Horizon Fitness VAC-100 Manual
The Horizon Fitness VAC-100 is a powerful collator designed for high-volume document finishing. It can collate up to 60 sheets per set at a speed of up to 8,000 sets per hour. This machine features a user-friendly operation panel with various settings for sheet thickness, speed, and delivery direction. It has a miss, double, and jam detection system, along with an error monitor to ensure accurate collation. You can also utilize optional receiving trays or stackers for convenient document handling.
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COLLATOR
VAC-100
Important Information
- This manual is designed to help you to install, operate and maintain Collator, VAC-100.
Read, understand and keep this manual in a safe and convenient place.
- Do not operate VAC-100 until you read and understand the instructions in this manual.
- Horizon International Inc. shall not be liable for incidental consequential damages resulting from : improper or inadequate maintenance by customer; unauthorized modification or misuse; operation outside of the environmental specifications for the product.
- Horizon International Inc. pursues a policy of continuing improvement in design and performance of the product. Therefore, the product design and specifications are subject to change without prior notice and without our legal obligation.
- All rights are reserved. No part of the manual may be photocopied, reproduced or translated to another language without the prior written consent of Horizon International Inc.
I UM201050-09 020702/VAC100/09E/DV
Safety Precautions
- The signal word WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
- The signal word CAUTION indicates a potentially hazardous situation which, if not avoided, may result in damage on machines. It may also be used to alert against unsafe practices.
- Read and understand all safety instructions with signal word such as WARNING and
CAUTION. If safety instructions are ignored, personal injury may result.
- Horizon International Inc. cannot anticipate every possible situation that might involve a potential hazard. The instructions in this manual and warning labels on the machine are therefore not all inclusive.
- All equipment shall be locked out or tagged out to protect against accidental or inadvertent operation when such operation could cause injury to personnel. Do not attempt to operate any switch, valve, or other energy isolating device where it is locked or tagged out.
- Do not operate the machines when any covers are removed.
- Some of the drawings in this manual show the machine uncovered for explaining the detail or inside of machine.
II
CONTENTS
1. Before You Begin
[2] Set 1 Page ....................................................................................................... 8
[3] Set 2 Page ....................................................................................................... 9
[4] Program Page ................................................................................................. 10
[5] Memory Page ................................................................................................. 11
[6] Preset Input Page ............................................................................................ 12
1-2-4 Remote Controller .......................................................................................... 13
1-2-5 Receiving Tray (CCR).................................................................................... 14
1-2-6 Receiving Tray (CCR-DX) ............................................................................ 15
1-2-7 Stacker (ST-20) .............................................................................................. 16
1-2-8 Stacker (ST-20R) ............................................................................................ 17
1-2-9 Stacker (ST-40) .............................................................................................. 18
1-2-10 Stacker (ST-60) ............................................................................................ 19
1-2-11 Hand Marry Unit (HMU-100) ...................................................................... 21
1-3 Accessories .......................................................................................................... 22
1-4 Consumables and Options ................................................................................ 24
2. Operation Procedures
2-1 Power ON ........................................................................................................... 26
2-2 Preparation for Operation ................................................................................ 27
2-2-1 Tower ON/OFF and Delivery Direction Setup .............................................. 27
2-2-2 Collating Sheet Preparation ............................................................................ 28
2-2-3 Small Size Sheet Setup ................................................................................... 30
2-2-4 Feed Height Adjustment ................................................................................. 32
2-2-5 Blower Adjustment......................................................................................... 32
III
2-2-6 Double Feed Stop Plate Height Adjustment................................................... 33
2-2-7 Separate Nose Adjustments ............................................................................ 33
2-2-8 Delivery Section Setup ................................................................................... 34
[1] Bulging Nose and Delivery Roller Setup ....................................................... 34
[2] Weight Setup .................................................................................................. 35
[3] Delivery Air Adjustment ................................................................................ 36
2-2-9 Tray Unit Setup .............................................................................................. 37
[1] When CCR or CCR-DX Is Used .................................................................... 37
[2] When ST-20/ST-20R Is Used ........................................................................ 40
2-2-10 Setup in Main Page....................................................................................... 41
2-2-11 Hand Marry Unit Setup (HMU-100: Accessary) ......................................... 42
2-3 Collating Operation ........................................................................................... 43
2-3-1 Sheet Thickness Calibration ........................................................................... 43
2-3-2 Collating Operation ........................................................................................ 44
2-4 Feed Error Indication and Remedy ................................................................. 45
2-5 Program Collation ............................................................................................. 47
2-5-1 Double Cycle .................................................................................................. 47
2-5-2 Dual Cover Feed ............................................................................................. 49
2-5-3 Tab Insert ........................................................................................................ 51
2-6 Job Memory ....................................................................................................... 53
2-7 Right Side Delivery ............................................................................................ 54
2-8 Hand Marry ....................................................................................................... 55
3. Troubleshooting
3-1 Error Indication and Remedy .......................................................................... 58
3-2 When Misfeeding Occurs .................................................................................. 59
3-3 When Double Feeding Occurs .......................................................................... 59
3-4 Sheets Are Fed on the Skew .............................................................................. 60
3-5 Paper Jam in Transport Conveyor .................................................................. 60
3-6 Sheet from Hand Marry Unit Is Jammed ....................................................... 61
3-7 Collating Operation Does Not Start Even If Pressing Start Buttom ............ 61
3-8 Fuse and Breaker Check ................................................................................... 62
3-9 Pump Does Not Work ........................................................................................ 65
IV
4. Maintenance
4-1 Daily Cleaning .................................................................................................... 68
4-1-1 Feed Ring .......................................................................................................68
4-1-2 Transport Belt .................................................................................................69
4-2 Monthly Cleaning .............................................................................................. 70
4-2-1 Bin Sensor ...................................................................................................... 70
4-2-2 Delivery Sensor .............................................................................................. 70
4-3 Double Feed Stop Plate Replacement .............................................................. 71
4-4 Feed Error Sensor Cleaning .............................................................................72
5. Move and Installation
5-1 Collator Installation ...........................................................................................74
5-2 Blower Box Installation .....................................................................................75
5-3 System Switch Set Up ........................................................................................ 77
5-4 Cable Connection ...............................................................................................78
5-5 Receiving Tray Installation ...............................................................................79
5-5-1 CCR/CCR-DX ................................................................................................ 79
5-5-2 ST-20/ST20R .................................................................................................. 80
5-6 EAB-100 Extra Air Blower (Option) Installation ...........................................82
5-7 VAC-100a Right Side Unit (Option) Attachment ...........................................87
5-7-1 Accessories .....................................................................................................87
5-7-2 How to Attach ................................................................................................ 89
5-8 HMU-100 Hand Marry Unit (Option) Installation .........................................97
5-8-1 Accessories .....................................................................................................97
5-8-2 Hand Marry Unit (HMU-100) Installation .....................................................98
5-8-3 Cable Connection ...........................................................................................101
V
VI
1. Before You Begin
1. Before You Begin
1-1 Specifications ........................................................................................... 2
1-2 Machine Descriptions .............................................................................. 4
1-3 Accessories ............................................................................................... 22
1-4 Consumables and Options ...................................................................... 24
1
1. Before You Begin
1-1 Specifications
1-1-1 VAC Series Specifications
Module Type
Number of Bins
Sheet Size
Bin Pile Height
Paper Weight Range
Collating Speed
Error Detection
Error Monitor
Power
Power Consumption
Motors
Machine Weight
VAC-100a (Main Module)
VAC-100m (Extension Module)
VAC-100c (Rear Delivery Module)
10, 20, 30, 40, 50, 60
148 x 148 mm to 350 x 500 mm
(5.8" x 5.8" to 13.8" x 19.7')
55 mm (2.2")
52 gsm to 208 gsm
8,000 sets/hr (Single or 2 to 3 towers installation and Straight Receiving)
5,000 sets/hr (4 towers installation and Straight Receiving)
4,500 sets/hr (5 towers installation and Straight Receiving)
4,000 sets/hr (6 towers installation and Straight Receiving)
Miss, Double and Jam detection system (Photocell)
Eight sets of Feed Error Monitors
3-Phase 200 V 50/60 Hz
3-Phase 220 V 60 Hz 10.4A
Single Phase 230 V 50 Hz 10.4A
200 V 1,500 W / 220 V 1,700 W / 230 V 1,800 W
1,200 W x 1 / 400 W x 1 / 200 W x 1 / 100 W x 1
60 W x 1 (only a, c towers)
VAC-100a : 290 kg (639.5 lb)
VAC-100m : 290 kg (639.5 lb)
VAC-100c : 290 kg (639.5 lb)
The machine design and specifications are subject change without any notice.
2
1. Before You Begin
1-1 Specifications
1-1-2 Receiving Tray (Option) Specifications
Model
Max. Sheet Size
Min. Sheet Size
Max. Pile Height
Machine Weight
CCR CCR-DX
318 x 470 mm (12.5" x 18.5")
ST-20 and ST-20R
320 x 450 mm (12.6" x 17.7")
148 x 210 mm (5.9" x 8.3")
A5 to A4 : 170 mm (6.7")
A4 to A3 : 100 mm (3.9")
128 x 185 mm (5.1" x 7.3")
320 mm (12.6")
56 kg (123.5 lb) 64 kg (141.2 lb) 56 kg (123.5 lb)
Model
Max. Sheet Size
HMU-100
350 x 500 mm (14" x 20")
Min. Sheet Size
Max. Sheet Height
Min. Sheet Height
120 x 148 mm (4.7" x 5.8")
80 gsm (21.3 lb) 50 sheets (5 mm)
80 gsm (21.3 lb) 1 sheets (0.1 mm)
The HMU-100 can be used with maximum of two-tower VAC-100.
The HMU-100 can not be connected with c-tower VAC-100.
The machine design and specifications are subject change without any notice.
3
1. Before You Begin
1-2 Machine Descriptions
1-2-1 Overview
Operation Panel (a-Tower)
This panel is used to operate or setup collator. Feed errors and troubles are indicated on this panel.
Transport Door
Belts, which transports sheets from each bin, are provided inside this door. This door can be opened or removed.
Stop Button
Power Switch
Operation Panel (c-Tower)
Sheets can be delivered to the right by setting with this panel. Feed errors and troubles are indicated on this panel.
Remote Controller
Main operation can be performed with this remote controller.
Bin
Sheets are loaded on this bin.
Accessories
Receiving tray or stitcher & folder
(option) can be connected as finishing device.
Delivery Section
Sheets are transported from this section to the accessory.
Hand Marry Unit (Option)
This unit is used to insert a sheet on or under the collated sheets in
VAC-100. It can be attached to a tower or m-tower.
Accessories (Option)
Receiving tray can be connected as finishing device.
Stool
This stool is used to load sheets on the upper bin. This stool is equipped with blower.
4
1. Before You Begin
1-2 Machine Descriptions
1-2-2 Feed Section
Feed Rotor
This rotor sucks and feed sheets.
Feed Height Adjust Lever
(White)
This lever is used to adjust the height of feed height sensor.
Separation air Adjust
Lever (Blue)
This lever is used to adjust separation air.
Feed Height Sensor
This sensor determines the sheet feed height.
Front Plate
This plate is the left register when sheets are loaded on bin.
Blower Nozzle
Blowing air comes out from this blower nozzle.
Side Guide
This guide is the rear register when sheets are loaded on bin.
Bin
Sheets are loaded on this bin.
Double Feed Stop Plates
These plates prevent double feeding.
Separate Nose Knob
Separate Nose
This separate nose supports to separate sheets to prevent double feeding.
5
1. Before You Begin
1-2 Machine Descriptions
1-2-3 Operation Panel
[1] Main Page
Tabs
These tabs are used to select the page on the screen.
Total Counter
This counter counts sets of collated sheets. This counter can be reset with clear button. When main power is turned off, this counter is reset.
Preset Counter
In case the required number of collated sets is input in this counter with the right preset button, the collation stops when the number of collated sets reaches the input number.
1 2 3
1 2 3
1 2 3
1 2 3
Tab Counter
This counter indicates the current number of times of tab insert and the preset number of tab insert.
Tab insertion must be set on the program page.
Double Cycle Preset Counter
In case the double cycle mode is turned on and the number of double cycle preset is input in program screen with the double cycle preset button, the collating section is automatically switched over when the number of collated sets reaches the input number.
C
Error Monitor Button
This button is used to indicate feed error.
Delivery Air ON/OFF Button
This button is used to turn on/ off delivery air.
60 min.
60 min.
?
Hand Marry Mode Indication
These icon indicate the selected mode on HMU-100.
: Sheet(s) from hand marry unit is inserted under collated sheets.
: Sheet(s) from hand marry unit is inserted on collated sheets.
: Hand marry unit is not used.
Stop Button
This button is used to stop the operation.
This button must be pressed three times to stop the collator completely and lower bins. Refer to the chart below.
Start Button
This button is used to start the operation. The operation will not start before sheet calibration is performed.
Feed Error Reject Function ON/OFF Button
This button is used to turn ON/OFF the function of delivering errored sets, to the feed-error tray.
Stop Button Pressing Times
0
1
2
3
Feeding
ON
OFF
OFF
OFF
Motor and Blower
ON
ON
OFF
OFF
Bin
Up
UP
UP
DOWN
6
1. Before You Begin
1-2 Machine Descriptions
1 2 3
1 2 3
1 2 3
1 2 3
C
60 min.
60 min.
?
Program Indication
These icons indicate the setup program function.
Feed Speed Indication
Feed speed can be set with triangle buttons below. The speed can be changed during operation.
Automatic Setup Button
This button is used only when SPF-20A is combined. When this button is pressed, the collator speed is adjusted automatically to match the SPF-20A speed.
Belt Speed Indication
The belt which transports collated sheets can be adjusted on three scales with triangle buttons below.
Suction Air Indication
Suction air power can be adjusted on two scales with triangle buttons below.
Overlap
The sheet overlap can be adjusted on four scales with triangle buttons below.
7
1. Before You Begin
1-2 Machine Descriptions
[2] Set 1 Page
Tower Indication
The current used towers (collators) are highlighted.
Finishing Device Button
This button is used to select the finishing device combined.
When CCR-DX is used, CCR-
DX icon must be selected. The standard icon ( ) must be used for all the other devices.
1 2 3 4 5 6
Delivery Direction Button
This button is used to select delivery direction. The c-tower is required to deliver collated sheets to the right.
Tower Main Power Button
The tower which is not used must be turned off.
Finishing Device Button
This button is used to select the finishing device combined. When
CCR-DX is used, CCR-DX icon must be selected. The standard icon ( ) must be used for all the other devices.
8
1. Before You Begin
1-2 Machine Descriptions
[3] Set 2 Page
Individual Calibration Buttons
These buttons are used to calibrate the sheet thickness in the individual tower.
All Tower Calibration Button
This button is used to calibrate the sheet thickness in all towers.
1
Sensor Button
This button is used adjust feed error sensor sensitivity on four scales.
: High
: Middle
: Low
: Double Feed Detect OFF
5
6
3
4
7
1
2
8
9
10
5
6
3
4
7
1
2
8
9
10
2
Lamp Button
This button is used to adjust the light intensity on two scales according to the sheet thickness and print darkness.
: for Normal to Thin
: for Thick or Dark Print Image
3
5
6
3
4
7
1
2
8
9
10 1
2
Page UP/DOWN Button
This button is used to see the rest of tower indication when four towers or more are combined.
Bin Power Button
This button is used to turn on/off bin. The bin where sheets are loaded during a sheet calibration is on. If sheets on the particular bin do not require to be fed, the bin must be turned off.
: ON
: OFF
9
1. Before You Begin
1-2 Machine Descriptions
[4] Program Page
Tab Insert Button
This button is used to turn on/off the tab insert.
Double Cycle Select
Button
This button is used to select which section is started in the double cycle program.
Double Cycle Button
This button is used to turn on/off the double cycle mode.
Dual Cover Feed Button
This button is used to turn on/off the dual cover feed mode.
Tab Sheet Button
This button is used to select one tab sheet or two to be used.
Preset Button
This button is used to set where tab sheets are inserted.
1
1 2 3 1 2 3
1 2 3
Bin Select Button
This button is used to select which bin is started in the dual cover feed program.
Stop Button
This button is used to input number of tab insert to stop operation when the number of tab insert reaches the input number.
Double Cycle Preset Button
In case the number of double cycle preset is input, the collating section is automatically switched over when the number of collated sets reaches the input number.
Double Cycl e : The VAC-100 system is divided into two sections. When any bin empties, the
VAC-100 immediately switches over to the second section and continues collating.
1 Tower
1
A
5
6
10
B
1
3 Towers
10
A
1
A
5
6
10
B
1
10
B
1
5 Towers
10
A
1
10
A
1
A
5
6
10
B
1
10
B
1
10
B
1
2 Towers
10
A
1
10
B
1
4 Towers
10
A
1
A
10
1
10
B
1
10
B
1
6 Towers
10
A
1
A
10
1
A
10
1
10
B
1
10
B
1
10
B
Dual Cover Feed : When one cover bin
empties, the VAC-100
automatically switches over
to the other cover bin.
Tab Insert : Up to two tab sheets can be inserted between preset collated sets.
Cover Sheets
Collated Sets
Tab Sheets
Collated Sets
Collated Sets
Collated Sets
Collated Sets
Tab Sheets
NOTE
- Double cycle and dual cover feed programs can be operated together. The place of cover sheets in the second section is the first two bins in the second section.
- Double cycle and tab insert programs can be operated together. The place of tab sheets in the second section is the first bin in the second section.
10
1. Before You Begin
1-2 Machine Descriptions
[5] Memory Page
Current Setup Button
This button is used to indicate the current setup condition of collator.
Job No. Button
Up to nine collating setup patterns can be stored with these buttons.
Write Button
This button is used to memorize the collating setup pattern in the selected job No.
1 2 3
1 2 3 4 5 hr.
6 7 hr.
8 9
1 2 3
Setup Indication
The setup condition is indicated when current setup button or job No. button is pressed.
Read Button
This button is used to read the memorized setup for the selected job No.
11
1. Before You Begin
1-2 Machine Descriptions
[6] Preset Input Page
The preset input page is shown by pressing preset button on the main page or program page.
7
1 1
4
1 1
1
1 1
C
1 1
UP Key
This key is used to increase the number indicated.
DOWN Key
This key is used to decrease the number indicated.
10-number Keys
The required number can be input with these keys.
Enter Key
This key is used to enter the number. The page goes back after pressing this key.
Clear Key
The key is used to clear the input number.
12
1. Before You Begin
1-2 Machine Descriptions
1-2-4 Remote Controller
1 2 3
Trouble Monitor
When collating operation stops, this monitor let the operator know the cause with lamp lighting.
Speed Button
This button is used to adjust the collating speed.
The speed can be adjusted during the operation.
This button has the same function as the one on the main page. While this button is being pressed, the speed is increased rapidly.
Inching Button
This button is used to inch roller and belt in the transport and delivery sections. They can inch during being pressed this button.
Start Button
This button is used to start the operation. The operation cannot be started before sheet calibration is performed. This button has the same function as the one on the main page.
Stop Button
This button is used to stop the operation. This button has the same function as the one on the main page. When this button is pressed with error page shown on the screen, the screen goes back to the main page. This function is the same as the OK button in the error page.
13
1. Before You Begin
1-2 Machine Descriptions
1-2-5 Receiving Tray (CCR)
Tray
Tray for A5 to A4 sheet size or for B4 to A3 sheet size can be selected.
Delivery Rollers
These rollers transport collated sets to receiving tray. Weights correct sheet skew.
Air Adjust Knob
This knob is used to adjust the delivery air.
Stopper
This stopper must be set according to the sheet size.
Tray Lock Knob
This knob is used to lock tray.
(Operation Panel)
Connecting Cable
This cable must be connected to the collator connector.
Operation Panel
Off-set ON/OFF Switch
This switch is used to switch on/off off-set.
L S
Off-set Timing Knob
This knob is used to adjust the side guide delay after sheets are delivered to CCR.
Single Motion Button
Tray rotation can be actuated with this button.
14
1. Before You Begin
1-2 Machine Descriptions
1-2-6 Receiving Tray (CCR-DX)
Tray
Tray for A5 to A4 sheet size or for B4 to A3 sheet size can be selected.
Full Tray Sensor
(Only for Small Receiving Tray)
This sensor detects full tray.
Delivery Rollers
These rollers transport collated sets to receiving tray. Weights correct sheet skew.
Air Adjust Knob
This knob is used to adjust the delivery air.
Stopper
This stopper must be set according to the sheet size.
Tray Lock Knob
This knob is used to lock tray.
(Operation Panel)
Connecting Cable
This cable must be connected to the collator connector.
Operation Panel
Full Tray Detection Switch
This switch is used to switch on/off full tray detection.
Off-set ON/OFF Switch
This switch is used to switch on/off off-set.
15
L
S
Off-set Timing Knob
This knob is used to adjust the side guide delay after sheets are delivered to CCR-DX.
Single Motion Button
Tray rotation can be actuated with this button.
1. Before You Begin
1-2 Machine Descriptions
1-2-7 Stacker (ST-20)
Delivery Rollers
These rollers transport collated sets to receiving tray. Weights correct sheet skew.
Operation Panel
Stopper Adjust Knob
This knob is used to adjust stopper according to the sheet size.
This knob can be locked with top knob on this knob.
Stop Button
Off-set Guide
This guide is for off-set receiving.
Side Guide Adjust Knob
This knob is used to adjust side guide according to the sheet size.
This knob can be locked with top knob on this knob.
Tray
Collated sets are loaded on this tray.
Stopper
Delivered collated-sets stops by hitting this stopper.
Side Guide
This guide moves up and down every single cycle for off-set receiving.
(Operation Panel)
Tray UP Button
This button is used to raise Tray.
Tray DOWN Button
This button is used to lower Tray.
Tray can be lowered only while this button is being pressed.
Off-set Timing Knob
This knob is used to adjust the side guide delay after sheets are delivered to ST-20.
Tray Lower Time Knob
This knob is used to adjust the lowering length of tray every single cycle.
Single Motion Button
Movable side guide can be actuated with this button.
Off-set ON/OFF Switch
This switch is used to switch on/off off-set.
16
1. Before You Begin
1-2 Machine Descriptions
1-2-8 Stacker (ST-20R)
Emergency Stop Button
Side Guide Adjust Knob
This knob is used to adjust side guide according to the sheet size. This knob can be locked with top knob on this knob.
Stopper
Delivered collated-sets stops by hitting this stopper.
Side Guide
This guide moves up and down every single cycle for off-set receiving.
Tray
Collated sets are loaded on this tray.
(Operation Panel)
Tray UP Button
This button is used to raise tray.
Tray DOWN Button
This button is used to lower tray.
Tray can be lowered only while this button is being pressed.
Tray Lower Time Knob
This knob is used to adjust the lowering length of tray every single cycle.
Single Motion Button
Movable side guide can be actuated with this button.
17
Stopper Adjust Knob
This knob is used to adjust stopper according to the sheet size. This knob can be locked with top knob on this knob.
Delivery Rollers
These rollers transport collated sets to receiving tray. Weights correct sheet skew.
Operation Panel
Off-set Guide
This guide is for off-set receiving.
Off-set Timing Knob
This knob is used to adjust the side guide delay after sheets are delivered to ST-20R.
Off-set ON/OFF Switch
This switch is used to switch on/off off-set.
1. Before You Begin
1-2 Machine Descriptions
1-2-9 Stacker (ST-40)
Feed Error Tray
All errored sets are delivered to this tray.
Delivery Section
Removing the feed error tray and to bring the transport section to a level, collated sets are delivered to the stitcher.
Delivery Section
Collated sets are delivered to the stitcher through this section.
Connector Section
Connect to the stitcher
Stopper
Delivered collated sets stop by hitting this stopper.
Folk
The stack tray is placed on this folk. Collated sets are accumulated on the tray.
Stopper A Adjust Knob
This knob is used to adjust stopper
A according to the sheet size. The knob can be turn-locked into position by the lock knob.
Feed Error Lamp A
When the feed error occurs at the collator, then the last set is delivered to the stack tray A, this lamp will blink to alart the operator.
Stop Button
Side Guide A Adjust Knob
This knob is used to adjust side guide According to the sheet size.
The knob can be turn-locked into position by the rock knob.
Side Guide
This guide moves up and down with
every cycle for off-set receiving.
Off-set Guide
This guide is for off-set receiving.
Single Motion Button
The movable side guide can be actuated with this button.
(Operation Panel)
Stack Tray UP Button
Depressing this button is raises the stack tray.
Stack Tray Down Button
Depressing this button lowers the stack tray.
1 2 3
1 2 3
Off-set ON/OFF Switch
This switch turns the off-set function ON/OFF. This button is used to raise the stack tray.
Stack/ Stitch Select Button
Lamp ON : Stitch the collated sets at
stitcher .
Lamp OFF : Stack the collated sets at
ST-40.
18
Off-set Delay Button
This button is used to select a delayed time for the off-set function.
Lamp ON : Delayed time for off-set is 0.3
second
Lamp OFF : Delayed time for off-set is zero.
Feed Error Reject Function ON/OFF Button
This button is used to turn ON/OFF the function of delivering errored sets, to the feed-error tray.
1. Before You Begin
1-2 Machine Descriptions
1-2-10 Stacker (ST-60)
Side Guide B
This guide moves up and down every cycle for off-set receiving.
Stopper B
Delivered collated
sets stop by hitting
this stopper.
Feed Error Tray
All errored sets are delivered to this tray.
Transport Unit
Collated sets are transported to side B through this unit.
Power Switch
Stack Tray B
Collated sets are accumulated on this tray.
Off-set Guide A
This guide is for off-set receiving.
Stop Button
Operation Panel A
Stopper A
Collated sets are stopped by hitting this stopper.
Stack Tray A
Collated sets are loaded on this tray.
Side Guide A
This guide moves up and down with
every cycle for off-set receiving.
Side Guide A Adjust Knob
This knob is used to adjust side guide A according to the sheet size. The knob can be turn-locked into position by the rock knob.
Feed Error Lamp A
When the feed error occurs at the collator, then the last set is delivered to the stack tray A, this lamp will blink to alart the operator.
Stopper A Adjust Knob
This Knob is used to adjust stopper A according to the sheet size. The knob can be turn-locked into position by the rock knob.
19
1. Before You Begin
1-2 Machine Descriptions
(Operation Panel A)
Counter Button
This button is used to select the mode of the counter. For further information, refer to 2-3.
Counter Input Button
Stack Tray UP Button
Depressing this button is raises the stack tray.
1 2 3
1 2 3
Single Motion Button
The movable side guide can be actuated with this button.
Stack Tray Down Button
Depressing this button lowers the stack tray.
Off-set ON/OFF Switch
This switch turns the off-set function
ON/OFF. This button is used to raise the stack tray.
Off-set Delay Button
This button is used to select a delayed time for the off-set function.
Lamp ON : Delayed time for off-set is
0.3 second
Lamp OFF : Delayed time for off-set
is zero.
Stack Mode Select Button
Lamp ON :
The collated sets are alternately routed to the stack trays A/B one after the other.
Lamp OFF :
The collated sets are alternately routed to one of the stack trays only. When one stack tray is full, the collated sets are routed to the other stack tray.
(Operation Panel B)
Stack Tray Up Button
This button is used to raise the tray.
Feed Error Reject Function ON/OFF Button
This button is used to turn ON/OFF the function of delivering errored sets, to the feed-error tray.
ON :
When a feed error occurs at the collator, the errored set is delivered to the feed error tray without stopping the collator. The collator will stop after 4 consecutive errored sets are delivered to the feed error tray.
OFF:
When a feed error occurs at the collator, collating will stop. Errored sets will be delivered to the stack tray.
Stack Tray Down Button
This button is used to lower the stack tray. Stack tray can be
lowered only while this button
is being pressed.
Single Motion Button
The movable side guide can be actuated with this button.
Stack Tray B Height Select Button
Lamp ON : 580 mm Maximum
( 55 kg. about 700 sheets)
Lamp OFF : 580 mm Maximum
( 55 kg. about 430 sheets)
20
Delivery Air ON/OFF Button
This button is used to turn ON/OFF the delivery air on the side B( left side).
Lamp ON : Delivery air is ON
Lamp OFF : Delivery air is OFF
1. Before You Begin
1-2 Machine Descriptions
1-2-11 Hand Marry Unit (HMU-100)
Sheet Detection Sensor
When this sensor detects a sheet, collating operation starts.
Sheet Registration Guide
Sheets to marry are registered with this guide.
Sub-table
Hand Marry Table
Sheets to marry are placed on the table.
Sheet Guide
This guide is set according to sheet width.
Insert Mode Selecting Switch
This switch is used to select the mode to insert a sheet on or under collated sheets from VAC-100 or to be off.
21
1. Before You Begin
1-3 Accessories
Connecting Plate (A920112-00) m:1pc c:1 pc
Detector (A924699-00) a:1 pc
Connecting Plate (A920111-00) m:1 pc c:1 pc
Leveling Bolt (M12-120), Nut (M12) a: 3 pcs m:3 pcs c:3 pcs
Setting Plate (M000025-01) a: 3 pcs m: 3 pcs c: 3 pcs
Grease (4-001272-00) a:1 pc c:1 pc
Sheet Guide (A924698-01) a: 20 pcs m: 20 pcs c: 20 pcs
Tool Box (4-003344-00) a: 1 set c: 1 set
Hose Band a: 3 pcs m: 3 pcs c: 3 pcs
Reversible Screwdriver (4-005382-00) a:1 pc c:1 pc
22
1-3 Accessories
Allen Wrench
1. Before You Begin a: 1 pc each c: 1 pc each
5 mm (4-000968-00) 4 mm (4-001439-00) 3 mm (4-001438-00) 2.5 mm (4-001437-00) 2 mm (4-001320-00)
Spanner a: 1 pc each c: 1 pc each
19 x 24 mm (4-005401-00)
Fuse
1 A (4-008911-00) : 2 pcs
2 A (4-008912-00) : 1 pcs
5 A (4-008915-00) : 3 pcs
13 x 17 mm (4-005400-00)
Blower Box a: 3 pcs m: 1 pcs c: 1 pcs
8 x 10 mm (4-005397-00)
Cleaning Brush (M072641-00) a: 1 pc Sheet Hold Plate (M072585-00) a: 5 pcs
Double Feed Stop Plate P (A924701-00)
10 pcs
23
1. Before You Begin
1-4 Consumables and Options
Consumables
Grease (4-001272-00) Double Feed Stop Plate (A924697-01)
Fuse
1 A (4-008911-00)
2 A (4-008912-00)
5 A (4-008915-00)
Options
Support Guide(A924629-01) Extra Air Blower (EAB-100)
Sheet Guide (A924700-00) Hand Marry Unit (HMU-100)
24
2. Operation Procedures
2. Operation Procedures
2-1 Power ON ................................................................................................. 26
2-2 Preparation for Operation ...................................................................... 27
2-3 Collating Operation ................................................................................. 43
2-4 Feed Error Indication and Remedy ....................................................... 45
2-5 Program Collation ................................................................................... 47
2-6 Job Memory ............................................................................................. 53
2-7 Right Side Delivery .................................................................................. 54
2-8 Hand Marry ............................................................................................. 55
25
2. Operation Procedures
2-1 Power ON
NOTE
- When two towers or more are used, turn on power from the right tower.
1.
Turn on power switch.
NOTE
- When turning off main power, turn off atower. Other towers can be turned off by turning off only a-tower.
- The initial page as shown in the drawing at right appears and 20 to 30 seconds later the main page appears.
Power Switch
VAC-100
Now Loading....
1 2 3
1 2 3
1 2 3
1 2 3
C
60 min.
60 min.
?
NOTE
- When start button is pressed with inching button pressed, the collator starts warming up with " " indicated on the screen. Five minutes later, warming up is stopped automatically. Press stop button when stopping warming up.
Inching Button
1 2 3
Start Button
Stop Button
26
2. Operation Procedures
2-2 Preparation for Operation
2-2-1 Tower ON/OFF and Delivery Direction Setup
1.
Select Set 1 page.
1 2 3 4 5 6
2.
Turn on tower switch of collator which is used, turn off tower switch of collator which is not used.
: ON
: OFF
3.
When the c-tower is combined, select the delivery direction.
NOTE
- When the c-tower is not combined, the delivery direction is only left side.
- When the right side delivery is required, refer to "2-7 Right Side Delivery."
Delivery Direction Tower Switch
27
2. Operation Procedures
2-2 Preparation for Operation
2-2-2 Collating Sheet Preparation
This section shows how to load sheets to be collated.
1.
Select the main page.
2.
When bins are raised, press stop button on the main page or remote controller to lower bins.
1 2 3
1 2 3
1 2 3
1 2 3
C
60 min.
60 min.
?
Stop Button
1 2 3
Stop Button
3.
Place sheets against side guide and front guide.
Front Plate
NOTE
- When collated sheets are delivered to the left, load sheets from the top bin in page order. When collate sheets are delivered to the right, load sheets from the bottom bin in page order.
- When the number of collate pages are few, it is efficient to load sheets from the bottom bin.
- When two towers or more are used, it is efficient to load sheets equally into each tower. For example, it is more efficient to load seven pages of sheets on both first and second towers than to load ten pages of sheets into the fist tower and four pages of sheets into the second tower.
28
Collate Sheets Side Guide
The Page Number of Collate Sheets
P1
P2
P3
P10
P9
P8
P9
P10
P2
P1
[Left Side Delivery] [Right Side Delivery]
2. Operation Procedures
2-2 Preparation for Operation
NOTE
- Fan sheets well before loading them into bins. Otherwise double feeding may occur. If the sheets are bend, straighten then before loading them into bins.
- Press firmly folded sheet edges when 4-page signatures are collated to prevent misfeeding or double feeding and to keep the sheet pile height low level. Load sheets so the folded edges touch front plate.
- The optional support guide allows collator to collate 120 to 148 mm (4.7" to 5.8") width sheets. (Refer to the next page.)
Support Guide
3.
Set sheet guides so that they touch the operation and right sides of sheet edges respectively.
Sheet Guides
NOTE
- When handling acccordion-folded sheets or
NCR papers, set sheet hold plate on the right sheet guide.
Sheet Hold Plate
Sheet Hold Plate
Right Sheet
Guide
29
Setting Direction of Accordion-folded Sheets
2. Operation Procedures
2-2 Preparation for Operation
2-2-3 Small Size Sheet Setup
When small size sheets whose width is 120 to
148 mm (4.8" to 5.9") are handled, use optional support guide.
1.
Set support guide on bin where small size sheets are loaded.
Support Guide
Sheet
Bin
2.
Raise feed height sensor and move it to the operation side.
Support Guide
Feed Height Sensor
30
2-2 Preparation for Operation
3.
Place sheets against support guide and front guide.
Front Guide
2. Operation Procedures
Sheets
Support Guide
4.
Set sheet guides so that they touch the front and right sides of sheet edges respectively.
Sheet Guides
31
2. Operation Procedures
2-2 Preparation for Operation
2-2-4 Feed Height Adjustment
This section shows how to adjust the feed height.
1.
Adjust feed height adjust lever (White).
UP : High
DOWN : Low
NOTE
- The standard position of feed height adjust lever is where lever is level.
3
Feed Height Adjust Lever (White)
- When feed height adjust lever is raised, the feeding position is raised.
- When feed height adjust lever is lowered, the feeding position is lowered.
- After test collating, raise feed height adjust lever when thick sheets are handled and misfeeding occurs. Lower feed height adjust lever when thin sheets are handled and double feeding occurs.
- When double feeding occurs on all bins, weaken suction air on the main page.
Feeding Side
2-2-5 Blower Adjustment
This section shows how to adjust blower air on each bin.
1.
Adjust separation air adjust lever (Blue).
UP : Strong
DOWN : Weak 3
NOTE
- Air is stronger where separation air adjust lever is raised; weaker lowered.
- Normally, use blower with separation air adjust lever on the top position.
- When sheets are blown up or pushed by air, weaken air by lowering separation air adjust lever.
Separation Air Adjust Lever
(Blue)
32
Blowers
2. Operation Procedures
2-2 Preparation for Operation
2-2-6 Double Feed Stop Plate Height Adjustment
This section shows how to adjust the double feed stop plate height on each bin.
Double Feed Stop Plates
1.
Adjust double feed stop plate adjust lever by moving up and down.
Lever UP : Lower plate
Lever DOWN : Raise plate
NOTE
- Double feed stop adjust lever is usually used in the lowest position.
- After test collating, raise double feed stop plate adjust lever to lower double feed stop plates when misfeeding occurs.
Double Feed Stop Plate Adjust Lever
2-2-7 Separate Nose Adjustments
When double feeding occurs because of thin sheets, use separate nose.
1.
Move separate nose to the left and push out separate nose.
NOTE
- Use separate nose only when double feeding occurs because of thin sheets.
Separate Nose Knob
Separate Nose
33
2. Operation Procedures
2-2 Preparation for Operation
2-2-8 Delivery Section Setup
WARNING
- Press stop button before setting up the delivery section. Otherwise the delivery section may hurt your hands.
Delivery Roller
[1] Bulging Nose and Delivery Roller Setup
Attach bulging nose and adjust delivery rollers so that sheets are delivered smoothly and jogged well.
1.
Attach bulging nose so that it positioned in the middle of the sheet.
NOTE
- Sheets are delivered with 2 cm (0.8") distance from the rear side.
Bulging Nose
2 cm
(0.8")
Push here to lock.
Push here to remove.
2.
Set delivery rollers by sliding so that bulging nose is positioned in the middle of delivery rollers according to the sheet size and weight.
- Delivery rollers can be slid by raising the end of rollers.
NOTE
- When thick sheets or 4-page signature are handled, lower bulging nose. When thin sheets or soft sheets are handled, raise bulging nose. When large and thin sheets are handled, use two bulging noses.
Delivery Rollers
Bulging Nose
Thick Sheet
4-page Signature
Thin Sheet
Soft Sheet
Large and Thin Sheet
34
2. Operation Procedures
2-2 Preparation for Operation
[2] Weight Setup
1.
Adjust the weight positions according to the sheet thickness.
- Weights can be moved by turning counterclockwise.
- The standard position of weight is the middle.
NOTE
- When sheets are delivered on the skew, the skew can be corrected by moving weight.
- When sheets are skew in the (1) direction shown in the drawing at right, move weights in the A direction.
- When sheets are skew in the (2) direction shown in the drawing at right, move weights in the opposite direction of A.
- Weight pressure is reduced in the UP direction. When thin sheets are handled, set weights in the UP direction. When thick sheets are handled, you do not have to set weight in the DOWN direction if sheets are delivered smoothly.
Weight
(1)
A
(2)
A
UP
MIDDLE
DOWN
Weight Position
UP : For thin sheets
MIDDLE : For normal sheets
DOWN : For thick sheets
35
2. Operation Procedures
2-2 Preparation for Operation
[3] Delivery Air Adjustment
1.
Release stop button.
Stop Button
2.
Turn on delivery air ON/OFF button.
3.
Adjust delivery air with delivery air knob.
1 2 3
1 2 3
1 2 3
1 2 3
C
60 min.
60 min.
?
Delivery Air ON/OFF Button
Air Nozzles
NOTE
- When thin collated sets or sheets which are difficult to be transported are handled, use delivery air.
- Turn delivery air knob within the range of the arrow mark shown in the drawing at right.
Delivery Air Knob
Max.
OFF
36
2-2 Preparation for Operation
2-2-9 Tray Unit Setup
[1] When CCR or CCR-DX Is Used
1.
Insert small or large tray into shaft.
Small Tray : A5 to A4
Large Tray : B4 to A3
NOTE
- Two shafts project into tray. Insert these shaft properly.
Shaft
2. Operation Procedures
Insert Position
- The sheet set direction is different depending on the tray to be used.
Small Tray Large Tray
(The arrow direction is the feed direction.)
2.
When using ST-20, insert full tray sensor cable into main connector.
Full Tray Sensor Cable
37
2. Operation Procedures
2-2 Preparation for Operation
3.
Place two sheets as shown with dotted lines in the drawing at right and adjust stoppers and off-set bar to the sheet size in number order.
(Small Tray)
Sheet Registers
(Large Tray)
Sheet Register
Off-set Bar
3
Stopper
2
Stopper
1
Off-set Bar
- Stoppers and off-set bar can be moved by loosening lock knobs.
Stopper
NOTE
- Provide 5 to 10 mm (0.2" to 0.4") between the sheet edge and stoppers, and between the sheet edge and off-set bar.
Lock Knob
Stopper
38
2. Operation Procedures
2-2 Preparation for Operation
CAUTION
- Set receiving tray so that it does not hit the collator delivery section when turning receiving tray by 90˚.
4.
Adjust the tray position.
- Move tray close to the collator where it does not touch collator delivery section and the lock tray with tray lock knob.
NOTE
- Press single motion button to turn tray and check the distance between tray and collator.
Stopper
Tray Lock Knob
Collator
5.
Set the operation mode.
- When off-set receiving is required, turn on off-set ON/OFF switch.
- Set off-set timing knob to the required position.
- When using small tray of CCR-DX, turn on full tray detection switch.
(CCR)
Off-set Timing Knob
L S
Off-set ON/OFF Switch
Single Motion Button
(CCR-DX)
L
S
Full Tray Detection Switch
Off-set Timing Knob
39
2. Operation Procedures
2-2 Preparation for Operation
[2] When ST-20/ST-20R Is Used
WARNING
- Press stop button before setting stoppers and guides on tray. Otherwise personal injury may result.
Tray UP Button Off-set Timing Knob
(Off-set Receiving)
1.
Press tray UP button to raise tray.
Guide Strip
Off-set Guide
Support Stopper Sheet Registers
2.
Press stop button.
3.
Place a sheet as shown with dotted lines in the drawing at right and then adjust side guide and stopper in number order.
NOTE
- Provide 5 mm (0.2") gap between the sheet edge and stopper, and between the sheet edge and side guide.
- When the sheet size is B4 or more, attach guide strip.
4.
Attach support stopper on the same position as stopper's.
Stopper
Sheet
5 mm
(0.2")
Side Guide
5 mm
(0.2")
1 2
Stopper Adjust Knob
Side Guide Adjust Knob
5.
Set the operation mode.
- Turn on off-set ON/OFF switch. (" " position)
-Set off-set timing with off-set timing knob.
Turning knob clockwise makes off-set time longer.
- Set tray lower time with tray lower time knob according to the collated set thickness. Tray lowers by turning knob clockwise.
(Straight Receiving)
CAUTION
- Turn off off-set ON/OFF switch
(" " position) when straight receiving is required.
Tray Lower Time Knob Off-set Timing Knob
Off-set ON/OFF Switch
Straight Receiving Guides
1.
Attach straight receiving guides and lock them with lock knob.
2.
Adjust stoppers and side guide in the same procedure as the step 3 above.
40
Lock Knob
2. Operation Procedures
2-2 Preparation for Operation
2-2-10 Setup in Main Page
This section shows how to set the feeding condition in main page.
1.
Set the belt speed. (3 scales)
NOTE
-The belt speed can be adjusted on three scales. Normally, set the middle speed. After test collating, set the fast speed if sheets are fed smoothly. On the contrary, if misfeeding occurs, set the slow speed.
2.
Set the feed speed.
NOTE
- The feed speed changes depending on the belt speed and overlap used.
- The feed speed can be adjusted during the operation.
- When SPF-20A is combined, the feed speed is automatically adjusted by pressing automatic set up button.
3.
Set air strength. (2 scales)
NOTE
- Air strength can be adjusted on two scales.
Normally, select strong. When double feeding occurs because of thin sheets, select weak to decrease the sucking force of the rotor.
4.
Set overlap. (4 scales)
NOTE
- Overlap can be adjusted on four scales.
- After the actual collation, adjust the overlap for good delivery to the receiving tray or stitcher & folder.
5.
When using total counter, press clear key to reset the counter.
6.
When using preset counter, press the required number with 10-number keys, and then press enter key to input the number.
To clear the input number, press clear key.
After pressing enter key, the main page appears.
41
[Main Picture]
1 2 3
1 2 3
1 2 3
1 2 3
C
60 min.
60 min.
[Preset Input Picture]
?
1
7
1 1
1
4
1 1
1
1
1 1
C
1 1
Clear Key Enter Key
2. Operation Procedures
2-2 Preparation for Operation
2-2-11 Hand Marry Unit Setup (HMU-100: Option)
When using hand marry unit, set the sheet guide and select the mode to insert a sheet on or under collated sheets.
1.
Select the mode with the insert mode selecting switch.
: A sheet from hand marry unit is inserted on collated sheets.
: Hand marry function is not used.
: A sheet from hand marry unit is inserted under collated sheets.
Insert Mode Selecting Switch
- The selected mode on HMU-100 is indicated by the icon on main page of VAC operation panel.
1 2 3
1 2 3
1 2 3
1 2 3
C
60 min.
60 min.
?
(Main Page Of VAC Operation Panel)
2.
Place sheets on hand marry table registering with the sheet registration guide and set the sheet guide according to sheet width.
Place the sheets registering with this guide
Sheet Guide
42
2. Operation Procedures
2-3 Collating Operation
2-3-1 Sheet Thickness Calibration
Before actual collating operation, sheets thickness must be calibrated and memorized.
Adjust sensor and/or lamp on each bin on the
Set 2 page with sheet calibration.
1.
Select Set 2 page.
NOTE
- When each bin power is off, sheets are not fed even if sheets are loaded on the bin.
2.
Set senor to middle sensitivity and lamp to normal.
NOTE
- The initial setting of sensor is middle sensitivity and lamp, normal.
- When sensor detects double feeding without double feeding during the actual operating, set sensor to low sensitivity. After that, sensor still detects double feeding occurs, turn off sensor. When sensor detects misfeeding without misfeeding, set sensor to low sensitivity.
- When sensor is turn off, sensor detects only misfeeding, not double feeding.
- Normally, set lamp to normal. When sensor senses thick image on sheets or detects misfeeding without misfeeding, set lamp to bright.
3.
Press all tower calibration button.
- Each bin on all used towers feeds one sheet.
NOTE
- When individual calibration button is pressed, sheets only on the tower whose button is pressed are fed once.
4.
Check the number of collated sheets is correct.
NOTE
- When the number of collated sheets is not correct, press individual calibration button of the tower which has a problem.
- When double feeding is monitored during a sheet calibration, set lamp to bright and check again.
- When double feeding of a collated set is missed on receiving tray, misfeeding will be detected during the actual operation.
All Tower Calibration Button
Individual Calibration Buttons
9
10
5
6
3
4
7
8
1
2
1
9
10
5
6
3
4
7
8
1
2
2
9
10
5
6
3
4
7
8
1
2
3
Sensor
: High Sensitivity
: Middle Sensitivity
: Low Sensitivity
: Double Sheet Detection OFF
Lamp
: Normal
: Bright
Bin
: ON
: OFF
1
2
43
2. Operation Procedures
2-3 Collating Operation
2-3-2 Collating Operation
This section shows how to operate the collator.
1.
Select the main page.
2.
Press start button either on the main page or on remote controller.
NOTE
- The operation will not start before sheet thickness calibration is completed. (Refer to
"2-3-1 Sheet Thickness Calibration.")
- When using the hand marry unit, refer to
"2-8 Hand Marry"
3.
Press stop button either on the main page or on remote controller.
NOTE
- When stop button is pressed during operation, only feeding is stopped, not motor and blower. When stop button is pressed again, motor and blower are stopped, but bins are not lowered. When stop button is pressed again, bins are lowered.
1 2 3
1 2 3
1 2 3
1 2 3
C
60 min.
60 min.
?
1 2 3
Start Button Stop Button
Start Button
Stop Button
Stop Button Pressing Times
0
1
2
3
Feeding
ON
OFF
OFF
OFF
Motor and Blower
ON
ON
OFF
OFF
Bin
Up
UP
UP
DOWN
44
2. Operation Procedures
2-4 Feed Error Indication and Remedy
When jam, misfeeding and double feeding occur, the collator delivers the collated sets and then stops with errors indicated on the screen and remote controller.
1.
When the operation is stopped because of feeding errors, the numbers 1 and 3 on the right side on the screen mean that top collated sets and 3rd collated sets from the top on receiving tray have feed error. The feed error icons indicate all errors when the collator is stopped.
NOTE
- The feed error can be indicated on up to the eighth collated set.
3
4
1
2
9
10
7
8
5
6
1
Feed Error Mark
: Double Feed
: Jam
: Misfeed
2 3
3
4
1
2
9
10
7
8
5
6
4 5
2.
Press the number 1 button on the right side. Check the top collated set delivered on receiving tray.
- Jam occurred on the second bin of the second tower.
- Double feeding occurred on the first bin of the fourth tower.
NOTE
- Jam may be monitored though sheets are ejected. This is because feed timing is delayed. Check that sheets are not jammed.
When jammed, press inching button to transport the sheet, open transport door and then remove the sheet.
3
4
1
2
9
10
7
8
5
6
1
1 2 3
2 3
3
4
1
2
9
10
7
8
5
6
4 5
Inching Button
O K
6
3
4
1
2
7
8
5
6
9
10
1
3
6
O K
3
4
1
2
7
8
5
6
9
10
1
3
Transport Door
45
2. Operation Procedures
2-4 Feed Error Indication and Remedy
3.
Press the number 3 button on the right side. Check the third collated set from the top on receiving tray.
- Double feeding occurred on the first bin of the sixth tower.
- Misfeeding occurred on the third bin of the sixth tower.
9
10
7
8
5
6
1
2
3
4
1 2 3
9
10
7
8
5
6
1
2
3
4
4 5 6
O K
5
6
7
8
9
10
1
2
3
4
1
3
NOTE
- When sheet feed timing is delayed, the operation stops immediately with all tower numbers and jam marks indicated on screen as shown in the drawing at right. When this occurs, eject the jammed sheet by pressing inching button and check from the top to the fifth collated sets on receiving tray.
9
10
7
8
5
6
1
2
3
4
1 2 3
9
10
7
8
5
6
1
2
3
4
4 5
O K
6
1
4
5
6
2
3
7
8
5
6
7
8
9
10
1
2
3
4
4.
Press
O K button or stop button on remote controller to go back to the main page.
NOTE
- When feed error monitor is required to see again, press error monitor button on the main page.
1 2 3
1 2 3
1 2 3
1 2 3
C
60 min.
60 min.
?
46
2. Operation Procedures
2-5 Program Collation
2-5-1 Double Cycle
The VAC-100 system is divided into two sections. When any bin empties, the VAC-100 immediately switches over to the second section and continues collating.
1 Tower
1
A
5
6
10
B
3 Towers
1
A
10
1
A
5
6
10
B
1
10
B
5 Towers
1
A
10
1
10
A
1
A
5
6
10
B
1
10
B
1
10
B
2 Towers
1
10
A
1
10
B
4 Towers
1
A
10
1
A
10
1
10
B
1
10
B
6 Towers
1
A
10
1
A
10
1
A
10
1
10
B
1
10
B
1
10
B
1.
Load sheets on bins so that the first section
A and the second section B in the drawing above have the same contents.
NOTE
- When using only 1 tower and 1 collated sets use four bins, load sheets from the bins 1 to
4, and then load the same content sheets from the bins 6 to 9, from the bins 7 to 10, or the bins 6, 8 to 10.
- On the tower divided half of 1 tower, 3 or 5 towers, load sheets by 40 mm (1.5") height or less because separation air may curl loaded sheets.
2.
Prepare for collating referring to the "2-2
Preparation for Collation."
3.
Select program page.
4.
Turn on double cycle button.
5.
Select which section is started first with double cycle select button.
NOTE
- When sheets are delivered to the right, the A and B sections are reversed.
Double Cycle Select Button
Double Cycle Button
1
1 2 3 1 2 3
1 2 3
47
2. Operation Procedures
2-5 Program Collation
6.
Press all tower calibration button on the Set
2 page referring to the "2-3-1 Sheet Thickness Calibration."
Individual Calibration Buttons
All Tower Calibration Button
1 2 3
- All sheets on bins of all towers are collated once.
8
9
6
7
10
1
4
5
2
3
8
9
6
7
10
1
4
5
2
3
8
9
6
7
10
1
4
5
2
3
1
2
7.
Select the main page and press start button.
- When any bin empties in the first section, the collator switches over to the second section automatically and continues collating.
NOTE
- Add sheets on bins which are paused.
- Double cycle and dual cover feed programs can be operated together. Refer to "2-5-2
Dual Cover Feed" and "2-5-3 Tab Insert."
- When the collating speed is too fast or some bin empties in one section, misfeeding may be indicated on screen. In this case, remove the top collated set on receiving tray and press start button. The collator switches over to the other section automatically to start collating operation.
1 2 3
1 2 3
1 2 3
1 2 3
C
60 min.
60 min.
Start Button Stop Button
1 2 3
?
Start Button
Stop Button
48
2. Operation Procedures
2-5 Program Collation
2-5-2 Dual Cover Feed
Normally, cover sheets are thicker than inside sheets, so the bin loading cover sheets empties earlier than other bins. This dual cover feed program enables operation to continue without interrupting by switching over to the other bin loading cover sheets when one bin loading cover sheets empties.
1.
Load cover sheets into the top two bins, and inside sheets into the rest bins. (Refer to "2-2 Preparation for Collation.")
NOTE
- For example, when using the third to ninth bins, load cover sheets into the third and fourth bins.
2.
Select the program page.
3.
Turn on dual cover feed button.
4.
Select which bin loading cover sheets is used first with bin select button.
Cover Sheets
Inside Sheets
1
1 2 3 1 2 3
1 2 3
Dual Cover Feed Button Bin Select Button
5.
Press all tower calibration button on the Set
2 page referring to "2-3-1 Sheet Thickness
Calibration" and check the collating condition.
All Tower Calibration Button
Individual Calibration Buttons
- All sheets of all towers are collated once.
Cover sheets on both bins are also collated.
1 2 3
9
10
5
6
3
4
7
8
1
2
9
10
5
6
3
4
7
8
1
2
9
10
5
6
3
4
7
8
1
2
1
2
49
2. Operation Procedures
2-5 Program Collation
6.
Select the main page and press start button.
- When one bin loading cover sheets empties, the collator switches over to the other bin automatically.
1 2 3
1 2 3
1 2 3
1 2 3
C
60 min.
60 min.
?
Start Button Stop Button
1 2 3
Start Button
Stop Button
NOTE
- Dual cover feed and double cycle programs can be operated together. The position of cover sheet loading in the second section is the top two bins in the second section.
- Dual cover feed and tab insert programs can not be operated together.
- When the collating speed is too fast or some bin empties in one section, misfeeding may be indicated on screen. In this case, remove the top collated set on receiving tray and press start button. The collator switches over to the other section automatically to start collating operation.
1
5
6
10
Cover Sheets
(The first and second bins)
Cover Sheets
(The sixth and seventh bins)
50
2. Operation Procedures
2-5 Program Collation
2-5-3 Tab Insert
Up to two tab sheets can be inserted between collated sets preset.
1.
When one tab sheet is inserted, load the tab sheets into the top bin. When two tab sheets are inserted, load the tab sheets into the top two bins. And then load inside sheets into the rest bins. (Refer to "2-2
Preparation for Collation.")
Tab Sheets
Collated Sets
Collated Sets
Collated Sets
Collated Sets
Tab Sheets
Tab Insert Button Preset Button
Tab Sheet Button Preset Stop Button
2.
Select the program page.
1 2 3 1 2 3
1
3.
Turn on tab insert button.
4.
Select one or two with tab sheet button.
1 2 3
5.
Input the required number of collated sets between tab sheets with preset button.
6.
When the operation is required to stop after any tab inserting times, input the required number of inserting times with preset stop button.
7 8
1
9
4 5
1
6
1 2
1
3
C
1 1
7.
Press all tower calibration button on the Set
2 page referring to "2-3-1 Sheet Thickness
Calibration" and check the collating condition.
All Tower Calibration Button
Individual Calibration Buttons
1 2 3
- All sheets of all towers are collated once.
Cover sheets on both bins are also collated.
9
10
5
6
3
4
7
8
1
2
9
10
5
6
3
4
7
8
1
2
9
10
5
6
3
4
7
8
1
2
1
2
51
2. Operation Procedures
2-5 Program Collation
8.
Select the main page and press start button.
- Tab sheets are inserted between the preset number of collated sets and operation is stopped with preset number of tab inserting times.
NOTE
- When preset stop is used, the set number is indicated in tab counter on the main page.
1 2 3
1 2 3
1 2 3
1 2 3
C
60 min.
60 min.
?
Tab Counter Start Button
Stop Button
1 2 3
Start Button
Stop Button
NOTE
- Tab insert and double cycle programs can be operated together. The position of tab sheet loading in the second section is the top bin or two in the second section.
- Tab insert and dual cover feed programs can not be operated together.
1
5
6
10
Tab Sheets
(The first and second bins)
Tab Sheets
(The sixth and seventh bins)
52
2. Operation Procedures
2-6 Job Memory
The collation set up can be memorized and used in the future operation. Up to nine jobs can be memorized.
NOTE
- The following setups can be memorized.
Feed Speed
Belt Speed
Air Strength
Overlap
Using Bin Number
Preset Counter
Type of Program Collation
Delivery Direction
Sensor Lamp Adjustment
- The job memory function is not available on c-tower.
1.
Select the main page.
2.
When current setup button is pressed, the current collator setup is indicated. When job No. button is pressed, the memorized setup is indicated.
Current Setup Button
Job No. Button Write Button
1 2 3
1 2 3 4 5 hr.
6 7 8 9 hr.
1 2 3
3.
When the current set up is required to memorize, press job No. button and then write button.
- The former input set up is cleared and the current set up is memorized.
4.
When the memorized set up is required to read, press job No. button and check the set up indication. And then press read button.
- The set up of the collator is changed to the memorized setup.
Read Button
53
2. Operation Procedures
2-7 Right Side Delivery
When c-tower is combined, collated sets can be delivered to the right.
1.
Select the Set 1 page on a-tower operation panel on the left end.
2.
Select the delivery direction.
NOTE
- The delivery direction can be set as shown in the drawing at right. While 1 and 2 towers are delivering on the left side, 3 and 4 towers can perform the right side delivery.
- The delivery direction can not be set on ctower.
3.
To change the delivery direction, select another page to determine the delivery direction.
4.
Set up the collator referring to "2-2 Preparation for Collation"
NOTE
- To deliver collated sets to the right, load sheets from the bottom in order with the front side down as shown in the drawing at right.
Collated sheets are delivered upside down.
1 2 3 4 5 6
Delivery Direction Button
Page Order of Collated Sets
P20
P19
P18
P10
P9
P8
P12
P11
[Right Side Delivery]
P2
P1
5.
Set the collating condition and start/stop operation on c-tower.
NOTE
- The right side delivery operation can be performed only on c-tower.
- Program collations are available in the right side delivery operation.
54
2. Operation Procedures
2-8 Hand Marry
This section shows how to hand marry a sheet on or under collated sheet with hand marry unit.
1 2 3
1.
Select the main page.
2.
Press start button either on the main page or on remote controller.
NOTE
- The operation will not start before sheet thickness calibration is completed. (Refer to
"2-3-1 Sheet Thickness Calibration.")
1 2 3
1 2 3
1 2 3
C
60 min.
60 min.
?
3.
Place sheets on the hand marry unit.
-when the senser detects a sheet, collating
operation starts.
Start Button Stop Button
NOTE
- When selecting the mode with insert mode selecting switch, sheets on hand marry table are deliveried in a second after placing sheets on the table and then the collating operation starts.
When selecting the mode with insert mode selecting switch, the collating operation starts in a second after placing sheets on the table and then sheet on hand marry table is deliveried.
-Even changing the mode with the insert mode selecting switch after pressing start buttom in VAC-100, the mode does not change.When changing the mode, press stop buttom to stop collating and change the mode with the insert mode selecting switch.
1 2 3
Put the sheets registering with this guide
ATTENTION
- When sheet from hand marry unit is jammed on the mode , only collated sheets in VAC are deliveried to the finishing device.
The error is not indicated on the panel in
VAC-100.
- When sheet from hand marry unit is jammed on the mode , after the collated sheets in VAC-100 are deliveried, the rollers continue to rotate and the finishing device waits the sheet to be deliveried from hand marry unit. In this case, press stop buttom to stop collating.When a sheet from the hand marry unit is jammed, refer to "3-6 Sheet from hand marry unit is jammed"
Start Button
Stop Button
Sheet Guide
55
2. Operation Procedures
2-8 Hand Marry
4.
Press stop button either on the main page or on remote controller.
NOTE
- When stop button is pressed during operation, only feeding is stopped, not motor and blower. When stop button is pressed again, motor and blower are stopped, but bins are not lowered. When stop button is pressed again, bins are lowered.
Stop Button Pressing Times
0
1
2
3
Feeding
ON
OFF
OFF
OFF
Motor and Blower
ON
ON
OFF
OFF
Bin
Up
UP
UP
DOWN
56
3. Troubleshooting
3. Troubleshooting
3-1 Error Indication and Remedy ................................................................ 58
3-2 When Misfeeding Occurs ........................................................................ 59
3-3 When Double Feeding Occurs ................................................................ 59
3-4 Sheets Are Fed on the Skew ................................................................... 60
3-5 Paper Jam in Transport Conveyor ........................................................ 60
3-6 Sheet from Hand Marry Unit Is Jammed ............................................. 61
3-7 Collating Operation Does Not Start Even If Pressing Start Button ... 61
3-8 Fuse and Breaker Check ......................................................................... 62
3-9 Pump Does Not Work ............................................................................. 65
57
3. Troubleshooting
3-1 Error Indication and Remedy
When some error occurs during collation, the cause is indicated on operation panel.
?
1 2 3 4 5 6
O K
Feed Error
Double feeding, misfeeding or jam occurred.
Refer to "2-4 Feed Error Indication and Remedy."
?
?
?
?
?
?
Bin Empty
Bin is empty. Add sheets.
?
Operation Error
Operation error occurs;
- Start button is pressed before sheet thickness calibration.
- The number of used bins are different between the fist and second sections in double cycle.
- Bin power is off.
Operate collator in the proper procedures.
Door Open
Transport door is open. Close the door.
101
System Error Code
(Refer to the table
below for detail)
Accessory Error
Some error happened in the finishing device.
Remove the cause from the accessory. When stop button of the finishing device is being pressed, this mark is indicated. And also, this mark is indicated when transport belt of stitcher & folder is not rotating.
Emergency Stop
Emergency stop button is being pressed.
Release the button.
Full Tray
Receiving tray is full. Unload collated sets from tray.
X01
X02
X07
X25
X50
X51
X52
X87
X88
X89
X99
Jam in the Delivery Section
Sheets are jammed in the delivery section.
Remove the jammed sheets.
System Error
System error happened. Turn off main power and five seconds later turn on power. If the system error X51 or X52 (X:Number of tower where the system error happened) happened, press the "OK" Button on the operation panel or the Stop Button on the remote controller to reset.
System Error Code Table
Codes Causes
Communication Error with Operation Panel
Communication Error with Operation Panel
Internal Error
Control Software Error
Inverter Error
Delivery Sensor Error
Pulse Error
Communication Error between Towers
Communication Error between Towers
Communication Error between Towers
Internal Error
NOTE
- When the stacker ST-20R is connected to the single VAC-100a and the collated sets are delivered to the left, this full tray indication will appear. When the stacker ST-20 is connected to the single VAC-100a and the collated sets are also delivered to the left, this full tray indication will appear. This error indication can disappear by adjusting the volume on the printed circuit board. Contact with the dealer.
Actions
Turn off the power. Wait 5 sec. or more and turn on the power.
Turn off the power. Wait 5 sec. or more and turn on the power.
Turn off the power. Wait 5 sec. or more and turn on the power. See how the condition improves for some time.
Turn off the power. Wait 5 sec. or more and turn on the power.
Turn off the power. Wait 5 sec. or more and turn on the power.
Check the paper dust on the delivery sensor or the sensor position.
Check the loading of the pulse encorder or the paper dust on the encorder.
Check the communication cable between towers and the dip switch on the P.C.B..
Turn off the power. Wait 5 sec. or more and turn on the power.
Turn off the power. Wait 5 sec. or more and turn on the power.
Turn off the power. Wait 5 sec. or more and turn on the power.
58
3. Troubleshooting
3-2 When Misfeeding Occurs
This section shows how to remedy misfeeding.
(Cause)
1. Sheets are too thick. (Out of specifications)
(Remedy)
1. Use sheets within the specifications.
2. Sheets are not fanned well.
Ink on sheets is not dry.
2. Fan sheets well.
Dry ink on sheets.
3. Double feed stop plates are too high.
3. Lower double feed stop plates.
4. Sheets are not loaded properly into bins.
5. Air strength is set to "weak" position.
4. Load sheets into bins properly referring to "2-2-2 Collating Sheet Preparation."
5. Set air to "strong" position.
3-3 When Double Feeding Occurs
This section shows how to remedy double sheet feeding.
(Cause)
1. Sheets are too thin. (Out of specifications)
(Remedy)
1. Use sheets within the specifications.
2. Sheets are loaded into bins too much.
2. Reduce the sheets.
3. Sheets are not fanned well.
Ink on sheets is not dry.
3. Fan sheets well.
Dry ink on sheets.
4. Double feed stop plates are too low.
4. Raise double feed stop plates.
5. Air strength is set to "strong" position.
5. Set air to "weak" position.
6. Separation air is weak.
6. Strengthen separation air with separation air adjust lever (Blue).
59
3. Troubleshooting
3-4 Sheets Are Fed on the Skew
This section shows how to remedy sheet skew.
(Cause)
1. Sheets are not loaded properly into bins.
2. Sheet guides are not set properly.
(Remedy)
1. Reload sheets into bins referring to "2-2-2
Collating Sheet Preparation."
2. Set guide by slightly hitting sheets, or change the guide position.
3. Sheets are loaded too much.
4. Paper dust is collected in the feed and transport sections.
5. Double feed stop plates are worn out.
3. Reduce the sheets.
4. Remove paper dust.
6. Sheets are curling because or separation air.
5. Replace double feed stop plates with new ones referring to "4-3 Double Feed Stop
Plate Replacement."
6. Adjust separation air with separation air adjust lever (Blue) on bin.
3-5 Paper Jam in Transport Conveyor
1.
When the paper jam occurs in transport conveyor, pull the lever to left and lock lever as shown in the drawing at right.
Transport
Conveyor
NOTE
- Normally, operate the machine without locking the lever.
Lever
60
3. Troubleshooting
3-6 Sheet from Hand Marry Unit Is Jammed
This section shows how to remedy jammed sheet delivered from hand marry unit.
(Cause)
1. Sheets on hand marry table are more than
50 sheets of 80 gsm (5 mm height).
(Remedy)
1. Hand marry unit can accept 50 or less sheets at a time (5 mm).
2. The hand marry unit are not installed properly.
2. Install the hand marry unit so that the positioning guide (arrow) of this unit fits in the rear cover of VAC-100 completely.
Rear Cover
Hand Marry Unit
Positioning Guide
3-7 Collating Operation Does Not Start Even If Pressing Start Button
This section shows how to remedy the collating problem when the collating operation does not start even if pressing start button.
(Cause)
1. Sheets thickness is not calibrated.
(Remedy)
1. Calibrate sheets thickness before actual collating operation referring to "2-3-1
Sheet Thickness Calibration".
2. The insert mode selecting switch is set either or on HMU-100.
2. Turn OFF the insert mode selecting switch when hand marry function is not used installing hand marry unit to VAC-
100. When using hand marry function, the collating operation does not start until sheets are put on hand marry table.
Insert Mode Selecting Switch
61
3. Troubleshooting
3-8 Fuse and Breaker Check
When one part of collator or whole does not operate, check fuse and breaker.
WARNING
- Remove power cord before checking fuse and breaker. Otherwise high voltage can cause sever personal injury.
1.
Remove power plug or power cord.
2.
When the collator is locked, remove the cause.
3.
Loosen a fix screw on panel cover and open panel cover.
4.
Check fuses as shown in the drawing at right. If fuse is cut, replace it with a new one.
NOTE
- When fuses are cut, the collator has trouble as follows.
F1 (5A) : The whole machine do not operate.
F2 (2A) : Delivery air does not come out.
F3 (1A) : Not used.
F4 (5A) : Receiving tray on the left side does not operate.
F5 (5A) : Receiving tray on the right side of c-tower does not operate.
Fix Screw
Panel Cover
Power Cord
5.
Close panel cover and fix it with a fix screw.
F2
F3
Fuses
62
3-8 Fuse and Breaker Check
The following procedures (steps 6 to 12) shows how to check breaker.
6.
Remove top on blower box. (4 fix screws)
Fix Screws
3. Troubleshooting
Fix Screws
Top
Blower Box
7.
Remove 2 fix screws inside of blower box.
8.
Remove front cover. (3 fix screws)
Fix Screws
Fix Screw
63
Front Cover
Fix Screws
3. Troubleshooting
3-8 Fuse and Breaker Check
9.
Check breakers as shown in the drawing at right. If some breakers trip, turn on breakers.
NOTE
- When breakers trip, the collator has trouble as follows.
Q10 (16A) : The whole machine do not operate.
Q01 (2A) : Receiving tray does not operate and delivery air does not come out.
10.
Attach front cover. (3 fix screws)
Breaker Q10 Breaker Q01
11.
Fix blower box on the collator. (2 fix screws)
12.
Attach top on blower box. (4 fix screws)
Fix Screws
Fix Screws
Fix Screws
Top
Blower Box
64
3-9 Pump Does Not Work
There is a function to prevent the inside circuit from overheating in the pump and it might work. The inside temperature might increase because the air slits of blower box are obstructed. Follow the steps to work pump again.
1.
Turn off the power switch.
2.
Install the pump so that it does not obstruct the air slits of the blower box.
3.
Wait until the inside temperature decrease and turn on the power switch.
3. Troubleshooting
Blower Box
Air Slits
65
3. Troubleshooting
This page is intentionally left blank.
66
4. Maintenance
4-1 Daily Cleaning .......................................................................................... 68
4-2 Monthly Cleaning .................................................................................... 70
4-3 Double Feed Stop Plate Replacement .................................................... 71
4-4 Feed Error Sensor Cleaning ................................................................... 72
4. Maintenance
67
4. Maintenance
4-1 Daily Cleaning
4-1-1 Feed Ring
After operations, clean feed rings. If feed rings are dirty, collated sheets may be smeared.
WARNING
- Turn off main power before cleaning feed rings. Otherwise personal injury may result.
1.
Wipe 4 gray feed rings on bin with alcohol-soaked cloth.
NOTE
- Feed rotor can be turned manually.
- Do not use thinner and benzine.
Feed Rings
68
4-1 Daily Cleaning
4-1-2 Transport Belt
After operations, clean transport belt. If transport belt and rollers are dirty, collated sheets may be smeared.
WARNING
- Turn off main power before cleaning transport belt. Otherwise personal injury may result.
Transport Door
1.
Open transport door.
NOTE
- When transport door can not be opened completely because a collator is combined on the left side, remove transport door by opening and lifting the door.
- Transport door weights 9 kg (19.9 lb). Take utmost care when removing it.
Transport Belt
2.
Wipe transport belt and rollers with alcohol-soaked cloth.
3.
Close transport door.
Transport Roller
4. Maintenance
69
4. Maintenance
4-2 Monthly Cleaning
4-2-1 Bin Sensor
Clean bin sensor monthly. If paper dust stick on bin sensor, sensor determines that sheets are loaded into bin without any sheets and misfeeding is indicated.
WARNING
- Turn off main power before cleaning bin sensor. Otherwise personal injury may result.
1.
Remove bin sensor cover by pulling to the right.
2.
Remove paper dust on bin sensor with brush.
3.
Attach bin sensor cover.
Bin Sensor Cover
4-2-2 Delivery Sensor
Clean delivery sensor monthly. If paper dust stick on delivery sensor, double feeding error monitor is indicated.
WARNING
- Turn off main power before cleaning delivery sensor. Otherwise personal injury may result.
1.
Remove paper dust on delivery sensor with brush.
70
Delivery Sensor
Bin Sensors
4-3 Double Feed Stop Plate Replacement
When double feed stop plates are worn out and double feeding occurs, replace double feed stop plates with new ones.
WARNING
- Turn off main power before replacing double feed stop plates. Otherwise personal injury may result.
Fix Screws
1.
Loosen 2 fix screws on double feed stop plate.
2.
Remove double feed stop plate by sliding upward.
Double Feed Stop Plate
4. Maintenance
3.
Attach new double feed stop plate and fix it with 2 fix screws.
NOTE
- Do not fasten screws too tight.
Double Feed Stop Plate
Fix Screws
71
4. Maintenance
4-4 Feed Error Sensor Cleaning
When paper dust sticks to feed error sensors, bins which require sensor cleaning are indicated on the screen as soon as turning on power switch.
1.
Clean feed error sensor(s) indicated on maintenance page of screen with cleaning brush.
9
10
7
8
5
6
1
2
3
4
1 2 3
9
10
7
8
5
6
1
2
3
4
4 5 6
5
6
7
8
9
10
1
2
3
4
O K
Paper dust sticks on the bins 2 and 7 of tower
1, and the bin 5 of tower 2.
NOTE
- Feed error sensors light inside the feed section.
- Insert cleaning brush into the feed section with the face down.
Feed Error Sensor
2.
Turn off power switch and 10 seconds later turn on power switch. When the main page appears, feed error sensor has been cleaned. When the maintenance page appears again, clean feed error sensor again.
Power Switch
72
5. Move and Installation
5. Move and Installation
5-1 Collator Installation ................................................................................ 74
5-2 Blower Box Installation .......................................................................... 75
5-3 System Switch Set Up .............................................................................. 77
5-4 Cable Connection .................................................................................... 78
5-5 Receiving Tray Installation .................................................................... 79
5-6 EAB-100 Extra Air Blower (Option) Installation ................................ 82
5-7 VAC-100a Right Side Unit (Option) Attachment ................................ 87
5-8 HMU-100 Hand Marry Unit (Option) Installation .............................. 97
73
5. Move and Installation
5-1 Collator Installation
WARNING
- Do not turn on main power before instruction.
CAUTION
- VAC-100 weights 298 kg (657.1 lb).
Install VAC-100 on rigid and level floor.
- Avoid direct sunlight and high humidity.
1.
Prepare space for installing VAC-100.
NOTE
- Required space is shown as follows.
1 Tower : 1507 x 952 mm (59.4" x 37.5")
2 Towers : 2317 x 952 mm (91.3" x 37.5")
3 Towers : 3127 x 952 mm (123.2" x 37.5")
4 Towers : 3937 x 952 mm (155" x 37.5")
5 Towers : 4747 x 952 mm (186.9" x 37.5")
6 Towers : 5557 x 952 mm (218.8" x 37.5")
2.
Position collator(s). When installing two collators or more, attach connecting plates
(U) and (L).
3.
Put setting plates under adjust bolts.
4.
Raise collator(s) by turning adjusts bolts until casters slightly separate from the floor.
NOTE
- Collator must not tilt by 5 mm (0.2") or more.
- The difference between tower heights must be within 3 mm (0.12").
550
ST-20 VAC 65
Blower 302
506.6
600 842
CCR VAC
Blower
650
Tray 1 Tower 2 Towers 3 Towers 4 Towers 5 Towers 6 Towers
Blower Blower Blower Blower Blower Blower
1507
2317
3127
3937
4747
5557
952
5 mm
(0.2")
Connecting Plate (U)
3 mm
(0.12")
Connecting Plate (L)
Adjust Bolt
Setting Plate
74
5-2 Blower Box Installation
This section shows how to install blower box.
1.
Remove top on blower box. (4 fix screws)
5. Move and Installation
Fix Screws
Fix Screws
2.
Connect collator hose to blower through hole and fix the hose.
3.
Connect signal and power cords to terminal board through cord bushes.
1
3
2
1
Top
2 3
Signal Cord
Power Cord
Signal Cord
(Thin)
3
2
1
Power Cord
(Thick)
4.
Fasten cord bushes to fix cords.
Cord Bushes
75
5. Move and Installation
5-2 Blower Box Installation
5.
Fix blower box on collator. (2 fix screws)
NOTE
- Do not obstruct the air slits of the blower box.
6.
Attach top on blower box. (4 fix screws)
Fix Screws
Fix Screws
Fix Screws
Top
76
5. Move and Installation
5-3 System Switch Set Up
This section shows how to set up system switches inside panel cover.
WARNING
- Remove power cord before setting up system switch. Otherwise high voltage can cause sever personal injury.
TOTAL ORDER
1.
Loosen each fix screw on panel covers on all towers and open panel cover.
1
2.
Set "TOTAL" and "ORDER" with system switches of all towers.
1 Tower
2 Towers
TOTAL:1
ORDER:1
TOTAL:2
ORDER:1
TOTAL:2
ORDER:2
3 Towers
TOTAL:3
ORDER:1
TOTAL:3
ORDER:2
TOTAL:3
ORDER:3
4 Towers
TOTAL:4
ORDER:1
TOTAL:4
ORDER:2
TOTAL:4
ORDER:3
TOTAL:4
ORDER:4
1
5 Towers
TOTAL:5
ORDER:1
TOTAL:5
ORDER:2
TOTAL:5
ORDER:3
TOTAL:5
ORDER:4
TOTAL:5
ORDER:5
6 Towers
TOTAL:6
ORDER:1
TOTAL:6
ORDER:2
TOTAL:6
ORDER:3
TOTAL:6
ORDER:4
TOTAL:6
ORDER:5
TOTAL:6
ORDER:6
3.
Close panel cover and fasten each fix screw on panel covers on all towers.
77
5. Move and Installation
5-4 Cable Connection
This section shows how to connect signal and power cords.
WARNING
- Turn off breakers in the building before connecting power cord. Otherwise high voltage can cause sever personal injury.
1.
When using two towers or more, connect signal cord on the right tower to the left tower.
NOTE
- The a-tower does not have signal cord.
Signal Cord
2.
Connect power cords of all towers on terminal in the building.
78
Red
Power Cord
Ground
White
Green
Power Cord
5. Move and Installation
5-5 Receiving Tray Installation
5-5-1 CCR/CCR-DX
1.
Loosen lock knob and set the angle of the delivery unit on the collator at low position.
Delivery
Direction
Lock Knob
Handle
2.
Hold handle and raise the collator and insert pins into holes.
3.
Connect connecting cable to connector (U) of collator.
Pin
Handle
Holes
Pin
4.
Adjust CCR/CCR-DX with adjustor so that
CCR/CCR-DX is stable.
Connecting Plate
Connecting Cable
Connector (U)
Adjustor
5.
Select CCR with finishing device button on the Set 1 page.
1 2 3 4 5 6
CCR
79
Finishing Device Button
5. Move and Installation
5-5 Receiving Tray Installation
5-5-2 ST-20/ST20R
1.
Loosen lock knob and set the angle of the delivery unit on the collator at up position.
(Only for ST-20)
Delivery
Direction
Lock Knob
2.
Attach stacker guide on the delivery section.
NOTE
- Attach stacker guide so that it does not touch rollers.
Roller
Stacker Guide
3.
Lift connecting plate on stacker and insert stacker pins into holes on the collator.
4.
Connect connecting cable to connector on collator.
Small Cable ... Upper Connector
Large Cable .... Lower Connector
Holes
80
Connecting Plate
Pin
5. Move and Installation
5-5 Receiving Tray Installation
5.
Turn on collator power.
- Press tray UP button. Tray will rise and stop at the top.
- Load sheets into only one bin, press sheet calibration button, and press stop button immediately so that the sheet stops before it reaches the delivery section.
- Press inching button on remote controller to transport the sheet to the position where it overlaps with stacker tray by 10 mm (0.4").
- Loosen thumb nuts, slide stacker back and forth, and position stacker at the position where the gap between off-set guide and sheet edge is 5 mm (0.2") as shown in the drawing at right.
- Fasten thumb nuts.
- Adjust stacker with four adjustor so that stacker is stable.
Off-set Guide 5 mm (0.2")
Sheet
Adjustors
Thumb Nuts
6.
Select standard ( ) with finishing device button on the Set 1 page.
1 2 3 4 5 6
81
Finishing Device Button
5. Move and Installation
5-6 EAB-100 Extra Air Blower (Option) Installation
This section shows how to install extra air blower (option).
NOTE
- Extra air blower increases feed rotor suction. Separation air does not change by installing it.
Fix Screws
WARNING
- Remove power cord before installing extra air blower. Otherwise high voltage can cause sever personal injury.
Fix Screws
Top
Blower Box
1.
Remove top on blower box. (4 fix screws)
2.
Remove 2 fix screws inside blower box
Fix Screws
Fix Screw
3.
Remove front cover. (3 fix screws)
82
Front Cover
Fix Screws
5. Move and Installation
5-6 EAB-100 Extra Air Blower (Option) Installation
Right Side Cover
4.
Remove 2 right side covers on collator. (4 fix screws)
NOTE
- The cover can be removed by removing upper 2 fix screws and loosening lower 2 fix screws.
Fix Screws
5.
Remove rear cover. (2 fix screws)
NOTE
- Rear cover can be removed by loosing 2 fix screws, tilting the cover to rear side, and lifting cover.
Fix Screws
Rear Cover
6.
Place extra air blower behind tower.
7.
Remove plate on the rear side of collator.
(2 fix screws)
NOTE
- After removing plate, attach fix screws into tow holes not to put air inside air pipe.
83
Fix Screws
Plate
5. Move and Installation
5-6 EAB-100 Extra Air Blower (Option) Installation
8.
Attach hose joint. (4 fix screws)
Fix Screws
Hose Joint
9.
Put power and signal cables of extra air blower inside collator through holes from the right side as shown in the drawing at right.
Power Cord Signal Cord
10.
Connect power cord of extra air blower to the collator as shown in the drawing at right.
84
Green
Red
White
5. Move and Installation
5-6 EAB-100 Extra Air Blower (Option) Installation
11.
Connect signal cord of extra air blower to the connector on the rear side of collator as shown in the drawing at right.
12.
Attach front cover, 2 right side covers, rear cover and blower box on the reverse order of removal.
NOTE
- When attaching 2 right side covers, lead power and signal cords of extra air blower on the right side under the covers.
Signal Cord
Connector
Hose
Extra Air Blower
Hose Band
13.
Insert extra air blower hose into hose joint and fix the hose with hose band.
- Do not obstruct the air hole of the blower box.
Hose
85
5. Move and Installation
5-6 EAB-100 Extra Air Blower (Option) Installation
NOTE
- When not using extra air blower, remove extra air blower hose from hose joint and put plug into hose joint.
Hose Joint
Plug
86
5. Move and Installation
5-7 VAC-100a Right Side Unit (Option) Attachment
5-7-1 Accessories
Delivery Unit C (A204602-00) 1 pc Connector 16S (A924631-00) 1 pc
Connector 10S (A924632-00) 1 pc Delivery Belt (M072683-01) 1 pc
Idler Shafts (A924633-00) 3 pc Cord Clamper (3N) 1 pc
Delivery Drive Pulley (M072319-00) 1 pc Pin (PP-20h7) 1 pc
87
5. Move and Installation
5-7 VAC-100a Right Side Unit (Option) Attachment
Snap Ring (STW-15) 1 pc Fix Screws
Washers
W3:1 pcs
W5S:3 pcs
W5(Extra-Large):1 pcs
SB3-8:1 pcs
SB5-10:3 pcs B4-8ZP:4 pcs
B3-10ZP:4 pcs
Flanged Nuts (N3F) 4 pc
88
5. Move and Installation
5-7 VAC-100a Right Side Unit (Option) Attachment
5-7-2 How to Attach
WARNING
- Turn off breakers in the building before removing power cord. Otherwise high voltage can cause severe personal injury.
Lamps
Speed Buttons
Bins
1 2 3
1.
Raise the bins following the procedures below.
(1) Turn on power switch while pressing both speed buttons simultaneously.
- Service mode page appears on the screen.
NOTE
- Keep on pressing both speed buttons until 3 lamps light as shown in the drawing of controller at right.
(2) Press the right speed button on remote controller or the bins UP button on the screen to raise all bins.
1 2 3
Power Switch
Pressing this button raise all bins.
Bins UP Button
VAC-100 ROM
Life counter
Ver.
Bins
DOWN
Motor
ON/OFF
Delivery Direction front / rear
Bins
UP
Blower
ON/OFF
2.
Turn off power switch and remove power cord.
Power Switch
89
5. Move and Installation
5-7 VAC-100a Right Side Unit (Option) Attachment
3.
Remove front cover (3 fix screws) and rear cover (2 fix screws).
Fix Screw
Front Cover
NOTE
- Rear cover can be removed by loosing 2 fix screws and moving the upper part of the cover to near side before lifting cover.
Fix Screws
Fix Screws
Rear Cover
4.
Remove upper guide plate in the transport conveyor.
Upper Guide Plate
90
5. Move and Installation
5-7 VAC-100a Right Side Unit (Option) Attachment
NOTE
- The upper guide plate can be removerd by lifting up the right part of plate and moving to the right.
Upper Guide Plate
5.
Remove right side cover (2 fix screws) and covers (2 fix screws each).
Covers
Right Side Cover
Cover
Fix Screws
6.
Remove lower guide plate.
NOTE
- The lower guide plate can be removerd by lifting up the right part of plate and moving to the right.
Lower Guide Plate
91
5. Move and Installation
5-7 VAC-100a Right Side Unit (Option) Attachment
7.
Attach delivery unit C (4 fix screws:B4-
8ZP).
Delivery Unit C
8.
Remove side covers of delivery unit C (2 fix screws each) before removing fix screw on front side cover.
NOTE
- When delivery unit C fix screw is removed, nut plate is also removed.
Lock Screws
Side Covers Fix Screws
Nut Plate
9.
Attach a delivery drive pulley to shaft as shown in the drawing at right.
(1) Insert a pin into hole of shaft.
(2) Attach the delivery drive pulley to shaft.
(3) Fit snap ring in the groove of shaft.
Pin
Delivery Drive
Pulley
Snap Ring
92
5. Move and Installation
5-7 VAC-100a Right Side Unit (Option) Attachment
10.
Attach 3 idler shafts as shown in the drawing at right.
Fix Screws : SB5-10, W5S and W5
(extra-large) for the lowest
idler shaft.
SB5-10 and W5S for the
other two shafts.
NOTE
- Do not fasten the lowest idler shafts yet.
Idler Shafts
Do not fasten this shaft yet.
11.
Attach a delivery belt to the pulleys as shown in the drawing at right.
Delivery Belt
12.
Fix the lowest idler shaft pushing the arrow direction in the drawing at right so that delivery belt has tension.
93
Idler Shaft
5. Move and Installation
5-7 VAC-100a Right Side Unit (Option) Attachment
13.
Attach side covers (2 fix screws each ) and secure the lock screw with nut plate before attaching fix screw on nut plate.
Lock Screw
Side Covers
14.
Connect connectors 10S and 16S (2 fix screws each:B3-10ZP and N3F), cables and ground wire as shown in the drawing at right.
Ground Wire
Connector 10S
94
Cables
Connector 16S
5. Move and Installation
5-7 VAC-100a Right Side Unit (Option) Attachment
15.
Connect sensor connector on rear side.
NOTE
- Fix the sensor cord with cord clamper (fix screw : SB3-8 and W3) on the delivery roller.
Connector
Cord Clamper
16.
Insert air hose into hole on the right side of tower.
NOTE
- Delivery unit C blows air when delivery air knob is turned downward.
95
Air Hose
Delivery Air Knob
Normal (Left Side Unit)
Right Side Unit
5. Move and Installation
5-7 VAC-100a Right Side Unit (Option) Attachment
17.
When the sirial number of your machine is below 007001, replace the P.C.B. (QPW-
492C) on the back side of panel cover (1 fix screw).
P.C.B.(QPW-492C)
18.
Attach the lower guide plate to the original position.
Lower Guide Plate
19.
Attach the upper guide plate to the original position.
20.
Attach front cover (3 fix screws) and rear cover (2 fix screws) to their original positions.
NOTE
- When the stacker ST-20R is connected to the single VAC-100a and the collated sets are delivered to the left, the full tray indication will appear. When the stacker ST-20 is connected to the single VAC-100a and the collated sets are also delivered to the left, the full tray indication will appear. The full tray indication can disappear by adjusting the volume on the printed circuit board. Contact with the dealer.
Front Cover
96
Upper Guide Plate
Rear Cover
5. Move and Installation
5-8 HMU-100 Hand Marry Unit (Option) Installation
5-8-1 Accessories
Delivery Drive Pulley (M072319-00) 1 pc Idler Shafts AS(A924633-00) 2 pc
Delivery Belt (M120026-00) 1 pc Sheet Guide (A924698-01) 1 pc
Support table (M120031-00) 1 pc Delivery Drive Pulley Locking Snap Ring (STW-15) 1 pc
Idler Shafts Fixing Screws 1 pc Pin (PP5-20) 1 pc
(SB5-12) 2pc
(W5S) 2pc (W5Large)(For under idler shaft
AS) 1pc
97
5. Move and Installation
5-8 HMU-100 Hand Marry Unit (Option) Installation
5-8-2 Hand Marry Unit (HMU-100) Installation
When a-tower and m-tower are connected, the hand marry unit is installed on the right side of m-tower. It can be installed to maximum two towers.
WARNING
- Turn off breakers in the building before disconnecting and connecting power cord. Otherwise high voltage can cause severe personal injury.
1.
Turn off power switch and disconnect power cord.
Power Switch
2.
Remove the front cover of VAC-100 installed with hand marry unit.
Front Cover
3.
Remove the right side cover of VAC-100, the cover for a-tower or m-tower and the hole cover.
Fix Screws
Cover For a-tower Or m-tower
Hole Cover
Fix Screws Right Side Cover
98
5. Move and Installation
5-8 HMU-100 Hand Marry Unit (Option) Installation
W5S
SB5-12
4.
Insert a pin into a shaft and delivery drive pulley and fix with a snap ring.
Idler Shafts AS
5.
Fix a idler shafts AS(2pc) with fixing screws (SB5-12, W5S, W5) from the opposit side of the cover.
NOTE
- Fix the only lower idler shaft with the fixing screw (W5 Large).
(W5Large)
Shaft
Delivery Drive Pulley
Snap Ring
Pin
6.
Reattach the right side cover.
7.
Attach the hand marry unit on the right side of VAC-100 on the following procedures.
1. Hang the hook of the hand marry unit on the stay of VAC-100.
2.Attach the hand marry unit to VAC-100 so that the positioning guide (arrow shows) fits closely to the rear cover of
VAC-100.
Stay
Hook
(Hand Marry Unit)
Rear Cover
99
Hand Marry Unit
Positioning Guide
5. Move and Installation
5-8 HMU-100 Hand Marry Unit (Option) Installation
8.
Remove the front cover of the hand marry unit. (3 fixing screws)
NOTE
- Loosen the two fixing screws underneath the cover.
Front Cover
Delivery Belt
9.
Draw 100 mm line on the delivery belt with pen.
10.
Install the delivery belt on the pully of
VAC-100 and hand marry unit and idler shaft. Arrow direction must be same as an arrow in the drawing at right.
Idler Shaft
Pully
Delivery Belt
Pully
Idler Shaft
(VAC Front Side) (Hand Marry Unit Front Side)
Idler Shaft AS
Upper Idler Shaft
11.
Adjust the upper idler shaft position of hand marry unit so that the 100 mm line marked on the delivery belt streches 101.5
to 102 mm.
12.
Attach the front cover of hand marry unit and VAC-100.
Pully
Idler Shaft AS
Pully
Idler Shaft AS
(VAC Front Side) (Hand Marry Unit Front Side)
100
5. Move and Installation
5-8 HMU-100 Hand Marry Unit (Option) Installation
5-8-3 Cable Connection
When a-tower is connected with m-tower, the connecting cable is connected with m-tower.
Panel Cover
WARNING
- Make sure the main power is turned off before connecting the cable.
Control Panel
(QPW-492C)
1.
Open the panel cover of VAC-100.
2.
Connect the thick cable (input signal) from hand marry unit to the CON 8 and CON 9 on control panel QPM-119C inside of panel cover.
NOTE
- It is the easy way to unplug the CON
8 connector and insert the cable pin into the connector and connect the connector at the original position.
- Make sure the inserting direction of pin. When inserting to the proper direction, feel click.
a or c tower only
QPW502A
P.C.B.(QPW-492C)
QPW506A
CON4
1
2
3
4
5
6
7
8
9 W
10 D
3
4
5
6
CON9
1
2
C
D
B
CON8
1
2
9
10
11
12
3
4
5
6
7
8
13
14
R
W
Y
G
CON8
CON10
CON11
CON12
CON14
CON15
CON16
CON17
CON18
QPM119C
CON2
QPW492C
CON4
CON7
CON11
CON9
CON12
CON10
CON13
CON16
CON14
CON17
CON15
CON18 CON20
CON19 CON21
(Right Side)
(How To Insert Pin Into Connector)
101
5. Move and Installation
5-8 HMU-100 Hand Marry Unit (Option) Installation
3.
Connect the thin cable (output signal) from hand marry unit to the CON 4 on control panel QPM-492C inside of panel cover.
NOTE
- It is the easy way to unplug the CON
4 connector and insert the cable pin into the connector and connect the connector at the original position.
4.
Check the version of ROM. When the version is low, exchange it to a new one.
(The ROM coordinated with HMU-100)
Control ROM
(Both a-tower and m-tower)
V1.20 (QPM-119C)
Image ROM (a-tower only)
V1.20J/E (the new panel QPM-157A)
V1.20E (the old panel QPM-120C)
NOTE
- When removing the ROM, it is recommended to use IC puller.
CON4
CON5
CON1
CON2
CON9
QPM157A
Image ROM
QPM120C
CON1 CON2 CON5
CON3
CON4
CON7
VAC Image ROM (IMG)
Control ROM
IC Puller
Grip
5.
Turn off the breaker in the building and connect the power cord.
6.
Turn on the breaker in the building.
102
QPM119C

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Key features
- High-capacity towers hold up to 6,000 sheets
- Adjustable feed height and blower system for optimal paper handling
- Intuitive operation panel with customizable collating programs
- Memory storage for quick recall of frequently used settings
- Remote controller for added convenience
- Optional receiving tray and stackers for automated stacking and organization
- User-friendly interface simplifies operation and reduces training time
- Compact design saves valuable workspace
- Durable construction ensures longevity and reliability
- Horizon International Inc.'s commitment to continuous improvement ensures the latest features and performance enhancements