estefold 2400/2402
Contents
1. W Light barrier 3 cut 4 Light barrier 4 cut permanent light on the receiver receiver from LB 0 is always on high level receiver from LB 1 is always on high level receiver from LB 2 is always on high level receiver from LB 3 is always on high level receiver from LB 4 is always on high level 1 Direct reflection from sender to receiver dust on sender receiver or prism Port on PCB damaged N 09 X processing error for stepper control board error during calculate the step width e mostly electrostatic 2 error during counting the steps developer tool Hardware error 2 2O22 O OO lack of 5 Volt external e Check fuses and connectors lack of LF 38 Volt or CF door open e fan folder top cover open 03 e _ cross folder door open 26 am PO after cut no signal for ready e Jam on the printer s knife after cut no paper on LB 1 e Jam on the bridge NO Eas W _ a T o 5 without cut signal no paper on LB 1 e Jamon the bridge Jamonthebridge 05 notpaperendonIB1 e Jaminthefanfolder _ 06 toomanyfols copytoolons 07 noendofpaperoniBO e Jamatoutput fan folder Unexpected Paper on LB4 in Online Mode Unexpected Paper on no fold switch LB5 in Online Mode oOo an wrong direction at last sheet folding e defective LB e Switch to offline mode Page 18 of 19 Change Log 02 07 2007 e Error code list2. error during start stepper control board error during stop stepper control board pt tt te tT f Light barrier O cut Light barrier 1 cut Light barrier 2 cut Light barrier 3 cut Light barrier 4 cut Ol 02 03 04 _ Page 11 of 19 User Manual estefold 2400 2402 There are 8 folding programs available By pressing the keys and you select a folding program of your own choice On the left hand side of the display the selected program number will appear The centre of the display shows an image of a folded package Multicolor Number of oe folding program Cross fold size Folding Style Width of Filing Margin Status online offline or manual Panel Width Folding programs Factory programmed folding programs Prog 1 He The package can be applied with a tab adhesive as shown in program 3 by a separate automatic Tab Applicator Ask your system provider Page 12 of 19 User Manual estefold 2400 2402 Editing folding programs Select Folding Style In order to change the folding style press the cursor will start to blink Buttons and move the cursor from icon to icon Selected icons blink frequently Pressing buttons and edit the blinking settings Example Program 5 should process another folding style Select folding program 5 with button or Press button Press button until the symbol of the fold package blinks Press buttons or in order to set the f
3. the distributor who has been notified first must immediately take emergency measures to provide relief to affected persons and to prevent further damage If a report of a serious accident has been received from a cus tomer an on site evaluation must be carried out quickly and ES TE must be notified To determine the cause of the accident conditions and materials must be recorded through direct on site checks in accordance with instructions issued by ES TE For reports and measures concerning serious accidents follow the regulations specified by every distributor Page 6 of 19 User Manual estefold 2400 2402 Estefold 2400 2402 is an automatic folder that folds large sized plots created by any monochrome printer according to DIN 824 One of the 8 folding programs available can be selected by pressing a button on the folder s keyboard Details of the selected program are displayed on a large LCD display that allows the folder s easy operation Documents will be folded lengthwise according to the selected folding program The specially designed bridge takes the plot from the printer and transports it to the folder Documents that are not supposed to be folded will be deployed in the unfolded print bag In order to control the folding process the documents pass the automatic bridge to the folder s inlet A switcher at the bridge s entrance selects the plots that are not supposed to be folded and directs them into the unfolded
4. total load must not exceed the rating of the wall outlet If excessive current flows in the wall outlet fire may result Make sure the power cord is plugged in the wall outlet securely Contact problems may lead to increased resistance overheating and the risk of fire Check whether the product is grounded properly If current leakage occurs in an ungrounded product you may suf fer electric shock while operating the product Connect power plug to grounded wall outlet Warning When using the power cord set inlet type that came with this product make sure the connector is securely inserted in the inlet of the product When securing measure is provided secure the cord with the fix ture properly lf the power cord inlet type is not connected to the product se curely a contact problem may lead to increased resistance overheating and risk of fire Check whether the power cord is not stepped on or pinched by a table and so on Overheating may occur there leading to a risk of fire Check whether the power cord is damaged Check whether the sheath is damaged If the power plug cord or sheath is dam Warning aged replace with a new power cord with plug and connector on each end specified by ES TE Using the damaged power cord may result in fire or electric shock Do not bundle or tie the power cord Overheating may occur there leading to a risk of fire Check whether dust is collected around the power
5. 1 7 P Legarth o Page 14 e Safety and warning o Page 3 e Integration cross fold o 6 PagelO e Editorial changes 17 07 2007 e Editorial changes P Legarth P Legarth o Page 14 P Legarth e Cross fold face up instead face down P Legarth o Page 14 06 10 2008 e 2402 P Legarth e Book folding implemented Page 19 of 19
6. ES TE Folding Systems GmbH Zitadellenweg 34 13599 Berlin S te Berlin Telefon 030 369961 3 Fax 030 369961 59 eMail info es te de Internet www es te com Automatic inline folder estefold 2400 2402 Purpose Folding of Documents User Manual Safety Installation Operation Trouble shooting Page 1 of 19 Edition 1 7 06 10 2008 User Manual estefold 2400 2402 Contents Salely and important Warming WOM Sirine ikoe teeta eaves alee N a a arose 3 SISTA oa r EN A N 7 What is the difference between 2400 and 2402 ceccccccsssseccccccenseeccccaeusecececseueececseseueeeeessaauseeesssaaeseessaageeees 7 DIMENSIONS ae et oat a eaters e NE seta ceeseacuavet eae eae ee 8 Seting UP The Folderin ersatz end en dared rele eee a a 9 WOKO WITHINe TOJE seca cura cnesociateecs N naeeroreeaeaee eee A 10 Bal 0 6 0 gt ee eeret preter er err ere en or Reet a eR GRE A nD eo Re E orem ee eee Re eeer 11 Selecting Folding Prodr amS jcc sy ax fe esscsateg pees N EE E E a 12 FOAN PrOJgraNS ienn a a a ties teiueaaeuene tasie 12 Edin TOIGIIG PrO aS nran e a E N NNN 13 Sae WC elses esac a E E E N G r 14 ULE 19 od ax OMAS anaa A N a r A N N E 14 PAU MYG documen S en a N a a ue ebnanave a etealarmuavati es aaoea aca eevee ae 14 Manual T6COiInG faim Oldies ieee E dis Cekecia peea vec epaavada teas NA 15 Wantal feCGiniG sGhOSS TONG savaciicceteicrsaaveee sive a tele ediand ed te vecuduaaveei en eure vunkaterean vaca anit esaecauane
7. con to icon Selected icons blink frequently Select the number below the cross fold symbol Pressing buttons and edit the blinking settings Press buttonwithin three seconds The LED on top of the display shining red and a blinking icon for the fan folded document indicates an error either on the bridge or in the fan folder After pressing button once the display shows an error code indi cating type and location of the error The most probable cause for a cut light barrier is that there is still a whole or a part of a document on the bridge In order to remove the document on the bridge you lift the bridge cover by gripping it at the edge Page 15 of 19 As soon as you have lifted the cover you may lock it in the raised position by extending the suspending link b n You can now inspect the bridges inside and remove Suspending Link ka A any paper leftovers M As soon as the leftovers have been removed the cover needs to be closed Press button once in order to commence your job You may have to call for a service engineer in case paper was not the cause to the error Resolving a Paper Jam in the Fan Folder The LED on top of the display shining red and a blinking icon for the fan folded document indicates an error either on the bridge or in the fan folder After Lift Top Cover pressing button once the display shows an error Here code indicating type and location of the error The most probable ca
8. eses 15 Resolving a Paper dam Onm ine Bridges secs a Ae eee sae ee et 15 Resolving a Paperdany in thes Fan FOC xsicterscsvaecsovatetocsersiaieiod a donss secretes seca eal 16 POSIUION Ol Ue Honba S savecaccestareess Reeves N 17 Error Gode MIS tsacrie excess concoct E N aes eee 18 greg 6 e Lorensen cere ee rc eR NNI N ee eat eee ee ee 19 Page 2 of 19 User Manual estefold 2400 2402 Safety and important warning items Read carefully the safety and important warning items described below to understand them before doing work Because of possible hazards to an inexperienced person servicing this product as well as the risk of damage to the product ES TE Folding Systems hereafter called ES TE strongly recommends that all servicing be performed only by ES TE trained service engineer Changes may have been made to this product to improve its performance after this Service Manual was printed Accordingly ES TE does not warrant either explicitly or implicitly that the information contained in this manual is complete and accurate The user of this manual must assume all risks of personal injury and or damage to the product while operating the product for which this manual is intended Therefore this manual must be carefully read before doing work both in the course of technical training and even after that for performing control of the product properly Keep this manual always near to the folder DANGER Indicates an imminently hazardo
9. necting cable only The power supply box is at the right bottom side of the folder Please use either the connecting cable delivered with the folder or cables of the same safety standard only The folder is pre adjusted to 230 Volts 50 cycles Make sure that the main supply voltage is identical with your supply Do not use a multi outlet power strip These cords will not stand the power consumption of plotter and folder Page 9 of 19 User Manual estefold 2400 2402 Working with the folder Switch the folder on The display must show a short message as indicated For a short time the Firmware versions are shown in the display First window The versions of the several components are shown Second window The version of the Web Controller is shown Multi color led Indicates the status of the folder Red error Green ready Yellow in operation Page 10 of 19 User Manual estefold 2400 2402 Error Code In case of any error during startup or operation the folder will give a beep signal and an error message in the dis play The remaining paper will be trans ported out with low speed automatically or by pressing f or To get a clear message refer to the Error Code List at the end of the user manual The example shows the error code 22 OO this indicates that the light barrier O is cut Find the light barrier positions at page 17 a a Fan folder error Error on stepper control board
10. olding style Press button within three seconds Calculated Package folding Calculated Package folding With binding margin Uncalculated Package folding Calculated Book folding 2402 First page of panel ee Calculated Book folding First page 1 2 of panel With binding margin Uncalculated Book folding First page 1 2 of panel Page 13 of 19 User Manual estefold 2400 2402 Select Size All folding programs can be edited in increments of 1 mm within the following range e Filing margin 0 30 mm e panel width 180 450 mm In Order to change values press the cursor will start to blink Buttons and move the cursor from icon to icon Selected icons blink frequently Pressing buttons and edit the blinking settings Example Program 5 should process packages 185 mm wide with a filing margin of 25 mm Select folding program 5 with button or Press button Press button until the number below the fold package icon blinks Press buttons or in order to set the package width to 185 mm Move the cursor forward to the figure representing the margin width With buttons or select 25 mm Press button within three seconds Please notice that the adjustable width of the package must be at least 180 mm up to a maximum of 450 mm The range of adjustment of the margin is 0 30 mm Therefore a package of 165 35 is not adjustable Suitable Media e Film or materials with gloss
11. or the product s rated voltage and cur rent and gt the plug has pin terminal s for grounding and gt meets regulatory requirements for the area Use of inadequate cord set leads to the product connecting to inadequate power supply voltage current capacity grounding and may result in fire or electric shock Page 4 of 19 User Manual estefold 2400 2402 Checkpoints when performing On Site Service ES TE products are extensively tested before shipping to ensure that all applicable safety standards are met in order to protect the customer and customer engineer hereafter called the CE from the risk of injury How ever in daily use any electrical equipment may be subject to parts wear and eventual failure In order to maintain safety and reliability the CE must perform regular safety checks Connection to Power Suppl Connect power plug directly into wall outlet having same configu ration as the plug Use of an adapter leads to the product connecting to inadequate power supply voltage current capacity grounding and may re sult in fire or electric shock If proper wall outlet is not available advice the customer to con tact qualified electrician for the installation Plug the power cord into the dedicated wall outlet with a capacity greater than the maximum power consumption If excessive current flows in the wall outlet fire may result If two or more power cords can be plugged into the wall outlet the
12. plug and wall outlet Using the power plug and wall outlet without removing dust may result in fire Do not insert the power plug into the wall outlet with a wet hand Page 5 of 19 User Manual estefold 2400 2402 The risk of electric shock exists When unplugging the power cord grasp the plug not the cable The cable may be broken leading to a risk of fire and electric shock Never use multi plug adapters to plug multiple power cords in the same outlet If used the risk of fire exists When an extension cord is required use a specified one Current that can flow in the extension cord is limited sousing a too long extension cord may result in fire Do not use an extension cable reel with the cable taken up Fire Warning may result Prohibited Installation Places Do not place the product near flammable materials or volatile materials that may catch fire A risk of fire exists Do not place the product in a place exposed to water such as rain A risk of fire and electric shock exists When not Using the Product for a long time e When the product is not used over an extended period of time Warning holidays etc switch it off and unplug the power cord Dust col lected around the power plug and outlet may cause fire Warning Be sure to set the adjustable feet on the ground In the case of an earthquake and so on the product may slide leading to an injury If an accident has occurred
13. print bag When the plot enters the bridge it will be transported to the folder s entrance with the exact synchronized speed A sliding rail on the bridge allows documents to be fed manually A very useful feature demonstrating the various purposes this folder can serve The two gas pressure shock absorbers are supporting the bridge helping to tilt it into an almost vertical posi tion In consequence of that general access to the printer is assured What is the difference between 2400 and 2402 The only difference between these folders is the position of Light Barrier 0 It enables the 2402 to cover the Book Folding Style Ly 1 page panel Changing a 2400 to a 2402 is easy Please contact the ES TE Support Team for more information Page 7 of 19 User Manual estefold 2400 2402 Dimensions transport dimension 600 365 270 free access min 600 free access l 1015 free access Page 8 of 19 User Manual estefold 2400 2402 The room in which the folder is to be placed should be dry and dust free Humidity 20 80 R H not condensing Room temperature 15 C to 35 C The folder must stand horizontally aligned and very stable without shaking Always ascertain to place the folder in a way that does not block exits and allows an ergonomic workflow The set up of the folder should be done by a trained engineer in order to assure a 100 functionality of the folder Power Supply Use delivered con
14. solder or similar object Disabling safety functions interlocks safety circuits etc Safety will not be assured leading to a risk of fire and injury Making any modification to the product unless instructed by ES TE Using parts not specified by ES TE In some countries or areas the power plug provided with the product may not fit wall outlet used in the area In that case it is obligation of customer engineer hereafter called the CE to at tach appropriate power plug or power cord set in order to con nect the product to the supply Caution Only plug the folder to power circuits which are secured with max 16A for Europe and max 20A for North America Furthermore it is recommended to install an all pole disconnect device National installation standards have to be maintained Power Cord Set or Power Plug Le e Use power supply cord set which meets the following criteria gt provided with a plug having configuration intended for the connection to wall outlet appropriate for the product s rated voltage and current and the plug has pin terminal s for grounding and provided with three conductor cable having enough current capac ity and gt the cord set meets regulatory requirements for the area gt Use of inadequate cord set leads to fire or electric shock e Attach power plug which meets the following criteria Warning gt having configuration intended for the connection to wall outlet appropriate f
15. us situation which if not avoided WILL result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury ES TE products are renowned for their high reliability This reliability is achieved through high quality design and a solid service network Product design is a highly complicated and delicate process where nu merous mechanical physical and electrical aspects have to be taken into consideration with the aim of arriving at proper tolerances and safety factors For this reason unauthorized modifications involve a high risk of degra dation in performance and safety Such modifications are therefore strictly prohibited The points listed below are not exhaustive but they illustrate the reasoning behind this policy Move the folder only if the table is down in the transport position without the gas spring Move the machine carefully and slow with at least two persons Any unevenness of the ground can lead to the risk of tipping over Page 3 of 19 User Manual estefold 2400 2402 Using any cables or power cord not specified by ES TE Using any fuse or thermostat not specified by ES TE Safety will not be assured leading to a risk of fire and injury Disabling fuse functions or bridging fuse terminals with wire metal clips
16. use for a cut light barrier is that there is still a whole or a part of a document in the fan folder In order to remove the document in the fan folder you have to lift the fan folder top cover Rotate this roller manually in order to remove jammed Safety Switch Fan Folder The folder will be powered off as a safety switch on the documents top cover cuts power at the same instance As soon as you have lifted the cover you will see the fan folder s inside Retrieve documents stuck between the fold rollers by simply turning the fold rollers manually The paper pieces will appear either at the folder s top or its rear depending on the direction you are rotating the fold rollers Page 16 of 19 Position of the Lightbarriers Close the top cover as soon as the leftovers have been removed Press button once in order to commence your job You may have to call for a service engineer in case either paper was not the cause to the error or you were not able to retrieve all of the paper Page 17 of 19 Error Code List Code Fan folder error cause e 38V lost on board green led on Error on stepper control board bd error during start stepper control board stepper control board is off e internal logic error 8 N il error during stop stepper control board Light barrier O cut bd Light barrier cut e Paper between LB and prism e cable broken e Light barrier defective Light barrier 2 cut
17. y shiny surfaces are not suitable e For application of media types please contact the service engineer e The paperweight should not be less than 60 g m and not more than 110 g m Fan folding up to 50m two panels unfolded after Suitable Formats 5m cross folding up to 1 50m Longitudinal folding All documents with length from 420 mm up to 50 000 mm 80 gr m Paper and width up to max 930 mm Aligning documents In any case the title block legend has to be on the leading edge of the document entering the folder on the right hand side of the leading edge The title block position has to be set in the plot software you are using Page 14 of 19 User Manual estefold 2400 2402 Manual feeding fan fold You may also insert documents into the folder manu ally For some systems you need switching the folder offline on the printers display first Switch icon L H to manual mode 4 by pressing button twice Insert the sheet face down title block must be in front aligning centrically The insertion rail on the table can be slid into an optimized position for the document you are feeding Please take care to feed the paper as straight as possible Insert the sheet face up title block must be in front Please take care to feed the paper as straight as possible Change the cross fold size In Order to change the cross fold size press 4 the cursor will start to blink Buttons and move the cursor from i
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