Foldnak Compact User Manual ENGLISH
Contents Safety precautions .............................................................................................................. 4 1 Proper use .................................................................................................................. 5 1.1 Description and specifications ............................................................................ 5 1.2 Functional description.........................................................................................
© Ernst Nagel GmbH 9965201 User Manual Fk Compact Rev 1.4 21.6.2010 S.
Safety precautions 1. Please read this manual carefully and completely before operating the machine. 2. Please make sure the mains voltage is suitable and the outlet has a proper earth connection. 3. Repairs must be carried out by trained Nagel vendors and service technicians. 4. If the machine must be repaired, separate it from the mains by pulling the plug. 5. Caution! The Trimmer contains a very sharp knife. Be careful when removing paper jams! 6. Use original Nagel consumables and spare parts only. 7.
1 Proper use Foldnak Proper use of the Foldnak consists in the stapling and folding of paper within the limits defined in the specifications. Trimmer Proper use of the Trimmer consists in the cutting of paper within the limits defined in the specifications. 1.1 Description and specifications Foldnak The Foldnak is used to produce booklets. The paper to be processed is fed into the machine in sets, either manually or by a collator. Please observe the physical limits when processing heavy paper.
1.2 Functional description 4 2 1 6 3 5 fig 001 1. Switch panel with main switch 2. Delivery conveyor 3. Knob • for adjusting the Foldnak and the Trimmer to the paper format and for operating the motors by hand in service mode 4. Hood • The machine can only be operated with the hood closed. 5. Drawer • The machine can only be operated with the drawer closed. 6. Handwheel • for adjusting and triggering the back jogging stroke © Ernst Nagel GmbH 9965201 User Manual Fk Compact Rev 1.4 21.6.2010 S.
2 Installation • Remove the cardboard and packaging film • Lift the machine from the pallet and set it down on a solid, level surface. • Place the machine on adjusting feet, if necessary. 2.1 Delivery conveyor See the enclosed installation instructions for information on how to mount the delivery conveyor. The shaft and the two wheels (10) are part of the accessories.
3 Preparation 3.1 Stapling heads / Stapling head distance Foldnak stapling-folding machines come with two stapling heads. They can be operated with up to four stapling heads. The possible stapling head positions are: Type Foldnak C Distances in mm 30 x 50 x 80 x 50 x 30 The stapling heads can be mounted in any of these positions. Pull back the feeder shoe (26) and loosen the black plastic knurled screws (24).
3.2 Staples Foldnak stapling-folding machines use the following Nagel staples: • 26/6 26 = Wire gauge 6 = Shank length in mm for 2 up to ca. 20 sheets • 26/8 S 26 = Wire gauge 8 = Shank length in mm S = Steel wire for 15 up to ca. 40 sheets • Ri 26/6 Ri = Ring staples 26 = Wire gauge 6 = Shank length in mm for 2 up to ca. 20 sheets Use only original Nagel staples. They are precision-made and therefore guarantee troublefree and accurate functioning.
4 Operation 4.1 Control Panel 38 37 36 35 34 33 32 31 30 1234 fig005 30. Start • Press once to start the infeed belt. • Press while the infeed belt is running to trigger a stapling stroke. 31.
33 Error LED • Green if everything is OK. • Red in case of error. 34 Reset button • Acknowledgement of errors. • Keep pressed for a few seconds to reset the reset counter to zero. 35 Service switch • Position I is normal mode. • Position II allows motors to be turned manually. 36 Bypass switch • Switches off the trim function. The booklets run through the trimmer without being trimmed. 37 Potentiometer for the trimmer delivery belt • Adjustment see below.
4.2 Magazine control The Foldnak is fitted with a magazine control. If there are no more staples in the staple magazine, the machine does not trigger a stapling stroke. This condition is indicated by the red illumination of the error LED (33) on the control panel if the contact cable (fig003, 19) has been fitted. 4.3 Mis-stapling control The Foldnak is equipped with a mis-stapling control.
5.1.1 Adjusting the side stops Begin by adjusting the left side stop with the assistance of the scale (38) on the table. To do so, loosen the knurled screw (39) and move the stop to the side. Tighten the knurled screw after the adjustment. Then adjust the right side stop. 5.1.2 Adjusting the right side stop Insert a sheet of the paper to be processed, loosen the knurled screw (41) and move the right stop flush against the sheet. From there, move the stop ca.
5.1.3 Adjusting the rear stop The rear stop (fig008, 44) is adjusted using the knob (fig001, 3) on the left side of the machine. Insert a sheet of the paper to be processed. Turn the knob until the upper edge of the paper aligns with the format mark (for DIN formats), which corresponds to the paper format on the scale of the feed table. The adjustment of the rear stop must be checked in a stapling test. © Ernst Nagel GmbH 9965201 User Manual Fk Compact Rev 1.4 21.6.2010 S.
5.1.4 Adjusting the trigger mechanism The adjustment is made while the machine is switched off. The Foldnak has an adjustable photo cell with a connected baffle plate (48) below the feed table. 47 48 fig009 Adjustment: Switch off the Foldnak. Insert a sheet of the format to be used. Switch on the Foldnak and press Start. Turn the handwheel (fig001, 6) until the jogging plate (48) touches the upper edge of the sheet. • Position the pinch roll (47) slightly above the sheet edge.
5.1.6 Stapling After the machine is switched on, the paper is laid onto the feed table. If it is inserted correctly, the machine is triggered automatically. The first stapling should be a test to check the adjustments. The staples should be the same distance from the upper and the lower edge of the booklet, they should be exactly in the fold, and the fold should be in the middle of the format. Adjust the stops if necessary. 6 Accessories 6.1 Stapling heads, staples • • • • No.
7 Service 7.1 Possible malfunctions • Machine does not function: Mains plug connected? Main switch switched on? Safety covers open? • Power fails: Reset the circuit breaker (50) after a short time. 50 Changing drivers Drivers are wear parts and must be replaced occasionally. The driver (fig003, 20) is suspended from a spigot (fig003, 16) and secured with a knurled screw (fig003, 17).
7.2 Stapling head care and malfunctions Damaged staples must be removed from the staple channel of the stapling head. Pull back the feeder shoe (fig004, 26) until it engages, then loosen both knurled screws (fig004, 24) and swing the straps (fig004, 27) towards the bottom. The stapling head can be pulled off after the contact wire has been removed. Clear the remaining staples from the front plate of the stapling head with the magazine and from the front plate still in the machine.
7.4 Rotating the machine by hand When the machine is serviced, it may be necessary to rotate it by hand. • Remove the knob (fig001, 3) for the rear stop, open the sheet-metal cover and re-insert the knob. • Move the wide service switch (fig005, 35) to position I to disengage the motor brake. • Press the start switch (fig005, 30) briefly several times. Now the machine can be rotated clockwise by hand.
7.6 Pulling out the Foldnak The Foldnak can be pulled out for maintenance. Remove the two screws (65) of the housing and pull the Foldnak out toward the rear. 65 fig011 © Ernst Nagel GmbH 9965201 User Manual Fk Compact Rev 1.4 21.6.2010 S.
8 Trimmer 8.1 Adjusting the back stop The back stop is used to adjust the dimension T. The paper face to be trimmed must be wider the thicker the booklet is. The dimension T is anywhere between 225 mm max. and 100 mm min. fig012 Fold up the cover. Loosen the locking screw (28). Fit the handwheel (29). Adjust the back stop with the handwheel (29). Tighten the locking screw (28). fig013 28 29 fig014 © Ernst Nagel GmbH 9965201 User Manual Fk Compact Rev 1.4 21.6.2010 S.
8.2 Trimmer operational sequence The booklet (46) coming out of the Foldnak falls onto the infeed belt (40) and is transported underneath the knife bar (44). Here it is detected by photoelectric cell (43). The photoelectric cell stops the feeding belt and triggers the knife (45) stroke. During the stroke, the knife bar (44) presses against the fold of the booklet (46).
8.4 Rotating the machine by hand For service tasks or in the case of a malfunction it may be necessary to rotate the machine manually. • Remove the knob (fig001, 3) from the back stop, open the sheet-metal cover and reinsert the knob. • Move the service switch (fig005, 35) to position II to release the motor brake. The machine can now be rotated manually. After completing service tasks: Turn the machine to the upper dead centre (the knife bar is right at the top).
8.5 Adjusting the knife The pressing mechanism (61) must be removed for all assembly or adjustment work carried out on the knife. To do so, undo the screws (60) and remove the pressing mechanism toward the side. The upper knife (45) is screwed to the knife bar by 5 M6x16 DIN 933 hexagon screws. The lower knife is adjusted to the upper knife. The lower knife (63) is secured by five cylinder screws (62) and supported by four clamping screws (65).
8.6 Sharpening the knife The upper knife is more delicate than the lower knife and must be sharpened more often. Remove the knife as described in the section “Adjusting the knife”. The knife is sharpened at the bevel of the blade with an angle of 24 degrees. As the upper knife is not normally sharpened (and thereby made thinner) on the front side, it may not be necessary to readjust the lower knife. fig018 After re-inserting the upper knife, turn it downward by hand very carefully (see instructions).
9 Current overload protection switch 50 The current overload protection switch prevents overloading of the motor by switching it off. When this happens, eliminate the cause of the malfunction and then reset the current overload protection switch (50). fig020 10 Possible malfunctions, errors Error: The booklet rests against the stop and does not move easily away from the stop. The knife does not cut cleanly and produces a fibre ridge that hooks behind the knife and stops the booklet.
Error: In connection with a SP+ a paper jam occurs again and again. Remedy: Boost the delay time of the infeed belt a bit, so that the brochure has more time to get into the SP+.
11 Softwareupdate via Laptop © Ernst Nagel GmbH 9965201 User Manual Fk Compact Rev 1.4 21.6.2010 S.
© Ernst Nagel GmbH 9965201 User Manual Fk Compact Rev 1.4 21.6.2010 S.
© Ernst Nagel GmbH 9965201 User Manual Fk Compact Rev 1.4 21.6.2010 S.
© Ernst Nagel GmbH 9965201 User Manual Fk Compact Rev 1.4 21.6.2010 S.
© Ernst Nagel GmbH 9965201 User Manual Fk Compact Rev 1.4 21.6.2010 S.
Konformitätserklärung DECLARATION OF CONFORMITY DÉCLARATION DE CONFORMITÉ Wir/ We/ Nous: Breitwiesenstr.
Änderungsindex Rev. 1.0 12.2.09 Rev. 1.2 30.09.09: Softwareupdate via Laptop hinzu Rev. 1.3 4.12.09: Error in connection with SP+ Rev. 1.4 21.6.10 2.2 Dummy plug hinzu © Ernst Nagel GmbH 9965201 User Manual Fk Compact Rev 1.4 21.6.2010 S.
© Ernst Nagel GmbH 9965201 User Manual Fk Compact Rev 1.4 21.6.2010 S.
Ernst Nagel GmbH D – 70565 Stuttgart, Germany Inland 0711 78078 11 Export +49711 78078 21 Telefax +49711 78078 10 www.ernstnagel.
