FD 4400

High-Volume Cut-Sheet Burster

OPERATOR MANUAL

FIRST EDITION

TABLE OF CONTENTS

DESCRIPTION / SPECIFICATIONS

INSTALLATION

Burster Unpack and Assembly Pump Installation Feed Table Installation

OPERATION

Controls Burst Length Set-up Procedure Squaring Feed Table Vacuum Feed Sheet Separator Horizontal Separator Adjustment Feeding Paper Bleeder Valve (Vacuum Adjustment) Operating Hints

TROUBLESHOOTING

DESCRIPTION

FUNCTION

CUT-SHEET BURSTER

The FD 4400 High-Volume Cut-Sheet Burster is specifi cally designed to process Check21 IRD’s and other documents printed on perforated cut sheets. This machine sets the benchmark as the only high volume cut-sheet burster capable of processing up to 30,000 forms per hour and up to one million (input) per month. A bottom-feed air system is utilized to allow operators to continually load forms to maximize effi ciency and throughput.

CONVEYOR SEQUENCE STACKER W/ PHOTOEYE

The Conveyor Sequence Stacker w/ photoeye allows continuous runs of forms without stopping the burster to unload stacker. Conveyor belts carry forms from the burster output onto a catch grill where they are partially stacked for removal.

POWER DROP STACKER

The optional Power Drop Stacker collects forms in one neat stack without need for operator intervention at outfeed end of the machine during processing of each box of forms. The power drop stacker has automatic shut-off, which can be pre-set.

SPECIFICATIONS

Processing speed:

Variable, up to 30,000/hour (11”)

Feed table capacity:

Up to 500 sheets of 20# paper

Up to 1,666,667 forms per month (input)

Paper size:

Min: 4” W x 5.5” L - Max:14” W x 20” L

Power requirements:

110 V 50/60 Hz 20 Amp dedicated line required

Dimensions:

Weight:

INSTALLATION

Do not destroy shipping cartons or materials until machine has been inspected for damage, missing parts, and proper operation.

Burster Unpack and Assembly

CAUTION: Lifting should not be attempted by less than four people.

1. Remove bands which hold cardboard box to wooden pallet. Remove cardboard box.
2. Remove burster top supports.
3. Remove (4) carriage bolts: (2) on infeed end of burster and (2) outfeed end. NOTE: Leave carriage bolts in place on center burster support.
4. Remove (4) foam blocks.
5. With allen wrench supplied, unfasten four retaining bolts which hold machine to the board immediately below it. NOTE: Center burster support is not fastened to burster.

CAUTION: two people should unpack and install pump.

1. Unpackage and mount pump to the fl oor of the base. Orient the pump so that the blower is at the rear and the vacuum is toward the front of the base. Position the pump to the right side of the base aligning it with the mounting holes in the fl oor and fans as shown in Fig. 3. Insert mounting bolts and secure.

6. Attach burster feet to burster. (Fig. 1)

7. Remove burster cabinet from its carton. Note the Location of holes on top of cabinet.

8. Set burster on cabinet, lining up holes in table with holes in burster frame. (Fig.2) NOTE: Burster will line up evenly on all sides of the table.

9. Add 1/4-20 x 1 1/2 locating screws (included), to underside of table, screwing up into burster frame.

2. Connect the blower hoses (Fig 4) and feed thru the holes located on the infeed side of the base (holes are to the left if you are looking at the operator side of the burster).

2. Attach vacuum hose to the feed table, then set table into place (Fig 6).

3. Connect the vacuum hose (Fig 4) and feed up between the infeed of the burster and feed table support braces on the infeed side of the base (holes are to the left if you are looking at the operator side of the burster).

Vacuum hose

3. Guide the metal fi ngers under the blind roller and slide the table into position (Fig 7).

Air Feed Table Installation

4. Reset the table on infeed cover and align the holes on the side of the table with the brackets mounted on the cover (Fig 8).

1. Remove four Phillips head screws from infeed cover (Fig 5) and tilt cover back.

5. Secure table into place. First, insert screws into inner holes (Fig 9); do not tighten at this time. Next, insert allen screws through table wall into rear brackets (Fig 10). Now tighten down all the screws.

Insert screws here

Feed-deck mounting screws

6. Attach the left and right blower hoses to the appropriate ends of the pile guides on the feed table (Fig 11).

OPERATION

Controls

NAME

FUNCTION

Turns burster on and off

Advances forms forward or backward at infeed and outfeed

Press to start the burster at infeed and outfeed

Press to stop the burster at infeed or outfeed

Machine Speed Control Select the speed to run the burster

Sets the length of the form to be burst

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

Select the speed of the stacker in “Normal” mode

Press to stack forms on conveyor when burster stops

Power switch for Pump/Blower

Burst Length Set-up Procedure

1. Turn on the machine. Measure burst length.

2. Press the form length switch on the burster to align the alignment mark with the burst length on burst length scale. (Remove the magnetic backed accoustical foam to access the alignment mark.) (Fig. 12).

3. By pressing jog switch in forward position, advance form through feed rollers until snap rollers grab the form.

5. 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 (turn over) and replace, making sure that the square end of bar locks into brackets. (Fig. 13, shown in HIGH position)

4. If necessary, adjust form length so that form starts to burst when perforation is just under tear points.

NOTE: Tear points can be moved to allow operator to position them at any location along tear bar. Tear points should be set between perforations that run vertically along the length of the form. (Illust. 1)

6. Adjust the outfeed conveyor stacker wheels for the appropriate form length.

Squaring Feed Table

3. Raise the sheet separator counter clockwise (ccw) so it is away from the sucker wheel (Fig 16). Place a sheet of the paper to be folded on the feed table.

Slide the sheet forward into the rollers. The sheet must contact the rollers evenly and not touch the side guides. Turn Burster and blower on and press the jog button to feed in approx. 1/2” (12.7mm) of the form into the rollers.

In order for your machine to burst properly the forms must be fed into the rollers square. The feed table is adjusted at the factory and should only require periodic checks. The unique feed table adjustment feature allows for quick and easy adjustment if needed.

4. Position the operator side guide so it is just touching the sheet but not pushing it. The side guide must be even to the sheet from end to end. Tighten the front lock knobs then the rear knobs, (Fig 14 & 15).
5. Repeat step 4 on the non operator side guide.

New Pic

Feed Table Squaring Screw

6. The paper will now feed square into the rollers.

Now that the side guides are square, the feed table squaring screw, (Fig 14), can be adjusted for fi ne tuning the overall squareness.

Table Center Mark

Vacuum Feed Sheet Separator

Scale Center Line

The sheet separator will need adjusting for the weight of paper you are bursting. 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.)

1. Adjust the feed table squaring screw and align the center line of the scale with the center mark on the feeder table (Fig 14).

Front Guide Adjusting Knobs

1. Raise the separator (ccw) (Fig. 16) to avoid marking the sucker wheel. NOTE: Do not make separator adjustments while the burster is running.
2. Loosely position the feed table side guides to the scales on the feed table, (Fig 14 & 15). Read the front scale at the inside edge of the side guide clamp block.

The rear scale will line up with the inside edge of the side guide. The scales are set up to center the paper on the sucker wheel. Initially set each guide 1/4” (6.4mm) wide. Do not tighten the lock knobs.

Separator Guide Adjusting Knob

Separator Guide Plate

2. Turn the sucker wheel until the separator tip is positioned over a solid portion of it, i.e. between the rows of holes.

3. Place a single piece of paper under the tip of the separator plate. Lower the separator clockwise (cw) until there is a slight drag on the paper as it is pulled from the separator.

1. Load a stack of paper onto the feed table. The stack should be no higher than the side guides, 2” (51mm). Position the backstop up against the lift.

2. Turn on the air/vacuum pump. The air should fl oat the bottom of the paper stack approximately 1/16 to 1/8” (1.6 to 3.2mm). Air blast can be controlled by adjusting the knobs located on the side/pile guides (Fig. 18).

4. The vacuum advance knob is located on the side of the feed table (Fig. 17). Adjusting the knob will position where the vacuum contacts the stack of paper.

Raising the knob will move the vacuum away from the lift and toward the rollers (light papers). Lowering the knob will move the vacuum contact toward the lift and away from the rollers (heavy papers).

New Pic

1. Raise the separator (ccw) to avoid marking the sucker wheel.
2. Loosen knob (Illust. 2).
3. As a starting reference, turn the hand wheel until a set of sucker wheel holes is at the 12 o’clock position.
4. Adjust separator assembly so that the plate is 1/16” forward of the 12 o’clock position, measure from the feed side of the plate.
5. Tighten knob (Illust. 2).

Air Blast Control Knobs

Air Blast Openings

Separator Guide Lock Set Screw

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

2. To restart the 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.

3. Turn the speed control to ½ or full speed. Place your thumb on the back of the stack to keep paper from feeding. Press the power button, the sucker wheel will start to turn. Reduce the pressure of your thumb to feed only 3 to 4 sheets. Press your thumb down to stop the feeding again. Press the power button to stop the sucker from turning. If the paper did not feed, adjust the position of the vacuum advance, bleeder valve, or sheet separator.

5. Stacker wheel should not stop the form until form clears snap rollers.

Bleeder Valve (Vacuum Adjustment)

There is a bleeder valve on the vacuum pump, (Fig 20), which allows for vacuum adjustment from completely off to completely on. General settings for the bleeder valve are half open for 20# stock, and closed for 80# and heavier stock. If your machine is feeding doubles, this can be opened slightly to “relieve” some of the vacuum and stop the double feeding.

TROUBLESHOOTING

Feeding, bursting, and stacking problems are usually due to improper adjustment of machine to forms or due to a non-standard or defective form.

Most problems fall into one of three categories: Electrical, Mechanical, or Form Flow. Electrical troubles are USUALLY obvious because machine will not run or respond in a normal manner to its controls.

Mechanical problems are usually accompanied by noise, slippage, tearing, or binds. If a form fl ow problem is present, jamming, mis-stacking, or intermittent form damage will occur. Problem should be diagnosed to one of three categories, before proceeding to pinpoint problem. Best approach is a logical elimination of possible malfunctions.

TROUBLE

POSSIBLE CAUSE

REMEDY

Is the power on?

Make sure the power to the burster and blower are in the on position. Check to make sure the wall outlet has power.

Is the machine plugged in?

Make sure all the plugs are plugged in properly.

Are the safety covers lowered? Make sure the safety covers for the burster are lowered.

Paper jam occurs often

Forms creep to one side

No power even with machine turned on, plugged in, wall power is on and above steps have been taken.

Is the feeder set properly?

See pages 7,8 & 9.

Is paper stuck together?

Separate paper from each other.

Using paper other than specifi ed?

Paper other than specifi ed may cause mechanical trouble.

Is inside of machine dirty?

Clean inside of machine.

Are outfeed stacker 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.

Infeed guides not set properly.

Roller tension not uniform across roller.

Check and adjust roller tension, call for service.

Burster stalls or tears forms

Tear bar in high position.

Put bar in low position, see page 6.

Burster not running fast enough.

Increase burster speed, see page 5.

Incorrect form length setting.

Reset paper length, see page 6.

Tear points not adjusted properly across face of form.

Adjust tear points, see page 6.

Adjust tear points, see page 6.

Burster rollers don’t rotate / machine runs

Slipped belt, broken drive belt, loose pulley.

Check and adjust roller tension, call for service.

Carriage not properly positioned.

Tear point not set correctly.

Adjust tear points, see page 6.

Tear bar not set correctly.

Adjust tear bar position, see page 6.

Defective switch or motor.

Broken carriage drive chain.

Loose setscrew on carriage advance shaft or on motor.

Tighten setscrew, call for service.

Obstruction at the pivot arm. Stacker wheels positioned too close or too far from outfeed.

Remove obstruction. Move rollers in or out until positioned correctly.

Stacker wheels not directly over belts.

Adjust wheels left or right so they are aligned over the belts.

Snap roller carriage will NOT move

Stacker wheels binding on axle.

Edge of form not under roller.

Stacker grill not adjusted properly.

Stacker does not run but Burster does.

Loose stacker drive gear/broken drive pin.

Faulty stacker motor speed control .