skew adjustment

NOTE: Set folds with standard copy paper so that the folds line up with the perfs on the pressure seal forms.

1. Load a stack of paper onto the feed table. The stack should be no higher than the side guides, 2” (51 mm). Position the backstop up against the paper stack.
2. Turn on the air/vacuum pump. The air should fl oat the bottom of the stack approximately 1/16 to 1/8” (16 to 32mm). Air blast can be controlled by adjusting the feeder valve knob (Fig. 20b).

SETUP WITH OPTIONAL SLITTER

OUTPUT CONVEYOR STACKER ADJUSTMENT

1. Set the fold setting on folder. Select from one of the standard preset folds or set a custom fold if needed.

The output stacker has a variable speed control dial that can be used to adjust the shingle spacing or the space between each form in the stack.

2. If the slitting alignment mark is not preprinted, manually fold the form, determine where the slit should be and mark it for aligning the slitter blades.

To decrease the space and tighten the shingle, decrease the speed. To increase the space and loosen the shingle increase the speed of the conveyor.

3. Using the hand wheel, manually feed the marked form through the folder into the output wheels of the folder just before the slitting blades (Fig. 22a).
4. Loosen top and bottom blades of the slitter with an Allen wrench. Align the center of the slitter with the slitting alignment mark on the form (the center of slitter is where the top and bottom slitting blades meet) and tighten into position.
5. Manually fi nish feeding the form and remove.
6. Run a few test sheets to check alignment and adjust if needed. When the alignment is set begin operation.

Center of slitting blade assembly

OPERATION - 2084

4. Center leading edge of form at infeed end of the burster.
5. Position tractors to proper form width by releasing thumbscrews on top of tractors and sliding tractors to proper width. Raise tractor gates.

Slitter Adjustment Alignment Mark Screw

6. Lay margin holes of form over feed pins. (Fig. 24)

NOTE: Do not stretch form too tightly between pins; pins should be centered in margin holes.

7. Close tractor gates and lock tractors by tightening thumbscrews.

1. Turn on the machine. Measure form length.

8. If using edge slitters, position alignment mark where you wish to slit. (Fig. 22b)

2. Press the form length switch on the burster to align the alignment mark with the form length on form length scale. (Fig. 23)

9. If slitting, be sure that slitter blades are engaged.

This is accomplished by rotating wedger in a counterclockwise direction as far as they will go without force. (Fig. 22b)

10. Lock edge slitters in place by tightening thumbscrews clockwise. (Fig. 22b)

NOTE: If you do not want to slit, push edge slitters away from form and tighten thumbscrews.

11. By pressing jog switch in forward position, advance form through feed rollers until snap rollers grab the form.
12. If necessary, adjust form length so the form starts to burst when perforation is just under tear points.

NOTE: Tear points can be moved to position them at any location along tear bar. Tear points should be set between perforations that run vertically the length of the form. (Fig. 25)

3. Place form stack on pull down tray on right side of the burster.

13. The tear bar is adjustable to accommodate characteristics of various forms. To adjust height, bar must be pushed to compress spring and lift out. Rotate 180 degrees (turned over) and replace making sure that square end of bar locks into brackets. (Fig. 26, shown in HIGH position)

1. To stop the machine, push on either one of two stop buttons. Opening safety cover or lifting jam detection grill will also stop machine.

2. To restart machine start button must be pressed.

CAUTION: Machine will restart at same speed that it was running at unless speed control thumbwheel is turned down.

3. Some paper has a natural curve. Sometimes this curve tends to catch air and sail. If this occurs, try running them upside down.
4. Perforations vary in strength. If forms are bursting hard, tearing, or breaking behind tear bar, vary form length setting up to 1/2” ahead or behind actual form size setting, and/or put tear bar in low position.

Form Set-Up Procedures With Optional Imprinter

10. Move timing collar so that mark on collar aligns with mark on side frame. Tighten setscrews.

NOTE: It is recommended that numbered forms or checks fed into imprinter should be last form fi rst, right side up.

11. Remove forms from tractors. Install signature patches on imprint cylinder.
12. Move ink roller directly over signature patch on imprint cylinder. Jog forward, if necessary, so that imprint cylinder turns to a point where signature patch should touch ink roller. Adjust ink roll thumbscrews so ink roll turns when signature patch makes contact.

For darker impression, turn adjustment thumbscrews clockwise.

1. Center leading edge of form at infeed end of machine so that outer edges of form extend equally beyond guide straps on each side. If you fi nd that edges come within about 1/4” of guide straps, offset form in either direction to avoid this condition.
2. If form length is 3 1/2”, 7”, 10 1/2” or 14”, rollers must be timed. Time rollers by activating jog switch until timing marks on the rollers are vertical and in view in cutouts in feed and snap roller covers.

NOTE: The signature saddle has been factory adjusted to fi t a .092 thick signature patch. If adjustment is required to lower or raise the height of signature saddle for a different signature patch thickness, release imprinter side plates from their locked positions. Pull back latch fi nger to release plates. Loosen side setscrews to free top setscrew Turn top setscrew in at half-turn increments until required height is reached. Tighten side setscrews and slide imprinter module back into position.

3. Position tractors by releasing and sliding to proper form width. Raise tractor gates. Place forms on feed pins as shown in Fig. 24. Close tractor gates and secure in position.
4. Loosen thumbscrew on ink roller unit and slide unit away from signature area on form.
5. Loosen setscrews on plate cylinder. If setscrews are not in view, rotate free wheeling cylinder until they are in view. Horizontally align plate cylinder with signature area on form. Tighten setscrews.

NOTE: Imprinter must be timed each time you load a different form into Burster for imprinting.

1. Jog machine forward until timing collar mark is aligned with side panel mark.

6. Loosen setscrews on imprint cylinder. (If setscrews are not in view, use jog switch to bring them into view.)

2. Place forms to leading edge to timing mark.

3. Advance (jog) forms forward through imprint area.

Stop leading edge of form in front of slitters.

7. With no signature saddles on imprint cylinder, move forms forward so signature area is centered over plate cylinder shaft.

4. Move slitters to trim proper amount of trim and engage slitter blades by turning wedgers counterclockwise. Lock down slitters.

8. Center signature cylinder over signature area (NOTE: Setscrews should be facing you.) and center signature plate locator pins directly over imprint area on form. Tighten setscrews.

5. Advance forms through slitters and check for proper slitting. Advance on through to Tear Bar.

9. Advance forms forward so that next horizontal perforation aligns at top edge of plastic tractor or alignment mark on metal tractor.

6. Set up tear bar as before. (Fig. 26)

7. Close Safety covers. Machine is now ready to burst and imprint. Press the Start Button and adjust machine speed to speed desired.

JOB SETUP & PROGRAMMING

WARNING: When adjusting fold lengths on the fold plates using the keypad, the plates will move automatically. Be sure to keep hands away from fold plates when adjusting fold lengths. It is recommended that all guards be closed when adjusting fold lengths.

IMPORTANT NOTE:

The operator control panel contains a numerical keypad, which is automatically activated when a function requires numerical data. The operator panel is color coded to show this relationship. Numerical data is required for:

• Sheet Length
• Batch Size

Two pieces of information are required to set up a job, assuming that initialization has previously been accomplished; sheet length and fold type. Either order may be used. Select the fold type fi rst or the sheet length fi rst.

POWERING UP THE FOLDER

When power is supplied, the system will fi rst test all LEDs, memory and LCD display characters for 3 seconds.

After the self diagnostic phase, the display will show the version number for 3 seconds.

If there are no error messages the display will go to the jam detector screen if one of the jam detectors is disabled.

If none are disabled or after pressing enter, the display will go to the initialization screen. The initialization screen will remain for 10 seconds. If the “+” button is not pressed during this time no initialization will occur.

The display will go to the count screen. If there is any question about folding accuracy, reinitialize the system. LEDs in the memory, or the fold type buttons will light to indicate the last setting.

SETUP FOR A STANDARD FOLD

5. To adjust fold settings, press “PLATE 1” button to adjust top fold plate and/or “PLATE 2” button to adjust the bottom fold plate. Use the “+” or “-” keys to adjust settings up or down, then press “ENTER.”

Note: See page 30 to help determine fold type

Method 1: CHOOSING FOLD TYPE FIRST

To save, see “Saving Non-Standard Folds into Memory” on page 17.

1. To set up for a new fold, press a fold type button. For example, to set a “Z” fold, press the “Z” fold button. The display will show the last job sheet length.
2. If the sheet length is not correct, you will have 5 seconds to begin keying in the new sheet length and press the “ENTER” button (see below). If the sheet length is correct, you may immediately press the “ENTER” button, then proceed.

Method 2: ENTERING SHEET LENGTH FIRST

1. Setup a new job by pressing the “SHEET MODE” button.

The Sheet Length screen will be displayed showing the last set sheet length.

3. When the “ENTER” button is pressed, the fold plates and stacker will move to their new position. While the motors are running, a PLEASE WAIT message will be displayed.

You have the following two options: A) Enter a new sheet length, or B) do nothing.

NOTE: Pressing the enter button will accept the new data and eliminate any waiting time before moving to the next function.

4. When the motors have stopped, one of two screens will be displayed. If the sheet length data was changed, the single sheet mode screen is displayed.

If the sheet length data was not changed, the count screen will be displayed.

A) ENTERING A NEW SHEET LENGTH:

B) DO NOTHING:

1. After 5 seconds the data will be accepted and the last fold type indicator will start fl ashing. Select the desired fold type by pressing the appropriate “FOLD TYPE” button.

After 5 seconds, the count screen will be displayed.

SETTING A CUSTOM FOLD

The 2094/2084 has 3 memory locations that can be used to store custom fold settings. These will store the plate settings, the stacker wheel location, and the speed setting for a fold.

2. After 5 seconds the selection will be accepted and the fold plate stops will move to their new position. During this period the “PLEASE WAIT” screen will be displayed.

SAVING A NON-STANDARD FOLD INTO MEMORY

1. Set up the fold as you normally would.

2. Once the speed and folds are set the way you want, press a “MEMORY SET” button. Recall will appear in the display.

3. When the folder has completed its movement, the single sheet mode screen will be displayed. At this point, each time the “SHEET START” button is depressed a single sheet will be folded and delivered. Any adjustments to fold lengths or slitter shaft accessories may be made at this time.

3. Press the (-) button to get to the STORAGE screen.

4. Press the “ENTER” button to store the fold in the memory location selected.

4. Press the “SHEET MODE” button to return to the production mode. The count screen will be displayed.

RECALL A FOLD SAVED TO MEMORY:

1. Press the “MEMORY SET” button that corresponds to the memory location you wish to recall. RECALL will appear.

5. Accept the displayed sheet length by pressing the “ENTER” button. This will activate the single sheet mode.

2. Press the ENTER button.

STARTING PRODUCTION:

PROGRAMMING THE BATCH COUNTER

After the sheet length and the fold type have been selected:

Program the batch counter by pressing the “BATCH SET” button. The set batch screen will be displayed.

1. Start the main drive (press “DRIVE”)
2. Start the pneumatic pump (press “PUMP”).
3. Start sheet (press “SHEET START”)

NOTES: If the wrong “FOLD TYPE” button is pressed, you can either press the “RESET” button instead of the “ENTER” button or press the correct “FOLD TYPE” button, then the “ENTER” button.

After every new set up the machine speed will always be reset to 60%.

1. Using the numerical buttons ( ) enter the desired batch size; one, two or three digits (maximum setting is 999).

The fold type status LED, when lit constantly, indicates that the fold plates are set for this type of fold. Any time the folder is running and a change is made that causes the fold plate stops to move, the main drive will stop.

2. Using the “+” and “-” buttons, enter the desired feed interrupt time (0.3 to 9.9 seconds). This gives the separation.
3. When stop is displayed, pressing the “SHEET START” button will feed a batch and stop.
4. Press the “SHEET START” button to process the next batch.

COUNTER OPERATION

During normal operation, the display should show the total count (maximum count 9,999,999), current batch size (3 digits) and the total number of completed batches (5 digits). This display is known as the count screen.

RESETTING THE BATCH COUNTER

To reset the batch counters press the “RESET” button, then press the “BATCH SET” button. This will reset the batch count and the total batches. The Total Count will not be reset.

RESETTING THE TOTAL COUNT

To reset the total count press the “RESET” button, then press the “COUNT” button. This also resets the batch counter, (# of batches & # in the batch).

RATE

Pressing the “TIME” button will change the display to the time mode.

The “RATE” button is used to display the average pieces per hour, both current and average since the last total counter reset.

In this mode the fi rst line of the display will show job run time and have a 4-digit capability to show the number of hours since last reset. The second line will show total hours and have a 6-digit capability to show the total hours on the machine.

Pressing the “RATE” button will change the display to the rate screen consisting of two lines. The top line is the current rate. It will have a 5 digit display, and will refresh every 6 seconds. The second line will show the average pieces per hour since the last total counter reset. This line will also have a 5 digit display, and refresh every 30 seconds.

The “COUNT” button can be used to go back into the count screen from the rate screen.

NOTE: If a button is not pressed within 2 minutes, the machine will return to operating mode.

The display will stay in this mode until another mode button is pressed. The “ENTER” and “RESET” buttons will have no effect in this mode.

START/STOP BUTTON - DRIVE MOTOR

In the normal operating mode pressing the DRIVE button will activate the main drive motor and the LED below the button will light. Pressing the DRIVE button again will deactivate the main drive motor and turn off the LED.

NOTE: Every time the total count is reset the average rate per hour will also be reset.

NOTE: If a button is not pressed within 2 minutes, the machine will return to operating mode.

RUN TIME

The “TIME” button will display the time since the last total count reset and the total hours that the main drive has been on, the customer can not reset this meter. Both hour meters will increment only when the folder is running. The pump operation or the main power will have no effect on these meters.

START/STOP BUTTON - PUMP

In the normal operating mode pressing the PUMP button will activate the pump motor, and the LED below the button will light. Pressing the PUMP button again will deactivate the pump motor and turn off the LED.

NOTE: Every time the total count is reset the job run time should also be reset.

SPEED

FOLD PLATES

The speed of the machine can be changed by pressing the SPEED button while the main drive motor is running or stopped.

The fold plates can be set at any time from the operating mode by pressing the PLATE button that corresponds to the fold plate which needs to be adjusted.

Use the “+” and “-” buttons, to adjust the speed. The “+” button will increase the speed gradually, as long as the button is pressed.

1. To adjust the number 2 fold plate, press the PLATE 2 button.
2. Use the “+” and “-” buttons to move the stop into position.

Once either button is pressed the display will change to display the actual location of the plate stop.

Once the folder reaches its maximum speed a message will be displayed until the ENTER button is pressed.

Pressing the “+” button once will increment the plate stop 0.25 mm. Holding it for more than 2 seconds will increment the plate stop continuously at slow speed. Holding the “+” button for more than 5 seconds will increment the plate stop continuously at high speed until you release the button or the plate stop hits the home position switch.

The “-” button will decrease the speed gradually, as long as the button is pressed.

Once the folder reaches its minimum speed a message will be displayed until the ENTER button is pressed.

Full speed range travel of the motor takes 10 seconds.

Pressing the “-” button once will decrement the plate stop position 0.25 mm. Holding it for more than 2 seconds will decrement the plate stop position at slow speed. Holding the “-” button for more than 5 seconds will decrement the plate stop position at high speed until you release the button, or the plate stop hits the defl ect position switch.

Press the ENTER button to return to normal operation.

3. Press the ENTER button to return to normal operation.

CHANGING DIMENSION SETTINGS

Pressing the “-” button will decrement the stacker wheels position at slow speed. Holding the “-” button down for more than 2 seconds will decrement the stacker wheels position at high speed until you release the button or the stacker wheels hit the home position. Once the stacker wheels have reached the home switch the drive is disabled and a message will be displayed for 5 seconds after the “-” is released.

To change dimensions from English to Metric, press the SET U/M button. Now all the dimensions will be in metric. The setting will remain until this procedure is repeated.

After the stacker wheels are in position press the “ENTER” button. This will return you to the operating mode.

STACKER WHEELS

The stacker wheels can be set at any time from the operating mode by pressing the “STACKER” button.

1. To adjust the stacker wheels, press the “STACKER” button during operation.

PAPER JAMS

In the event of a paper jam, the machine will shut off and display will indicate where the jam occurred.

2. Use the “+” and “-” buttons to move the stacker wheels into position.

Any time a jam indication is showing in the display you can press the STACKER button and the stacker wheels will move to the end of the table to make it easier to clear any jammed paper.

Pressing the “+” button will increment the stacker wheels continuously at slow speed. Holding the “+” button down for more than 2 seconds will increment the stacker wheels continuously at high speed until you release the button, or the stacker wheels reach their outer limit. The system will track the stacker wheel location and if they reach the stop, the drive will be disabled and a message will be displayed for 5 seconds after the “+” is released.

Try to determine the cause of the jam and correct it before pressing the RESET button. Pressing the RESET button will clear the jam message, return the stacker wheels to their original position and re-enable the drive.

SHUTTING OFF JAM DETECTORS

NOTE: For optimal function, it is recommended to keep the jam detectors on.

Take a few minutes at the end of each day to wipe off accumulations of paper dust. Cover your machine when not in use. These practices will keep your machine clean and in tip-top operating condition.

1. To enter jam detector mode, press the SET JAM button:
2. Use the “+” button to toggle between enable and disable of the specifi c jam detector. Use “-” button to make no change.

Keep fold rollers clean. Most folding problems are the result of material accumulations on the fold rollers. Although designed to minimize accumulations, over a period of time, ink and dust buildup will prevent the rollers from gripping the stock evenly. Rollers must be cleaned on a regular basis to maintain optimum folding performance.

Display shows:

Disconnect the power, remove the fold plates and clean rollers with Formax-approved cleaner designed for the type of rollers your machine is equipped with. Turn the rollers with the hand wheel (never attempt to clean rollers with the machine running). Check rollers periodically for wear. During normal use, fold rollers will gradually wear. Worn rollers will be evident by increased setup times, increased spoilage, inaccurate folding and inability to control the sheet. If one or more of these conditions are noted, contact your authorized Formax folder dealer to inquire about inspection and/ or possible roller replacement.

When the “+” or “-” button is pressed, display shows:

Keep sealer rollers clean. Sealing problems may occur if printer toner builds up on the steel rollers. Disconnect the power, lift the sealer safety cover and wipe the rollers down with Formax-approved lint free cloth and roller cleaner.

When the “+” or “-” button is pressed, display shows:

The fi lters on the pump should be checked periodically and cleaned as needed. The fi lters can be reached by unscrewing the fi lter jars.

Occasionally wipe off both photo eyes with a dry cloth.

Cleaning Fold Stop Guides

The fold stop guides should be cleaned once a week with a dry cloth to keep the plate moving properly.

Display Messages

The following are other display messages that may appear

Home Not Reached

Keyboard Missing

Press Reset

Out Of Range

Bad Keyboard

Pump Thermal Contact Paper Size Incorrect

Press Reset

Or Pump Disconnected

Pump Overload No Paper

Press Reset

Out Of Paper

Folder Overload

Press Reset

No Tach.Check Install Delivery

Motor,Belts,Encoder Or Press Reset

JAM 2nd STATION INSTALL PLATE NO.1

Or Press Reset

Start Sheet Install Plate No.2

Or Press Reset

CHANGE +/- 100.00mm PAN 1STOP

Change With +/-

PLATE NO.

Language Selection

Switch location, on the electronic board, for language and voltage selection settings.

OR Settings Switch

Rodg

YoD14 .5A TYPEMDL

Rod3 Swi Type Mda F2.F3 5A

Jf2 Vr2 F4,F5 20A Typemda

Ac Mtr Running（Pump)

RODI 28 ACMTR OVERCURRENT（PUMP) VR3 Yo D16 DC MOTOR RUNNING

D4 5VdcSUPPLY D5 14Vdc SUPPLY

Ro Di7

D6 Batch On

D7 Panistep(Mtr.On)

Panilimit(Pan Athome Pos.)

Swi Switch Settings

D9 Pan2 Step(Mtr.On)

Pan2Limit（Panathomepos.)

Function

Dii Delivery Step(Mtr.On)

Language-English

LANGUAGE-GERMANY D12 DELIVERYLIMIT(PANATHOMEPOS.) LED LEGEND TACHOMETER (PULSE INPUT) LANGUAGE-SPANISH

Manual Override Engaged

Language-French Off

D15 Feed Sensor(Upper Jam)

115VOLT PROGRAM INITIALLYON

Deliverysensor(Lower Jam/Count)

220VOLT PROGRAM GRY GREEN PILE INTERRUPT

Microprocessor Control Red

Manual Override Yellow Vri Factory Setting-Ac Mtr Overload

Folder Runs Without Program

Vr2 Feed Sensor-Fullcw

Delivery Sensor-Full Cw

Sw Legend Switch Off

Switch On

Don'T Care

115VOLTS 220VOLTS

English English

German German

Spanish

Spanish

French French

BASIC THEORY OF BUCKLE FOLDING

If a sheet of paper is laid on a fl at surface and driven into a stationary object, a buckle or series of buckles will form along the surface of the sheet.

If the sheet of paper is pushed into a narrow channel before butting up against the stationary object, the buckles that form within the channel will be of a much smaller size than free-forming buckles. At the end of the channel, however, larger buckles will again start to form.

If the channel is angled to produce a downward pressure, and two folding rollers, spinning as indicated, are placed close to the end of the channel, the larger buckles that start forming there will always be formed downward and be pulled into the rollers, compressing into a fold.

On a buckle folder, the sheet is laid fl at on a feed table and then enters the fold plate assembly where it comes to a stop against the stationary sheet stop. A series of buckles then forms throughout the sheet. The buckles within the fold plate are kept very small by the narrow channel design.

The buckles at the end of the fold plate, however, will be larger. The fold plates and fold rollers are confi gured such that the large buckle will always form downward, where it can be grabbed by the fold rollers and compressed into a fold.

In the diagram below, fold plate #1 is angled upwards. Because of this and the confi guration of the fold rollers, sheets fed into the #1 plate will always be folded up (i.e. so that the “up” surface of the sheet is folded into contact with itself).

Likewise, because fold plate #2 is angled down, sheets fed into it will be down-folds; the “down” surface of the sheet will be folded into contact with itself. This diagram shows the plate #2 defl ector in position. In this case, the sheet does not enter plate #2, and produces a single fold.

SHEET STOP

FOLD PLATE #1

FEED TABLE

DEFLECTOR

DELIVERY

FOLD PLATE #2

Fault Detectors

Safety Covers

Burster (2084) - The burster is equipped with an outfeed jam detector grill (Fig. 27). This device senses jams between the burster and the transfer table and stops the burster until the jam is removed and the machine is restarted.

The 2084 burster is equipped with a plexi safety cover (Fig. 29), and will not run unless this cover is in closed position.

Sealer - A photo-eye sensor is located on the eight ball transfer deck before entering the sealer unit. This device senses jams and immediately stops the sealer, burster (2084) and folder until the jam is removed and the machine is restarted (Fig. 28).

JAM CLEARING & FAULT INDICATOR RESET

JAM OCCURS IN A FOLD TABLE

1. Unplug and remove the fold table and remove paper.

Use the hand wheel to assist in advancing the paper through the rollers.

2. Reinstall and plug in fold table.

3 Press the reset button on the control panel to clear the fault signal.

JAM OCCURS BETWEEN THE METAL SEALING

ROLLERS

1. Remove any remaining forms from the feed table.

2. Lift the rear cover of the folder to access the metal sealing rollers.

2. Remove the transport table ball deck (Fig. 30).

3. Using the jam-clearing tool, apply the tool to the holes in either upper metal rollers (Fig. 30) and turn clockwise until the paper jam is clear.

Caution: Do not turn counter-clockwise and/or force the form(s) to exit the machine or the rollers may be damaged.

4. Remove the jammed form.
5. Reinstall Ball Deck
6. Press the reset button on the control panel to clear the fault signal.

Jam clearing tool holes

DETERMINING FOLD TYPE

Two Standard Folds 11” “Z” & 11” “C” Refer to Operator Manual for custom fold setup.

TROUBLESHOOTING

TROUBLE

POSSIBLE CAUSE

REMEDY

Is the power on?

Make sure the power to the folder, sealer, conveyor and burster are in the on position. Check to make sure the wall outlet has power

Machine not plugged in

Make sure all the plugs are plugged in properly

Safety covers are raised/open

Make sure the safety covers for the folder and sealer are lowered.

No power even with machine turned on, plugged in and wall power is on? Feeder is not set properly

Paper is stuck together

Separate sheets from each other.

Using paper other than specifi ed Double feeding

Paper other than specifi ed may cause mechanical trouble. Turn power off, insert jam clearing bar into sealer roller and turn counter-clockwise until jam is cleared. Turn power off, turn hand wheel counter clockwise and clear jam.

Paper stuck in fold plate

Paper fold gets out of place

Paper jam occurs often

Toner is on metal rollers of sealer Paper stops have moved

See Gap Adjustment, pg 10.

Turn power off, remove fold plate and clear paper. Unplug machine and clean with approved cleaner. Rotate the fi ne adjustment knobs to correct movement, pg 10.

Folding roller is dirty Folding roller is dirty

Clean with approved cleaner. Clean with approved cleaner.

Is inside of machine dirty?

Clean inside of machine.

Are conveyor nip rollers in proper positions?

Set rollers to proper position.

Let paper sit curl side down with weight on top to eliminate curl.

If paper jamming continues.

Form is not exiting the folder straight

Check that the forms are being fed squarely.

Check that the eight ball track is sitting properly.

Check to see if the fold rollers are clean.

Documents are wrinkled or crunched

Forms in burster creep to one side.

Form is not entering the sealer straight

Check that the eight ball track is sitting properly.

Creasing continues Fold plates are not inserted correctly

Call service. Remove and reinstall fold plates. Be sure they’re properly positioned.

Piece of paper or other material Remove object from the fold plate. is stuck in the fold plate Infeed guides not set properly Reset Guides, page 12

Roller tension not uniform across roller.

Check and adjust roller tension, Call Service

Tear bar in high position

Put bar in low position pg. 14

Burster not running fast enough

Incorrect form length setting

Reset paper length pg. 13

Tear points not adjusted properly across face of form

Adjust tear points pg. 13

Adjust tear points pgs. 13 - 14

Burster rollers don’t rotate / machine runs.

Slipped belt Broken drive belt Loose pulley

Check and adjust roller tension Call Service

Carriage not properly positioned.

Tear point not set correctly.

Adjust tear points pgs. 13 - 14

Tear bar not set correctly.

Adjust tear bar position pg. 14

Slitter blades not making contact with one another.

Adjust slitter blade position, pg. 12

Replace blade, Call service

Burster stalls or tears forms

Forms pull out of burster tractors.

Large variations in trim accuracy

Snap roller carriage will NOT move

Loop forming between the slitter and the infeed roller.

Roller timing is off

Incorrect form length setting

Reset form length pg. 13

Incorrect feed roller tension

Check and adjust roller tension, Call Service

Tractor drive pulley bound up

Check for paper jam and clear, Call service.

Tractor pins not centered in margin holes

Adjust tractors pg. 13

Replace blade, Call service

Tractor timing is off Paper not centered to slitter feed

Call service. Realign paper

Margin slitter setscrew not tightened down Defective switch or motor

Broken carriage drive chain

Loose setscrew on carriage advance shaft or on motor

Tighten setscrew, Call service

Obstruction at the pivot arm Obstruction between the infeed and snap rollers

Remove obstruction Remove obstruction

Broken fl ow strap

Bent infeed fi nger

Tear bar in low position

Put bar in high position pg. 14

Too many tear points

Adjust tear points pgs. 13 - 14