MC-80. Important Information COLLATOR

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1 COLLATOR MC-80 Important Information - This manual is designed to help you to install, operate and maintain Automatic Collator, MC-80. Read, understand and keep this manual in a safe and convenient place. - Do not operate MC-80 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 /MC80/0E/DV I UM0006-0

2 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

3 CONTENTS Important Information...I Safety Precautions...II. Before You Begin... - Specifications... - Machine Descriptions Collator Module Sucker Bar Assembly Monitor Panel Remote Controller [] Remote Controller [] Accessories...8. Setting & Operation... - Setting Up MC Loading Sheets On Bins Sucker Stopper and Valve Setting Delivery Roller Unit Setting Receiving Accessory Setting Operation Procedure Right-side Delivery Function Hand Marrying Operation (HMU-80 : Option) Feed Error Indication Programming Collating Double Cycle Collation Dual Cover Feeding Mixed Modes of Collation Tab Insertion Mode & Preset Stop Mode Tab Insertion Mode Preset Stop Mode...30 III

4 -8 For Efficient Operation Detector Sensitivity Setting Paper Condition Folded Sheets Wet Ink Correct Loading Roller Pressure Maintenance Cleaning Detector Cleaning Delivery Sensor Cleaning Nip Roller and Transport Belt Cleaning Replacement of Fuses Replacement of Double Sheet Prevent Brush Filter on Air Pump Installation Instructions Installation of Collator Module Installation Location Installing MC Installation of Kit CTK-80 (Option) Parts Installation Procedure Installation of DDM-80 (Option) Parts Installation Procedure Installation of DDA-80 (Option) Parts Installation Procedure...5 IV

5 . Before You Begin. Before You Begin - Specifications... - Machine Descriptions Accessories... 8

6 . Before You Begin - Specifications Module Type MC-80a (Main Module) MC-80m (Extension Module) MC-80c (Right-side Delivery Module) Number of Bins 8, 6, 4, 3, 40 and 48 Sheet Size 48 x 0 mm to 38 x 470 mm (5.8" x 8.3" to.5" x 8.5") Bin Pile Height 50 mm (") Stock Weight 5 gsm to 60 gsm Collating Speed (A4) 3,500 sets/hr (8 bins),500 sets/hr (6 bins),400 sets/hr (4 bins),300 sets/hr (3 bins),050 sets/hr (40 bins),050 sets/hr (48 bins) Power 00 V 50/60 Hz 400 V 50 Hz Machine Weight MC-80a... 9 kg (505 lb) MC-80m... 3 kg (49 lb) MC-80c... 9 kg (505 lb) Machine Dimensions Height=,640(64.5") 400 (5.7") 575 (.6") 580(.8") 580(.8") 580(.8") Pump Pump Pump ST-0 MC-80a MC-80m MC-80m MC-80m MC-80m MC-80c PJ (9.6") 780(30.7") 780(30.7") 780(30.7") 780(30.7") 780(30.7") 780(30.7") 500(9.6") 5,680(44.3") 590 (3.") 580(.8") 580(.8") Pump Pump 60 (4") Conveyor FC-0II SPF-0II MC-80a MC-80c PJ (5.9") 570(.4"),470(57.8") 4,760(87.4") 780(30.7") 780(30.7") 500(9.6") 590 (3.") :mm(inch) The machine design and specifications are subject to change without any notice.

7 . Before You Begin - Machine Descriptions -- Collator Module Stop Button Used to shut down whole system in case of emergency. Transport Belt Section Transport belts carry fed sheet to delivery section. Roller Pressure Selector Lever Used to select pressure of support roller to hold sheets when collating NCR. Down Position : Normal Up Position : Weak Monitor Panel Monitor panel is equipped with two sets error monitor system. Bin Sheets will be piled on these bins for collating. Remote Controller Major operation switches are provided on remote controller. Accessories (Option) Six different accessories can be combined. (CCR(DX), ST-0, PJ-77, SPF-, SPF-0, SP-0 or SP-) Refer to each accessory operation or instruction manual. Delivery Unit Used to adjust angle of delivery unit according to connected accessory. Receptacle for Accessories Accessory connectors will be connected on these receptacles. Delivery Speed Control Knob Two different speed "Turtle" or "Rabbit" (fast or slow) can be selected. Right-side delivery Accessory (Option) Optional receiving tray for right-side delivery operation. Delivery Speed Control Knob Two different speed "Turtle" or "Rabbit" (fast or slow) can be selected. Power Switch Used to turn on/off main power of module. 3

8 . Before You Begin - Machine Descriptions -- Sucker Bar Assembly Sucker Stopper A Sucker stopper A is provided on each sucker bracket and used to provide a clearance between sucker rubber and sheets. - Stopper A should be set at fully DOWN position when collating less than around 30 gsm sheets; fully UP position when collating more then around 30 gsm sheets. NOTE : - Use sucker stopper A either fully DOWN position or fully Up position. Suction Air Valve Used to select suction air open or close. Open suction air valve according to size of sheets. Sucker Stopper B Used to provide a clearance between suckers and sheets when double sheet feeding often happens to collate heavier paper with sucker stopper A being Up position. Sucker Stopper C Used to adjust angle of sucker brackets. Use sucker stopper C when sucker stopper A can not eliminate double sheet feeding. Suction Adjusting Ring Used to adjust the vacuum air power. Sucker Rubber Two types of sucker rubbers are supplied with machine. Small Sucker Normal to Heavy Stock (Installed on MC-80) Large Sucker Very Heavy Stock (Packed in accessory box.) 4

9 . Before You Begin - Machine Descriptions --3 Monitor Panel Total Counter (Only for MC-80a and MC-80c) This counter shows total amount of collated sets. Memorizing Sheet Caliper Button - Used to check and memorize sheet caliper of sheet to be collated. - When lamp in memorizing sheet caliper button is flashing, incorrect communication from tower to tower may occur. Turn off main power and check system switch and system cable connection. (Refer to Page 39 and 40.) Module ON/OFF Button Used to turn on/off module. Jam Lamp When jamming occurs on each bin, this lamp comes on. Miss Feed Lamp When miss feed occurs on each bin, this lamp comes on. Double Feed Lamp When double sheet feeding occurs on each bin, this lamp comes on. Error Monitor Error monitor shows feeding errors in second set from top on receiving tray. Error Monitor Error monitor shows feeding errors in first set from top on receiving tray. Stop Button COLLATOR Preset Mode Switch (Only for MC-80a and MC-80c) Used to select function of preset counter MC-80 Both Off : a : Tab Insertion Mode : Preset Stop Mode Continuous Collating Preset Counter (Only for MC-80a and MC-80c) Detector Sensitivity Monitor Button Used to check detector sensitivity on all bins. Bin ON/OFF Button Used to turn on/off each bin. Detector Switch Used to select brightness of detector lamp. OFF : for Normal Sheet ON : for Dark Printed Sheet Detector Lamp (Green) Used to check dust on detector. When detector is contaminated with paper dust or projector lamp burned out, this lamp goes off. Inching Button Used to operate feed roller, transport belt and sucker intermittently. 5

10 . Before You Begin - Machine Descriptions --4 Remote Controller [] Preset Counter Lamp When collating stops with preset counter, this lamp comes on. Module Lamp () When module(s) is (are) turned on, this lamp comes on. () When stop button is depressed, this lamp flashes. (3) When delivery sensor on nd, 3rd, 4th, 5th or 6th module continues to detect sheets, this lamp flashes. Receiving Tray Lamp () When receiving tray becomes full, this lamp comes on. () When jamming occurs on delivery unit, this lamp flashes. (3) When delivery sensor is contaminated with paper dust or alike, main motor won't start and this lamp flashes Hand Marrying Indicator - When hand marrying function is selected, this lamp comes on. - When sensor on hand marrying unit is covered with paper or alike, this lamp flashes. Overlap Indicator Indicates overlap mode; minimum, middle, maximum or 00%. Speed Indicator Indicates collating speed (interval) in 3 steps. Speed Button Collating speed (interval) can be selected with those button. Start/Bin Up Button First Depression : Transport belts start rotating, pump starts and bins raise up. Second Depression : Collating starts. Stop/Bin Down Button First Depression : Collating stops. Second Depression : Transport belts stop rotating, pump stops and bins descend. Double Cycle Lamps Indicate double cycle working block. Double Cycle Selector Used to select double cycle mode. First section feeds sheets. Second section feeds sheets. Double cycle mode OFF. 6

11 . Before You Begin - Machine Descriptions --5 Remote Controller [] Feeding Error Lamp () Error lamp shows feeding errors in first set on receiving tray. () Error lamp " shows feeding error in second set from top on receiving tray. (3) Error lamp " flashes when three sets of collated sheets transported at same time. (6 modules operation). Operation Error Lamp Operation error lamp comes on; () when sheet is not existing on bin which is turned on, () when all sheets are fed and collating stops, (3) when bin is not raised, (4) when memorizing sheet caliper has not been performed. Right-side delivery Indicator Indicate right-side delivery function is selected. Right-side delivery Selector Button Used to select right-side delivery mode on MC-80c or MC- 80a with C Tower Kit (CTK-80). This button can be used on above two modules which installed at right end of system or single tower with C Tower Kit (CTK-80). Overlap Button Four overlapping can be selected. Maximum Overlap Middle Overlap Minimum Overlap All ON 00 % Overlap Dual Cover Feeding Lamps Indicate dual cover feeding working bin. Dual Cover Feeding Selector Used to select dual cover feeding mode. Upper cover feed bin works. Lower cover feed bin works. Dual cover feeding mode OFF. 7

12 . Before You Begin -3 Accessories Hose Clamp a-4 pcs, m- pcs, c-4 pcs Sheet Guide a-8 pcs, m-8 pcs, c-8 pcs Connecting Plate (Upper) m- pc Bulging Nose a-3 pcs, c-3 pcs Connecting Plate (Lower) m- pc Detector Cleaning Kit a- pc, c- pc Setting Plate a-3 pcs, m-3 pcs, c-3 pcs Detector a- pcs, m- pcs, c- pcs Double Sheet Prevent Brush (a-3 pcs, m- pcs, c- pcs) Tool Set a- pc, c- pc 8

13 . Before You Begin -3 Accessories Grease a- pc, c- pc Sucker Rubber (Small) (a-8 pcs, m-8 pcs, c-8 pcs) Sucker Rubber (Large) (a-8 pcs, m-8 pcs, c-8 pcs) 9

14 . Before You Begin 0

15 . Setting & Operation. Setting & Operation - Setting Up MC Operation Procedure Right-side Delivery Function Hand Marrying Operation (HMU-80 : Option) Feed Error Indication Programming Collating Tab Insertion Mode & Preset Stop Mode For Efficient Operation... 3

16 . Setting & Operation - Setting Up MC Loading Sheets On Bins NOTE (Before loading sheets) - Fan well sheets to be collated to minimize double sheets feeding. - Press firmly at folded edge when 4-page signature will be collated to minimize miss feed or jamming. - Dry printed ink on sheets before piling to minimize trouble on feed roller or transport belt.. Turn on main power of all modules.. Lower bins. - Depress stop/bin-down button on remote controller to lower all bins. 3. Load sheets on each bin. - Page No. in each set should be coincide with sequence of sheet delivery. Front Guide Side Resister - Sheets should be placed firmly against side resister and front guide. - Maximum pile height is 5 cm ("). (In case right-side delivery function is used.) Please refer to "-3 Right-side Delivery Function" in Page 8. 7 Sheets 4. Place sheet guide. - Place sheet guide tightly to right end of operation side of sheet. Sheet Guide NOTE - Use lower position bins for productive collating in case pages are less than 8.

17 . Setting & Operation - Setting Up MC Sucker Stopper and Valve Setting. Set sucker stoppers according to quality and condition of sheets. A: Sucker Stopper A Turn all four sucker stopper A fully clockwise to set them at DOWN position when collating less than 30 gsm sheets. Turn fully counterclockwise to set at UP position when collating more than 30 gsm sheets. NOTE - Sucker stopper A can be used only UP or DOWN position. Sucker Stopper B Sucker Stopper A Sucker Stopper A Sucker Stopper C B: Sucker Stopper B Use sucker stopper B when double sheet feeding often happens with sucker stopper A being UP position. Sucker stopper B can be moved down to provide gap between suckers and sheet by tuning clockwise. C: Sucker Stopper C. Turn sucker stopper C clockwise to provide gap between suckers and sheet when double sheet feeding often happens even if sucker stopper A set at DOWN position.. Turn sucker stopper C clockwise to provide gap between suckers and sheet when NCR paper is collated.. Close or open suction valve. - Close or open suction valve according to sheet size. Close position : Suction Valve Open position : 3

18 . Setting & Operation - Setting Up MC Delivery Roller Unit Setting CAUTION - Be sure to turn main power off whenever weight rollers and/or bulging nose position are adjusted. Bulging Nose Lock Knobs. Set bulging nose and weight roller - Set bulging nose and weight roller according to sheet weight and size to perform smooth and neat delivery of sheets. - Loosen lock knob and position weight roller unit. Push down this part to remove delivery sheet bulging nose. Push down this part to install delivery sheet bulging nose. (Patterns of setting bulging nose and weight rollers.) - When collating heavy-weight stocks or folded sheets. - When collating thin and less stiff paper (More bulging). Install three nosed when running large size sheets.. Set weight position. - Turn weight counterclockwise and slide it forward or backward to increase or decrease roller pressure. Weight 4

19 . Setting & Operation - Setting Up MC Use delivery air. - Use delivery air when collating thin stock or when statistic causes difficulty in transporting and jogging sheets. - Turn switch up to start delivery air and adjust air pressure with delivery air knob. OFF Max Pressure Air Nozzle (Delivery Air Knob) Delivery Air Knob --4 Receiving Accessory Setting CAUTION - Be sure to turn main power off whenever receiving accessory is installed. Up Down Delivery Air Switch. Set delivery unit. - Delivery roller position should be adjusted according to type of receiving accessory to be connected. UP... Down... ST-0, SPF-, SPF-0, SP-0 CCR(DX), PJ-77/75, SP- Lever Knob Lever Knob - Loosen lock knob pull up lever or push down lever to change delivery roller position.. Install and set receiving accessories. - Install and set receiving accessory according to instructions in each receiving accessory operation or instruction manual. 5

20 . Setting & Operation - Operation Procedure. Turn on power switch on each module. Power Switch. Turn on module. - Turn on module with module ON/OFF button on each module. Module ON/OFF Button 3. Select detector mode with detector switch on monitor panel. 3 Lamp OFF : for Normal sheet Lamp ON : for Dark Printed sheet Detector Switch 4. Raise bin with start/bin-up button on remote controller. - All bins are raised and transport belts start rotating. Start/Bin-Up Button 5. Memorize sheet caliper on each bin. - Depress memorizing sheet caliper button on monitor panel to check and memorize sheet caliper on all bins. NOTE - When SPF-/SPF-0 is connected, turn on motor on SPF-/SPF-0 before depressing memory button. - Press memory button from right side module in case more than two modules are used. Memorizing Sheet Caliper Button 6

21 . Setting & Operation - Operation Procedure 6. Check collated sheets. - When number of pages are not correct, or lamp in memory button is still on, readjust stoppers and depress memory button again. 7. Select overlap. - Select required overlap with overlap button on remote controller. Overlap Button NOTE - When 00% overlap is selected, please make sure that maximum thickness of one collated set should be less than 3.5 mm (0.4"). 8. Select speed. - Select required collating speed (interval) with speed button on remote controller. Slower Faster Speed Button 9. Select preset mode. - Select preset mode with preset mode switch on monitor panel and input required numbers. (Refer to "-7 Tab Insertion Mode & Preset Stop Modes" in Page 9.) : Tab insertion mode : Preset Stop mode Both OFF : Continuous collating 0. Reset total counter to zero with reset button on total counter if necessary. Total Counter 0 Reset Button 7

22 . Setting & Operation - Operation Procedure. Depress start button on remote controller to start collating. - Collating stops when feed error happens or one of bins becomes empty. Start/Bin Up Button. Stop collating. - Depress Stop/Bin-Down Button on remote controller to stop collating. Stop/Bin Down Button - Collating stops after one complete set of sheets delivered to receiving tray. NOTE - When stop button is depressed during collating, conveyor, transport belt and pump will brought to a halt immediately. 8 - When sheets stop inside transport belt, depress inching button to eject all sheets or open transport belt section and remove jammed sheets. Inching Button 8

23 . Setting & Operation -3 Right-side Delivery Function NOTE - Right-side delivery function is provided only on MC-80c and MC-80a with C Tower Kit (CTK-80). MC-80c or MC-80a with CTK-80 - Right-side delivery function can work only on a right end module of system.. Set up receiving tray. - Place PJ-77 at right-side delivery side of MC-80a or MC-80c. - Connect two cables of PJ-77 to ECR-80, and then connect ECR-80 to receptacle for receiving tray. NOTE - Operation panel or foot switches side of PJ-77 have to be faced at drive side. Receptacle ECR-80 Operation Side PJ-77. Place bulging nose. - Place bulging nose at delivery end of MC- 80a or MC-80c when collating thinner paper. Bulging Nose 3. Select right-side delivery function. - Select right-side delivery function on remote controller of MC-80c or MC-80a. - Right-side delivery module will be controlled by this remote controller. - Other modules can work as left-side delivery modules at same time as rightside delivery module is operated. Right-side Delivery Selector Button 9

24 . Setting & Operation -3 Right-side Delivery Function 4. Lower bins and load sheets on each bins. - Lower bins with stop/bin down button. - Load front page of sets or smaller page number sheets from bottom (No. 8 Bin). Collated sets will flip over during transportation. - Load sheets face down. Bin No. Page No. 3. Follow operation procedure in page 6 to 8. NOTE - For neat and smooth receiving of collated sheets, 00% overlap is recommended to use. 0

25 -4 Hand Marrying Operation (HMU-80 : Option). Setting & Operation NOTE - Hand marrying operation requires optional hand marrying unit. (HMU-80) - Hand marrying unit can be attached at any MC-80 modules. Delivery Roller. Install hand marrying unit. (HMU-80) - Remove delivery roller when hand marring unit is installed on MC-80c or MC- 80a with CTK-80. CTK-80 Hand Marrying Unit (HMU-80) - Attach hand marrying unit on to conveyor shaft. - Connect cable from hand marrying unit to receptacle of MC-80. Cable Selector Switch. Select hand marrying mode. - Select hand marrying mode with selector switch on hand marrying unit. Upper : Lower : Hand married set will be delivered on top of collated sets. Hand married set will be delivered first and collated sets will be delivered on top of hand married set. OFF Upper Lower

26 . Setting & Operation -4 Hand Marrying Operation (HMU-80 : Option) 3. Press start/bin up button on remote controller. Start/Bin Up Button 4. Place hand married set on table of hand marrying unit. Front Resister Sensor Side Resister - Place hand married set against front and side resisters. - As soon as sensor on table detects sheet(s), MC-80 will start cycle of collating. NOTE - Maximum thickness of hand married sheets should be less than 3.5 mm (0.4"). Table Hand Married Sheet(s)

27 . Setting & Operation -5 Feed Error Indication When feed error (misfeed, double sheet feed or sheet jamming) occurs, collation stops after current collating set are delivered to accessary. Depending on speed of collation or overlap selection error monitor indicates in several ways. Receiving Tray Lamp Lamp will be ON when... - receiving tray becomes full. - SPF-0II or SP-0 motor is OFF. Lamp will flash when... - jamming occurs at delivery section of collator. -delivery sensor is contaminated with paper dust or alike. (Remote Controller) 3nd Module nd Module 4th Module st Module 5th Module 6th Module Operation Error Lamp Lamp will be on when... - sheet is not existing on bins which are turned on, - all sheets are fed and collating stops, - memorizing sheet caliper is not performed. Module Lamp Lamp will be on when... - module is turned on. Lamp will flash when... - Stop button is depressed. - delivery sensor on nd, 3rd, 4th, 5th, or 6th module continues to detect sheets. 3

28 . Setting & Operation -5 Feed Error Indication Feed Error Indication Remote Controller Monitor Panel Description Check and correct top set staying on receiving tray or stitching unit Check and correct second set from top staying on receiving tray or stitching unit Check and correct both top and second sets staying on receiving tray or stitching unit Check and correct third set from top staying on receiving tray or stitching unit. Flashing (Detector Dust Monitor) When detector (receiver) is contaminated with dust, detector lamp will go off. In this condition, efficient miss/double sheet detection will not be performed. (Feed Timing Monitor) - When all three feed error lamps (miss feed, double sheet feed and jamming) will be on, sheet feed timing was wrong. - Clean rollers in feeding area. (Refer to "3- -3 Nip Roller and Transport Belt Cleaning" on page 35.) NOTE - In case these lamps continued coming on, call your local dealer for service check. - Three lamps can be reset by turn OFF and On bin ON/OFF switch. Detector Lamp 3 4 Bin ON/OFF Switch 4

29 . Setting & Operation -6 Programming Collating Programming collating can be set with two buttons on remote controller. By these two buttons, three programming collating modes are selected. -6- Double Cycle Collation Double cycle collation program allows you to divide bins available into two setups. Program will start feeding setup without interruption as soon as one of bins in setup runs out and vice versa. One modules Two modules Three modules Four modules Setup Setup Double Cycle Collation Programming Procedure (Example) 4 sheets collating job.. Load sheets. - Load same set of sheets on both setup and setup Setup Setup 5

30 . Setting & Operation -6 Programming Collating. Turn module on. - Turn on a-module with module ON/OFF Button on panel. NOTE - Other module should be off. 3. Memorize sheet caliper. - Depress memorizing sheet caliper button on monitor panel to check and memorize sheet caliper on all used bins. (All bins will feed sheets.) 4. Select double cycle mode. - Depress double cycle selector on remote controller. Left double cycle lamp will be on and this shows setup is ready for feeding. Module ON/OFF Button Memorizing Sheet Caliper Button Double Cycle Lamp Double Cycle Selector - In case you want to start setup first, depress double cycle selector again. Right double cycle lamp will be on and setup will be ready for feeding. 5. Start collating. - Depress start button on remote controller to start feeding. Start Button - When one of bins will be empty, feeding section will move to other setup automatically. 6. Load while running. - All bins in resting setup will move down or can be pushed down. - Load sheets on resting setup for continuous operation. NOTE - Tab insertion mode can work with double cycle collation mode. 6

31 . Setting & Operation -6 Programming Collating -6- Dual Cover Feeding Dual cover feeding permits two top bins to accommodate cover stock. Program will start feeding cover stock from lower bin without interruption as soon as cover stock in upper bin runs out and vice versa. (Example) Alternate Cover Cover SPF-0II 80a 80m Dual Cover Feeding programming procedure. Load cover. - Load same cover sheets on top two bins. (Top two bins are not necessarily No. and No. bins. Any top two bins can be used as cover feeding bins.). Load inside sheets. - Load inside pages on following bins } } Cover Sheets Inside Sheets 3. Turn on module(s). - Turn on module(s) which are going to use with module ON/OFF button on monitor panel. 4. Memorize sheet caliper. - Depress memorizing sheet caliper button on monitor panel to check and memorize sheet caliper on all piled bins. (Top two bins will also feed cover sheets.) Module ON/OFF Button Memorizing Sheet Caliper Button 7

32 . Setting & Operation -6 Programming Collating 5. Select dual cover feeding mode. - Depress dual cover feeding selector on remote controller. Left dual cover feeding lamp will be on and this shows upper cover sheet bins are ready for feeding. Lamp Selector - In case you want to start feeding lower cover sheet bin first, depress dual cover feeding selector one more time. - When upper cover feed bin will be empty, lower cover feed bin will start feeding automatically. 6. Load while running. - Load cover sheet on upper cover feed bin for continuous operation Mixed Modes of Collation You can mix Double Cycle Collation and Dual Cover Feeding into one operation. - Select both programming by pressing both double cycle selector and dual cover feeding selector on remote controller and follow the above operation procedure. 8

33 . Setting & Operation -7 Tab Insertion Mode & Preset Stop Mode Two types of preset function can be performed by use of preset counter. -7- Tab Insertion Mode One or two tab sheet(s) can be inserted according to predetermined number on preset counter. For example, when tab sheets are required after every 0 sets of inside sheets collation, use tab insertion mode. Tab Sheets Inside Sheets Inside Sheets Inside Sheets 3 Inside Sheets 0 Tab Sheets Tab Insertion Procedure. One Cover or Two covers. - Select number of covers ( or ) to be inserted with the switch inside operation panel. () Open operation panel. () Select bin or bins with switch 8. Up... Down... Covers (tabs) insertion Cover (tab) insertion P.C.B. Long Down Down Short Down Up Norm Twice c-tower Normal ST-0 OFF bins UP Down Once a-,m-tower HighCCR ON bin Nip Roller Rotating Time Blowing Air Tower CCR Sensitivity Tray Preload Tab Bin 3. Load tab (cover) sheet(s) on top one (two) bin(s). 3. Select tab insertion mode. - Select tab (cover) insertion mode with preset mode switch on monitor panel. Preset Mode Switch 9

34 . Setting & Operation -7 Tab Insertion Mode & Preset Stop Mode 4. Input number on preset counter. - Input required numbers in preset counter with input buttons, and depress reset button to set number. Preset Counter 5. Start collating. - To start collating, follow operation procedure in pages 6 to 8. R Reset Button Input Button -7- Preset Stop Mode Collating can be stopped after predetermined sets of collation by use of preset mode. 3 Preset stop Procedure. Select preset stop mode. - Select preset stop mode with preset mode switch on monitor panel. Preset Mode Switch. Input number on preset counter. - Input required number in preset counter with input buttons and depress reset button. 3. Start collating. - To start collating, follow operation procedure in pages 4 to 6. - Collation stops after predetermined sets of collation. 30

35 . Setting & Operation -8 For Efficient Operation -8- Detector Sensitivity Setting Detector sensitivity on each bin can be set in 5 levels according to sheet thickness or print quality. Detector Sensitivity Monitor Button. Depress detector sensitivity monitor button on monitor panel. Bin ON/OFF Button. Depress bin ON/OFF button while detector sensitivity monitor button is held to select sensitivity level. NOTE - Sensitivity of each bin should be adjusted separately. (No Lamp On) Double sheet detection OFF Low sensitivity Middle sensitivity -8- Paper Condition Before loading paper, fan through paper to loosen and separate the sheets. Jog on a flat surface so that papers' edge are squarely aligned in stack. If not fanned through sufficiently, poor sheet separation may cause feeding problems. When handling curled paper, be sure to flatten distorted, and/or wrinkled sheets before loading them in paper bins Folded Sheets When running folded sheets, be sure to press out excess air. Folded or closed edge must be well pressed and flattened. Otherwise, misfeed and jamming may occur Wet Ink If sheet are stuck to each other with printing ink, double-sheet feeding may occur. Wet ink tends to smear forward roller, vertical sheet transport belt, ejecting roller, and other parts, which may lead to various sheet feed troubles and machine failures. Because of this, printing ink on sheets should be sufficiently dry. Normal sensitivity High sensitivity -8-5 Correct Loading If bottom sheets in a stack are not aligned with front guide when sheets are loaded in paper bin, it will cause misfeed. Jog piled sheets against front guide and align them against front guide Roller Pressure Roller pressure against paper can be adjusted with roller pressure selector lever. Set roller pressure selector lever at upper position to decrease pressure; lower position increase pressure. NOTE - Roller pressure should be upper position when collating NCR paper. 3

36 . Setting & Operation 3

37 3. Maintenance 3. Maintenance 3- Cleaning

38 3. Maintenance 3- Cleaning 3-- Detector Cleaning Dust on detector may cause error detection or detector malfunction. Clean detector with supplied detector cleaning kit or brush. Joint Pipe How to use detector cleaning kit.. Put hose of detector cleaning kit (refer to page 4) on joint pipe of MC-80 module. Air Blower Knob Detector Cleaning Kit. Turn on pump with start/bin up button on remote controller. 3. Set air blower knob at maximum position. Start/Bin-Up Button OFF Max. 4. Install cleaning kit nozzle into feeding area in between upper guide and lower guide and set it as shown in the right drawings. Sucker Pipe Cleaning Kit Nozzle Upper Guide Cleaning Kit Nozzle Detector Lower Guide Sucker Pipe 34

39 3. Maintenance 3- Cleaning 3-- Delivery Sensor Cleaning When delivery sensor is contaminated with paper dust or alike, receiving tray lamp on remote controller will flash to alert cleaning requirement. Clean delivery sensor on each module with brush or cloth. Photo Sensor Receiving Tray Lamp 3--3 Nip Roller and Transport Belt Cleaning To prevent irregular feeding and transporting of sheets, clean nip roller and transport belts with alcohol soaked cloth. Nip Roller - Nip roller can be accessed from feeding (bin) side of MC To access transport belts, open transport belt unit. Clean the belts inside here. 35

40 3. Maintenance 3- Cleaning 3--4 Replacement of Fuses WARNING - Be sure to unplug power cord whenever fuses are replaced. - Fuses are housed in electric control box. - Remove screw behind control box cover and screws at front lower position. The cover will be opened toward yourself. - Replace fuse according to indication below. Electric Copntrol Box 400V 3A A 3A 3A A MC-80a 5 A 400V 5 A 5A 5 A A 3A 3A A MC-80m 5 A 400V 5 A 5A 5 A 3A A 3A 3A 3A A MC-80c 5 A 400V 5 A 5A 5 A 00V 3A A 3A 3A A MC-80a 0 A 00V 0 A 0A 0 A A 3A 3A A MC-80m 0 A 00V 0 A 0A 0 A 3A A 3A A A A A 3A A 0A MC-80c 00V 3--5 Replacement of Double Sheet Prevent Brush Wear out brush may cause poor performance of prevention of double sheet feeding. Replace brush with new one. Brush is fixed on front panel of paper bins with one fix screw. Double Sheet Prevent Brush 3--6 Filter on Air Pump Soiled filter may cause poor performance of air pump. Clean filter element clogged with paper dust or other substance every two to three months. Filter Unit Filter Fix Knob 36 Filter Case Rubber Packing

41 4. Installation Instructions 4. Installation Instructions 4- Installation of Collator Module Installation of Kit CTK-80 (Option) Installation of DDM-80 (Option) Installation of DDA-80 (Option)

42 4. Installation Instructions 4- Installation of Collator Module 4-- Installation Location - Select a flat, rigid floor free from vibration. - Select a place free from direct exposure to sunlight. - Select a place free from extremely high temperature and humidity. Connecting Plate A 5 mm 3 mm 4-- Installing MC-80. Combine each module. - Combine each module with connecting plates (A-Upper and B-Lower). - Place three setting plates under each leveling bolt and level each module with leveling bolt. - Raise up modules with casters slightly afloat. NOTE - Tilting allowance in each module should be within a dimension in the right drawing. Adjust Bolt Setting Plate (a) (m) Connecting Plate B Air Pump. Install air pump. - Install air hose between each module and between module and air pump. Upper... Lower... Pressure Vacuum Hoses - Fasten hoses with hose clamps. NOTE - In case rear delivery module, MC-80c or MC-80a with CTK-80, is installed, use one pump for only rear delivery module, other pump for MC-80a (left end module) and MC- 80m. - Provide 5 cm space behind air pump. Hose Clamp Pressure Hose Vacuum Hose 38

43 4. Installation Instructions 4- Installation of Collator Module (In case EAP-80 is installed). Install hoses of EAP-80 as shown in the drawing below.. Plug up a pipe on m-module with supplied cap. 3. Connect power cable on pump to MC-80m modules. a m m m m EAP-80 Original Pump Cap 3. Connect system cable. - Connect system cable on MC-80m or MC-80c modules to left side module. System Cable 39

44 4. Installation Instructions 4- Installation of Collator Module 4. Set system switches. - Open operation panel. - Set system switch on QPM-06 on each module according to number of module installed. SW SW System Switches P.C.B. tower SW: SW: towers SW: SW: SW: SW: 3 towers SW: 3 SW: SW: 3 SW: SW: 3 SW: 3 4 towers SW: 4 SW: SW: 4 SW: SW: 4 SW: 3 SW: 4 SW: 4 5 towers SW: 5 SW: SW: 5 SW: SW: 5 SW: 3 SW: 5 SW: 4 SW: 5 SW: 5 6 towers SW: 6 SW: SW: 6 SW: SW: 6 SW: 3 SW: 6 SW: 4 SW: 6 SW: 5 SW: 6 SW: 6 Fig

45 4. Installation Instructions 4- Installation of Collator Module 5. Set function switches. - Open operation panel to access function switches on P.C.B. (QPM-06). P.C.B. Long Down Down Short Down Up Norm Twice c-tower Normal ST-0 OFF bins UP Down Once a-,m-tower High CCR ON bin Nip Roller Rotating Time Blowing Air Tower CCR Sensitivity Tray Preload Tab Bin (Switch and ) Nip roller rotating time can be adjusted with these two switches. Keep both switches at DOWN position in most of operation. (Switch 3) Used to select blowing air mode; one time or two times. Up... Down... (Switch 4) Module switch Up... Down... Two times blowing One time blowing Rear Delivery Tower (MC-80c or MC-80a with CTK-80) MC-80a or MC-80m (Switch 5) Used to adjust full tray sensor sensitivity on CCR-DX. Up... Down... Normal High Sensitivity (Switch 6) Used to select type of receiving accessory to be combined. Up... Down... ST-0 CCR(DX) (Switch 7) Pre-load switch. Keep this switch at DOWN position for pre-loading. (Switch 8) Used to select tab insertion bin number. Up... Down... bins bin 4

46 4. Installation Instructions 4- Installation of Collator Module 6. Connect MC-80m (MC-80c) and pump power cord. WARNING - Be sure to turn off main power or breakers switch of factory or plant before plugging or unplugging power cord. Wire Connection Terminal Board R S T G R S T G Red Green Black White Red Green Black White - Open small cover on rear cover. - Connect power cords from MC-80m and pump to terminal of MC-80a. - Connect following module power cord to the module on left side. Pump Rear Tower MC-80m (MC-80c) Power Cord Terminal Pump Power Cord Cover (Rear View of MC-80a) MC-80a Power Cord 7. Connect main power. - Connect power cord of MC-80a to out let. - Check rotation of delivery roller with inching button. Delivery roller should rotate counterclockwise. If not unplug power cord and change wiring of power cord. Delivery Roller 4

47 4. Installation Instructions 4- Installation of Collator Module (In case more than four modules are installed.) One power source can work with up to three modules. When more than four modules are installed, plug main power cord as in drawing below. 4 modules a m m m C 5 modules a m m m m C 6 modules a m m m m m 8. Set delivery roller unit. - Set delivery roller angle to suitable position according to combined receiving accessory. Up : Down : ST-0 SP-0 SPF- SPF-0 CCR (DX) PJ-75/77 SP- - Loosen lock knob and pull up lever to set UP position; push down lever to set DOWN position. Lever Lock Knob Lever Lock Knob 9. Install receiving accessory. - Follow operation manual or Instruction manual for each receiving accessory. 43

48 4. Installation Instructions 4- Installation of Kit CTK-80 (Option) 4-- Parts. Rear Delivery Guide Unit set. Drive Unit set 3. Solenoid Unit set 4. Signal Cable pc 5. Bulging Nose pc Upper Sheet Guide Unit 4-- Installation Procedure Remove front and rear cover before start assembling C Tower Kit. () Rear Delivery Guide Unit and Drive Unit. Remove sheet guides. - Remove upper sheet guide unit and lower sheet guides. Lower Sheet Guides 44

49 4. Installation Instructions 4- Installation of Kit CTK-80 (Option). Remove idle shaft and pulley. Idle Pulley & Shaft 3. Slide belt guide. - To provide space for assembling, slide belt guide to operator side. 0MC80B69 Belt Guide Idle Pulley 4. Install drive unit. - Remove idle pulley on drive unit. Drive Unit - Install drive unit on belt guide and fix it with six screws. Drive Unit Screws 45

50 4. Installation Instructions 4- Installation of Kit CTK-80 (Option) 6. Install idle pulley - Install idle pulley to original position on drive unit. Belt Guide - Two belts must be installed as shown in the right drawing. - Tension belts by pulling idle pulley and fix it. Idle Pulley 7. Slide back belt guide with drive unit to original position. Idle Pulley 8. Install sheet guide. - Install lower sheet guides at original position. Lower Sheet Guides Rear Delivery Guide Unit 9. Install rear delivery guide unit. - Install rear delivery guide unit on sheet guides. 0. Connect motor cable. 46

51 4. Installation Instructions 4- Installation of Kit CTK-80 (Option) () Solenoid Unit. Install solenoid unit. - Install solenoid unit at operation side of module. Solenoid Unit - Put two screws to hold solenoid unit. Solenoid unit required positioning adjustment, do not tighten screws at this step. Snap Ring - Install plate on solenoid unit to gate bar and put snap pin into gate bar hole. Solenoid. Adjust solenoid position - Push down gate bar until gate touches transport belt frame. Transport Belt Frame Gate Bar Plunger 0MC80B50 - At above condition adjust solenoid position so that plunger pulled up fully by solenoid. QPW-06 CON-3 3. Connect cable. - Connect solenoid cable to CON3 (Pin No. and 3) on P.C.B (QPM-06). - Tie up solenoid cable with wire clamp so that cable will not touch any moving parts. 47

52 4. Installation Instructions 4- Installation of Kit CTK-80 (Option) (3) Signal Cable. Fix signal cable on frame. - Remove hole cover on frame. Hole Cover - Insert signal cable into hale and fix it with cable clamp. CON-4 - Connect cable to CON4 (Pin No.4, 5 and 6) on P.C.B. (QPM-06). Red... No.4 Signal Cable CON4 White... Black... No.5 No.6 - Tie up signal cable with wire clamp so that cable will not touch any moving parts. QPM-06 0MC80B54 48

53 4. Installation Instructions 4-3 Installation of DDM-80 (Option) 4-3- Parts. Delivery Unit set. Belt pc 4-3- Installation Procedure. Remove front and rear cover before start assembling DDM-80.. Install DDM-80 - Install DDM-80 at front delivery parts of MC-80a or MC-80c, and fix it with four screws. DDM-80 0MC80B39 3. Install belt. - Remove covers on drive side of DDM Install belt on pulley. - Tension belt by sliding tension pulley. Tension Pulley Belt Cover Cover 49

54 4. Installation Instructions 4-3 Installation of DDM-80 (Option) 3. Connect sensor cable. - Connect sensor cable with cable already installed at drive side of MC-80c or MC- 80a. Sensor and Cable Sensor Cable Cable on MC Place all removed covers at original position. 50

55 4. Installation Instructions 4-4 Installation of DDA-80 (Option) 4-4- Parts. Delivery Unit set. Speed Control Pulley set 3. Idle Pulley (Long & Short) pc each 4. Tension Pulley pc 5. Support Pulley ( pc) and Spacers ( pcs) 6. Knob pc 0MC80B45 7. Belts (Long & Short) pc each 8. Sensor Cable pc 9. Sheet smoother 3 pc 5

56 4. Installation Instructions 4-4 Installation of DDA-80 (Option) 4-4- Installation Procedure. Remove front and rear cover before start assembling DDA-80.. Install DDA-80 - Install DDA-80 at front delivery parts of MC-80c, and fix it with four screws. 3. Install two idle pulleys. - Install long idle pulley on operation side of MC-80c. - Install short idle pulley on drive side of MC-80c. 4. Install speed control pulleys. - Install speed control pulley on operation side of MC-80c. - Install support pulley and spacers as shown in the right drawing. - Install tension pulley. 5. Install belt. - Remove covers on both operation and drive side of DDA Install belts on pulley. - Tension belt by sliding tension pulleys. Speed Control Pulley Idle Pulley (Short) Tension Pulley Cover Belt Tension Pulley Support Pulley and Spacers Idle Pulley (long) DDA-80 Cover 5

57 4. Installation Instructions 4-4 Installation of DDA-80 (Option) 6. Connect jam sensor cable. - Connect jam sensor cable (connector side) to jam sensor. - Connect jam sensor cable (wire side) to CON-4A on P.C.B. QPM-06. Jam Sensor Cable CON-4A Red... No. 4 White... No. 5 Black... No. 6 QPM-06 Jam Sensor Sensor and Cable 7. Connect sensor cable. - Connect sensor cable with cable already installed at drive side of MC-80c. Sensor Cable 8. Install all removed covers on original position of MC-80c. Cable on MC Plug air hose. - Plug delivery air hose to nipple on MC- 80c. 53

58 4. Installation Instructions 54

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