BAUM 2020 AUTOSET FOLDER W/PILE FEED SERVICE MANUAL
Contents
1. So if stacker 15 connected to parallel check 25 in the parallel junction box Also check for 24Vdc between terminal blocks 201 and 202 in parallel junction box So if the stacker is connected to the 8 Page check F29 in the 8 Page junction box Also check for 24Vdc between terminal blocks 301 and 302 in 8 Page junction box So if the stacker 15 connected to 16 Page check F33 in the 8 Page junction box Also check for 24Vdc between terminal blocks 401 and 402 in 8 Page junction box Go to the initiate screen under the maintenance and check stacker for communication seeing a green communication block if green go to 10 4 If block 15 red press the initiate button for the stacker Block should go grey then back to red Turn off Autoset power switch wait 15 seconds and turn back on When all motors turn green problem 15 fixed If all is green except the stacker go to 10 4 F Go to stacker jogger control and try to move stacker wheel location Open stacker motor controller junction box check controller for flashing LED and proper network address Check stacker communication cable for continuity between both ends of cable use schematic as reference If continuity test fails replace cable assembly If continuity test passes replace drive controller 10 5 A single fold pan not moving A B C D Go to the initiate screen under the maintenance and check fold pan for communication seeing a green2. BAUM 2020 AUTOSET FOLDER W PILE FEED SERVICE MANUAL TP10512 2006 BAUMFOLDER CORPORATION All Rights Reserved WARNING e Do not operate this machine without all guarding in place e Do not make adjustments or perform maintenance on this machine with power e Keep the machine and the work area clean and free of spills to prevent accidents e Be sure to replace any safety decals that may have been detached for any reason Baumfolder Corporation reserves the right to make changes in design or to make additions or improvements in its products without imposing any obligation upon itself to install them on its previously manufactured products It is recommended that modifications to this equipment not be made without the advice and express written consent of Baumfolder Corporation FOLDER IDENTIFICATION MODEL NO SERIAL NO SALES AGENCY INSTALLED BY DATE PHONE NO TP10512 TABLE OF CONTENTS LAUTOSET LIST OF DO NO ES AGE AUTOSET MACHINE PAGE 1 HI AUTOSET STARTUP PAGE 3 IV AUTOSET SHUTDOWN PROCEDURES PAGE 4 Vs CLEANING TOUCHSCREEN PAGE 4 Vie WARRANTY NOLE ee mes sto users PAGE 4 PARALLEL CALIBRATION scsscccccccccccccccccccsccccccccecs PAGE 4
3. 8 13 Start folder and run three sheets 8 14 Check to see if the sheets are folded square If so continue to step 8 14 if not make the proper adjustments to square the fold and repeat steps 8 10 thru 8 13 8 15 Verify the 11 X 17 15 folded exactly in half if it is jump to step 8 20 If not touch the position 8 900 display box for that pan and a pendant will popup Use the keypad or the or buttons to correct the fold You can enter a new value and touch set or touch the or to adjust the fold Run three more sheets and repeat this step until the paper 15 folded exactly in half 8 16 Press the Home button for that pan 8 17 After the pan reaches it s home position touch the Refresh Values button Refresh Values nt 8 18 Press the Set button set 8 19 Pan will now move into position 8 20 Run three more sheets and verify the signiture is folded exactly in half if so continue to step 8 21 If not repeat steps 8 15 thru 8 20 TP10512 7 of 16 Deflect All 6 21 Press the Deflect All button so that the pan will go to its deflect position NOTE FOLDER DRIVE MOTOR MUST BE OFF AT THIS TIME 8 22 Repeat steps 8 11 through 8 20 for all the pans to be calibrated 8 23 Turn off folder drive AAA salou 8 24 After everything is calibrated Press the button to return to the main screen IX AUTOSET 16 PAGE PAN CALIBRATION 9 1 Before starting the 16 page c
4. 0 Autoset NOT CHANGE Once the numbers of plates in the Parallel are set this button will disappear Verify the settings are correct before setting the number of plates in the parallel AUTOSET STARTUP PROCEDURE The Autoset software should start up automatically when the machine is turned on The Autoset power switch on the side of the main control box needs to be switched on the switch is lighted and will show green when the switch is in the on position This power switch controls the power to the Autoset motor controllers If for any reason it does not start up properly cycle power to the machine If the Autoset software still will not start up contact your local dealer for support IV AUTOSET SHUT DOWN PROCEDURE It is very important to shut down Autoset properly before turning off the machine Before powering down the machine press the ot button to start the power down procedure A pop up box will appear asking if you are sure you want to power down Press OK From this point the power down is automatic Once the screen reads it is OK to turn off your computer you can shut down the machine with the main disconnect on the side of the main control box The Autoset power switch doesn t need to be switched off The purpose of the Autoset power switch is to turn off power to the Autoset drive controllers during reconfiguring the machine so that the network connections can be broken and reattached with out turning off the
5. 7 11 Press Set button for pan to be calibrated The pan will move its calibration position This indicator will change to yellow when the plate is moving and back to green when it is in position 7 12 Start folder and run three sheets 7 13 Check to see if the sheets are folded square If so continue to step 7 14 if not make the proper adjustments to square the fold and repeat steps 7 10 thru 7 13 7 14 Verify the 11 X 17 15 folded exactly in half if it is jump to step 7 20 If not touch the position 8 900 display box for that pan and a pendant will popup Use the keypad or the or buttons to correct the fold You can enter a new value and touch set or touch the or to adjust the fold Run three more sheets and repeat this step until the paper 15 folded exactly in half 7 15 Press the button for that pan 7 16 After pan reaches it s home position touch the Refresh Values button Refresh Values biai 7 17 Press the Set button set 7 18 Pan will now move into position 7 19 Run three more sheets and verify the 11 X 17 1s folded exactly in half if so continue to step 7 20 If not repeat steps 7 14 thru 7 19 TP10512 5 of 16 Deflect All 7 20 Press the Deflect button Pereca so that the pan will go to its deflect position NOTE FOLDER DRIVE MOTOR MUST BE OFF AT THIS TIME 7 21 Repeat steps 17 10 through 17 19 for all the pans to be calibrated 7 22 T
6. VETS PAGE CALIBRA TION PAGE 6 EX 16 PAGE CALIBRATION sicarios onena eeesecen diese PAGE 8 As TROUBLESHOOTING mate dns sesteasieracsnuadecinlases PAGE 10 XI REPLACING A PAN MOTOR DRIVE PAGE 12 INITIALIZING NEW DRIVE BOARD ccceeececcccees PAGE 13 ATT REPLACING A PAN 14 10512 I AUTOSET A LIST OF DO NOTS 1 1 Never initiate Autoset while fold rolls are running If any of the pans move in or out of deflect the pan deflectors will scrape across the fold roll damage to the fold roll or pan deflector could occur 1 2 Never plug in or unplug Autoset communication cables without turning off Autoset power switch This includes the pan and stacker cables Damage to the motor controllers could occur 1 3 Never initiate Autoset after a power up all pans and stacker must be homed first Damage could occur to the drive train of the pans or the stacker belt could be disconnected or damaged 1 4 Never put fingers into fold pans with Autoset powered up Injury to fingers will occur if pinched in fold pan movement 1 5 Never continually press a series of screen buttons when Autoset is in process of moving fold pans let Autoset complete each task before initiating another Autoset move Pans will most l
7. Autoset computer TP10512 3 of 16 V CLEANING TOUCH SCREEN COMPUTER It is very important to shut down the Autoset computer before cleaning the computer screen Use CRT screen cleaner ONLY on the interface touch screen VI AUTOSET COMPUTER WARRANTY NOTE WARNING Damage to the computer screen will occur if any instrument other than operator s finger is used to navigate the Autoset screens NOTE Warranty on the computer will be void if this is found to be the case for computer failure AUTOSET PARALLEL PAN CALIBRATION 7 1 Get folder ready to run paper Set a single sheet under each gap set 7 2 Select a half fold and the paper must be 11 X 17 Resource Maintenance 7 3 Go to main page and press Maintenance button 7 4 This will bring up the Maintenance screen From Maintenance page press Machine Setup button eal 1 ex 7 6 This will bring up the Machine Setup page From this page press the Calibration Page button TP10512 4 of 16 Deflect All 7 7 Then press the Deflect All button NOTE FOLDER DRIVE MOTOR MUST BE OFF AT THIS TIME 7 8 Set folder speed to 6 on the dial 7 9 Set folder mode to single sheet mode by pressing the single sheet mode button Ba on the folder control panel 7 10 Press Home button for pan to be calibrated The pan will move to the home position CRE Saas
8. be two set screws per hole Replace motor TP10512 11 of 16 10 7 A single motor moves fast and will not go into position A Check Encoder connection to drive in pan or stacker junction box If connection is not seated properly reseat If problem persists replace motor 10 8 A single motor moves home but computer fails to show finished A Open pan junction box and press home switch does D6 light up on board If yes go to B If not go to C B Power down Autoset and move pan by hand home Switch must close before pan stops at home position If not reposition switch Check continuity through the cable Replace if it fails continuity test D Activate switch check continuity through switch if it fails continuity test replace switch XI REPLACING A PAN MOTOR DRIVE BOARD 11 1 To replace a fold plate motor drive first make sure the power 15 off to the machine 11 2 Remove the cover from the fold plate electrical box on the plate 11 3 Then disconnect the 4 connectors 5 1 making note of there location and orientation 11 4 Then Remove the 2 screws 5 2 holding the drive board Remove the board from the fold plate electrical box Fig 5 11 5 Remove the connector with the jumpers and plug it onto the new driver board in the same location and orientation 11 6 Set the address on the selector switch 5 3 of the new board to the same address as the old board See table 1 for a list of all the addresses TP10512 12 of 1
9. must be reinstalled with blue LOCTITE 2 set screws per hole in gear hub 13 12 Mount motor guard reconnect motor wire connectors and reinstall covers TP10512 15 of 16 Baumfolder has authorized dealers located through out the United States Call toll free 1 800 543 6107 for parts or the number of your nearest authorized dealer BAUMFOLDER CORPORATION Quality Bindery Equipment Since 1917 1660 Campbell Road Sidney Ohio 45365 0728 Phone 937 492 1281 or 800 543 6107 Fax 800 452 0947 Internet www baumfolder com E mail baumfolder baumfolder com TP10512 16 of 16
10. step 9 21 If not touch the position 8 900 display box for that pan and a pendant will popup Use the keypad or the or buttons to correct the fold You can enter a new value and touch set or touch the or to adjust the fold Run three more sheets and repeat this step until the paper is folded exactly in half 9 16 Press the Home button for that pan 9 17 After the pan reaches it s home position touch the Refresh Values button Refresh Values ue 9 18 Press the Set button set 9 19 Pan will now move into position 9 20 Run three more sheets and verify the signiture is folded exactly in half if so continue to step 9 21 If not repeat steps 9 15 thru 9 20 TP10512 9 of 16 Deflect All 9 21 Press the Deflect All button so that the pan will go to its deflect position NOTE FOLDER DRIVE MOTOR MUST BE OFF AT THIS TIME 9 22 Repeat steps 9 11 through 9 20 for all the pans to be calibrated 9 23 Turn off folder drive 9 24 After everything is calibrated Press the Home button to return to the main screen AAA AUTOSET TROUBLESHOOTING GUIDE 10 1 Autoset computer screen not coming up A B C D Check power to machine Check main power switch Check F8 circuit breaker Check power switch on the computer Check voltage on the bottom of fuse block F20 amp F21 Check fuses F20 amp F21 Check power connector at the co
11. 4 Initiate Initiate _ Initiate Parallel Plate 5 8 Page Plate 5 stacker Bl Initiate i Initiate Initiate Parallel Plate 6 8 Plate 6 El Initiate Initiate BACK Fig 6 12 7 Then turn off the plate motor power switch located on the side of the folder electrical box under the main power switch 12 8 Wait 15 seconds then turn the switch back on 12 9 This will complete the initiation of the motor drive Press the Home button to return to the main screen REPLACING A PAN MOTOR 13 1 To replace fold plate motor first make sure the power 15 off to the machine 13 2 Unplug the Communication cable TP10512 14 of 16 13 3 Remove the cover from the fold plate electrical box 13 4 Unplug the 2 connectors 7 2 going from the motor to the drive board 13 5 Remove the 4 screws 7 1 that connect the fold plate electrical box to the casting Fig 7 13 6 Slide the fold plate electrical box 7 3 off of the motor 13 7 Remove the 4 set screws from the motor gear hub so it can be removed from the motor shaft Note 2 set screws per hole 13 8 Remove gear 8 1 from motor shaft 13 9 Remove the 2 mounting screws 8 2 holding the motor and remove the motor 13 10 Install the new motor motor orientation must be the same as the removed motor see figure 8 Fig 8 13 11 Insert gear 8 1 onto motor shaft align gears and set screw must sit on flat of motor shaft Note set screws
12. 6 11 7 Place the new drive into the fold plate electrical box and plug the three connectors 1 onto the new board in the same location and orientation as on the old board 11 8 Replace the cover and power up the Autoset Once the computer has restarted press cancel on the HOME ALL pop up 11 9 To finish the board replacement go thru the initiation procedure on the next page 11 10 Table 1 Address list PARALLEL UNIT 8 PAGE 16 PAGE STACKER Pan 1 1 1 5 1 9 D Pan 2 2 2 6 Pan 2 A Pan 3 3 Pan 3 7 Pan 3 B Pan 4 4 4 8 Pan 4 XII INITIALIZING NEW DRIVE BOARD Resource L Maintenance 12 1 Go to main page and press Maintenance button I 12 2 This will bring up the Maintenance screen From the Maintenance page press Machine Setup button 12 4 This will bring up the Machine Setup page From this page press the Initialization Page button 12 5 Press the Initiate button corresponding to the motor you need to initiate TP10512 13 of 16 12 6 The indicator box next to button will turn gray then after a few seconds turn red again Parallel Plate 1 8 Page Plate 1 16 Page Plate 1 _ Initiate E Initiate _ Initiate Parallel Plate 2 8 Page Plate 2 16 Page Plate 2 E Initiate El Initiate E Initiate Parallel Plate 3 8 Page Plate 3 16 Page Plate 3 _ Initiate Initiate _ Initiate Parallel Plate 4 8 Page Plate 4 16 Page Plate
13. alibration a 16 page fold must be set in Autoset 9 2 Get folder ready to run paper Set a single sheet under each gap set in the parallel and 2 sheets under each gapset in the 8 page and 4 sheets under each gapset in the 16 page 93 17 X 22 paper must be loaded on feed table Resource Maintenance 9 4 Go to main page and press Maintenance button I 9 5 This will bring up the Maintenance screen From Maintenance page press the Machine Setup button 9 7 This will bring up the Machine Setup page From this page press the Calibration Page button TP10512 8 of 16 Deflect All 9 8 Then press the Deflect All button NOTE FOLDER DRIVE MOTOR MUST BE OFF AT THIS TIME 9 9 Set folder speed to 6 on the dial 9 10 Set folder mode to single sheet mode by pressing the single sheet mode button Ba on the folder control panel 9 11 Press Home button for pan to be calibrated The pan will move to the home position ao 5 9 12 Press Set button for pan to be calibrated The pan will move its calibration position This indicator will change to yellow when the plate is moving and back to green when it is in position 9 13 Start folder and run three sheets 9 14 Check to see if the sheets are folded square If so continue to step 9 15 if not make the proper adjustments to square the fold and repeat steps 9 11 thru 9 12 9 15 Verify the 17 X 22 is folded exactly in half if it is jump to
14. communication block if green go to 10 5 If block 15 red press the initiate button for that pan Block should go grey then back to red Turn off Autoset power switch wait 15 seconds and turn back on When all motors turn green problem 15 fixed If all is green except the problem pan go to 10 5 C Go to pan jogger control and try to move pan location Open pan motor controller junction box check controller for flashing LED and proper network address Check pan communication cable by swapping communication cable between pans Power down Autoset power Swap communication cables Power Autoset back up If Problem is in the same fold pan replace drive controller If problem follows the cable run a continuity test on cable If cable fails the continuity test replace cable assembly If cable passes continuity test check all wiring connections of that cable 10 6 A single pan not moving but drive controller has drive communication shown by green block on initiation screen A B C D Turn off Autoset power Can pan be moved freely by hand If not look for mechanical bind in pan With Autoset power on test motor voltage when trying to move open motor junction box measure the voltage between the red and black conductors from the motor Approximately 6 Vdc will be seen when motor is moving and approximately 1 Vdc is applied when holding position Check to make sure that motor shaft is not rotating in gear Check set screws should
15. ikely be out of position and will not know where they are at Please home all pans if this occurs 1 6 Never use any other instrument than the operator s finger to navigate the Autoset screens See warranty note on page 4 II Autoset machine configuration instructions For service technicians use only Resource Maintenance Manuals 2 1 You can get back into the Machine Configuration screen at anytime by going to the main page then touching the Maintenance button Troubleshoot Fig 1 2 2 in the Maintenance screen touch the Machine Set up button Fig 2 ee 2 3 This will bring up a keypad asking you to enter the password Enter the password 4921281 then touch the enter button TP10512 1 of 16 Fig 4 4 1 4 2 4 3 4 4 4 5 How wide ist Factory use only DO NOT TOUCH THIS BUTTON This button will shut down the Autoset program but not the computer This should only be used when updating the program DO NOT TOUCH THIS BUTTON This button is for factory use only Press this button to tell Autoset if you have the optional Presser Stacker It will toggle between yes and no each time it is touched Press this button once you have completed all the configuration settings this button take you back to the main page Press this button to tell Autoset if you are using the single tier stacker It will toggle between yes and no each time it is touched This is very important if this
16. is a 20 Autoset NOTE The only time this should be set to YES is when the machine 15 a 20 Autoset with the standard Autoset single tier stacker TP10512 2 of 16 4 6 This Button will only appear if the machine type is 0 or 4 It should be set from the factory to the width of your machine It will toggle between 20 26 and 30 each time it is touched Once the number of plates in the Parallel are set this button will disappear Verify the settings are correct before setting the number of plates in the parallel 4 7 Press this button to tell Autoset if you want to display the optional exit sensor count in place of the standard infeed count It will toggle between yes and no each time it is touched 4 8 Press this box to tell Autoset if you have the optional Gatefold plate It will toggle between yes and no each time it is touched 4 9 Press this button to tell how many plates you have in the unit It will increment thru 0 2 3 4 6 each time you touch this box If you do not have a 16page unit leave it set to O 4 10 Press this button to tell Autoset how many plates you have in 8page unit It will increment thru 0 2 3 4 6 each time you touch this box If you do not have an 8page unit leave it set to 0 4 11 Press this box to tell Autoset how many plates you have in the parallel unit It will increment thru 0 2 3 4 6 each time you touch this box 4 12 Machine Type this button should be set from the factory
17. mputer 10 2 Autoset not working whole machine A B Check Autoset power switch Check 10 1 items A thru F 10 3 Autoset not working one of the machine sections A B C D Check machine configuration and fold setting to assure that connected configuration is what is being called for by Autoset Check power supply for that section for the power indication light Is it on If on go to 10 3 C If off go to 10 3 D If power supply indicator light is on check F24 in parallel junction box F28 in the 8 Page junction box F32 in the 16 Page junction box If power supply indicator light is off check F22 amp F23 in parallel junction box F26 amp F27 in the 8 Page junction box F30 amp F31 in 16 Page Junction box If fuses are good and 220 Vac is measured at the input of the power supply replace the power supply Is there 24Vdc between terminal blocks 203 and 202 in the parallel junction box 303 and 302 in the 8 Page junction box 403 and 402 in the 16 page box Check network fuse in the previous section So if problem is in the 8 Page or stacker connected to the 8 Page check F25 in the parallel junction box Also check for 24Vdc between terminal blocks 201 and 202 in parallel junction box Check Autoset wiring of junction box compared to schematic TP10512 10 of 16 10 4 Autoset stacker not working Check network fuse in the junction box the stacker 15 plugged into A B C D
18. urn off folder drive AAA A Aann 7 23 After everything is calibrated Press the Home button to return to the main screen AUTOSET 8 PAGE PAN CALIBRATION 8 1 Before starting the 8 page calibration a 8 page fold must be set in Autoset 6 2 Get folder ready to run paper Set a single sheet under each gap set in the parallel and 2 sheets under each gapset in the 8 page 6 3 11 X 17 paper must be loaded on feed table Resource Maintenance 8 4 Go to main page and press Maintenance button I 8 5 This will bring up the Maintenance screen From the Maintenance page press the Machine Setup button Machine Set up 8 6 This will bring up a keypad to enter the password Enter 4921281 then press Enter 8 7 This will bring up the Machine Setup page From this page press the Calibration Page button TP10512 6 of 16 Deflect All 8 8 Then press the Deflect All button NOTE FOLDER DRIVE MOTOR MUST BE OFF AT THIS TIME 8 9 Set folder speed to 6 on the dial 8 10 Set folder mode to single sheet mode by pressing the single sheet mode button Ba on the folder control panel 8 11 Press Home button for pan to be calibrated The pan will move to the home position CRE 8 12 Press Set button for pan to be calibrated The pan will move its calibration position This indicator will change to yellow when the plate 15 moving and back to green when it is position
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