RIG801x107 - REV-08 InletR-16Ring - Tec Man Ingl

RIG.801x107cm.
TECHNICAL MANUAL Rev.08

RIG.801x 107cm FOLDING SYSTEM rev.8
SUMMARY
SUMMARY ..................................................................................................................................................................................... 2
REVISIONS .............................................................................................................................................................................. 3
GENERAL INFORMATION .......................................................................................................................................................... 5
GENERAL INFORMATION .......................................................................................................................................................... 5

EQUIPMENT............................................................................................................................................................................... 5
TECHNICAL CHARACTERISTICS .......................................................................................................................................... 5
IDENTIFICATION...................................................................................................................................................................... 7
ASSEMBLING ................................................................................................................................................................................ 8
HOW TO PROCEED ................................................................................................................................................................... 8
NORMAL USE ................................................................................................................................................................................ 9
CONTROL PANEL ....................................................................................................................................................................... 10
FOLDING PROGRAMME SELECTION .................................................................................................................................... 11

CROSS-FOLD USE ................................................................................................................................................................... 13
SETTING KEY VALUES ............................................................................................................................................................. 15
DATA INPUT ............................................................................................................................................................................ 15
KEY VALUES TABLE ............................................................................................................................................................. 17
FOLDS SETTING RIG.801........................................................................................................................................................... 19
STACK MEASUREMENT ADJUSTMENT............................................................................................................................. 19
LEADING EDGE ADJUSTMENT............................................................................................................................................ 19
TRAILING EDGE ADJUSTMENT........................................................................................................................................... 19
PAPER INLET SETTING ............................................................................................................................................................. 20
DIAGNOSIS .................................................................................................................................................................................. 21
DIAGNOSIS WITH SIMULATION.......................................................................................................................................... 21
PHOTOCELL CHECK........................................................................................................................................................... 21
MOTOR/ENCODER CONTROL............................................................................................................................................ 21
PAPER JAM .................................................................................................................................................................................. 21
PAPER JAM .................................................................................................................................................................................. 22
TROUBLESHOOTING ................................................................................................................................................................. 23
ERROR CODES ............................................................................................................................................................................ 24

PHOTOCELL CHECK .............................................................................................................................................................. 25
MOTOR/ENCODER CONTROL .............................................................................................................................................. 26
FUSES CONTROL ........................................................................................................................................................................ 26
ELECTRIC DIAGRAM LEGEND PR503 UNTIL THE MACHINES S/N PQA0852 ....................................................................... 27
ELECTRIC DIAGRAM - PR503............................................................................................................................................ 30
ELECTRIC DIAGRAM RIG.801 N. PR504 – SINCE THE S/N. PQB0801............................................................................... 32
ELECTRIC DIAGRAM RIG.801 N. PR505 – SINCE THE S/N. PQC0801............................................................................... 36
MACHINE with MULTI/VOLTAGE....................................................................................................................................... 40
MACHINE with VOLTAGE 110V. 50/60 Hz. ........................................................................................................................ 41
RIG.801 page 2 of 55
COMPONENTS MAP................................................................................................................................................................42
ELECTR. COMPONENT MAP – RIG.801 .............................................................................................................................42
RIG.801 COMPONENTS ..........................................................................................................................................................44
ROLLERS ...............................................................................................................................................................................44
INLET-AXIS ASSEMBLY antil Series PQC0948....................................................................................................................45
INLET-AXIS ASSEMBLY since New Series PQD0901...........................................................................................................46
LEFT SIDE – Folding Motor..................................................................................................................................................47
RIGHT SIDE – Inlet Motor.....................................................................................................................................................48
ROLL BEARINGS & HOLDERS ............................................................................................................................................49
RING TRANSMISSION...........................................................................................................................................................50
DEVICE TO IMPROVE THE CROSS FOLDER..........................................................................................................................52
With the BELT .......................................................................................................................................................................52
With the ROPE.......................................................................................................................................................................54
The information in this document may change without prior notice and thus cannot be considered to be
binding on the Manufacturer.
Many product upgrades do not require changes to the manual and, vice versa, the manual can be
corrected without making changes to the product.
Therefore, the product upgrade may not always match the revisions to the manual.
Information
ownership
This manual contains information with reserved ownership. All rights are reserved. This manual cannot be
reproduced or photocopied, in all or part, without RIGOLI’s prior written approval. The use of this
documentation is authorised only for the customer to whom the manual was supplied together with the
machine and only for the purpose of installing, using and performing maintenance on the machine to
which the manual refers.
RIGOLI declares that the information in this manual corresponds to the technical and safety specifications
of the machine to which the manual refers. The manufacturer will not be held responsible for direct or
indirect damage to persons, things or pets subsequent to the use of this documentation or the machine
under conditions other than those which have been prescribed.
REVISIONS
REVISION: Rev.1 REV.02 increase the folding speed to 10, A0/minute (since machine s/n PQA0713)
- pag.16 (new values keys 70+90+91)
REVISION: Rev.3 : SINCE MACHINES – PQB0801 – NEW ELECTRIC DIAGRAM – PR-504

NEW PHOTOCELLS FO004A
New flat-cable FL168A
REVISION: Rev.4 : SINCE MACHINES – PQC0801 – NEW ELECTRIC DIAGRAM – PR-505

- NEW CONNECTORS 10pin FOR FLAT-CABLE PHOTOCELLS B3-B2
REVISION: Rev.5 -09/06/09

–: Since PR801.017 program: 2 NEW KEYS 155 and 156
for to see the counter copies and meter (pag. 17)
- Visualization on the control panel display the counter copies and meter (only on Simulation mode )
with button “Stop” and “Programs” (pag. 10+13)
- New instructions for setting the inlet paper (with keys 70 and 71) pag.19
REVISION: Rev.6 02/09/09 – NEW INLET ROLLER with 16 RUBBER RINGS

from machines s/n. PQD0901 - see pag. 47
value “Key 82” modified ( see pag. 17)
value “Key 116” modified ( see pag. 18-19)
REVISION: Rev.7 01/12/09 – NEW SISTEM with ROPE for DEVICE TO IMPROVE
THE CROSS FOLDER ( see pag. 53-54)
REVISION: Rev.8 24/02/11 – NEW PROGRAM PR801.021 with new key 66 with new special
“Random Final Program” ( see cap.Key Values Table)
GENERAL INFORMATION
EQUIPMENT
The folding machine RIG.801x107cm. is furnished complete of:
• SUPPORT with pivoting wheels
• Copy-feeding table
• Electric cable 220 V.
• Operator manual
OPTIONAL:
• Roll-holder
TECHNICAL CHARACTERISTICS
ELECTRIC DATA
Power supply: 220 Volt, 50 Hertz
Single-phase
Absorption: max. 1.2 Amp
Power: 270 Watts
37x40x134 cm
9 cm
Peso Kg 120 134 cm
37 cm
104 cm
40 cm
91 cm
92 cm
54 cm
113 cm
WEIGHTS & DIMENSIONS

Packed machine
Box dimensions: 137x62x69 cm
Weight: 140 kg
Machine body
Dimensions: 37x40x134 cm
Weight: 100 kg
Complete Machine
Weight: 120 kg
Noise
weighted equivalent continuous sound pressure level less than 70 dB
Paper width: max. 107 cm

min. 21 cm
Paper length: min. 42 cm
max .more than 20 m
Paper type: min. 60 g/m²
max. 110 g/m²
Folding speed: 10, A0/minute (since machine s/n PQA0713)
Folding
adjustment: on all programmes
from 175 to 215 mm
with 1 mm steps
Cross-fold: during 2nd run
max. A0, adjustable
from 280 to 310 mm
POLLUTION
NOISE: less than 70 dB
SAFETY: conforms to EEC Machine Directive 89/392 and subsequent amendments.
IDENTIFICATION
For any communication with the manufacturer/Distributor always refer to the serial number placed on all
the principal parts of the machines.
ASSEMBLING
HOW TO PROCEED
NORMAL USE
1 2 210 3
1. Make sure there are no foreign objects on the work table (fig. 1).
2. Press the on-off button (O) on the “I” symbol (fig. 2) and make sure the LED turns on.
3. Check that the display on the keyboard is on and that it indicates the standard set folding size. If other
information is displayed, consult the “Troubleshooting” chapter.
4. When turned on, the machine is set automatically on the standard programme: Fold with final
adjustment, fold size 210 mm (fig. 3).
5. Now the machine is ready to start folding.
6. Place the sheet on the table with the title block in the front and with the drawing facing up.
4 5 6
7. Align the sheet against the side of the table and push it towards the entry slot
(fig. 4).
8. The folded sheet (fig. 6) is delivered to the front rack (A) located below the feed table (fig. 5).
To set a folding programme that is different from the standard type, see the instructions in the “Folding
programme” paragraph.
NOTE
The sheet must always be inserted with the “front” title block as shown, i.e. facing the machine entry
slot (fig. 4), regardless of the selected folding programme.
CONTROL PANEL
A B
C D E F G H I
L
N
M O
A. DIGITAL KEYBOARD
B. ILLUMINATED DISPLAY
C. EJECT/STOP BUTTON
D. FOLD WITH FINAL ADJUSTMENT LED
E. FOLD WITH FILING BORDER LED
F. FOLD PROGRAMME BUTTON
G. FOLD WITH RANDOM FINAL ADJUSTMENT LED
H. FOLD SIZE ADJUSTMENT BUTTON
I. CROSS-FOLD BUTTON AND REGULATION FILING BORDER
L. EMERGENCY BUTTON
M. FUSE HOLDER
N. POWER OUTLET WITH ANTI-NOISE FILTER
O. ON-OFF SWITCH
FOLDING PROGRAMME SELECTION
Press the programme button (F) one or more times to select the required programme, and the
corresponding green LED will turn on (fig. 7).
• From the program 017:on Simulation Mode show on the display meters counter (1=1000 meters )
F
210
7 9
8
Final adjustment fold programme
Press the programme button (F) until the corresponding LED turns on (D).
Insert the sheet, positioning it with the front title block as shown (fig. 8).
The sheet will be folded as indicated in (fig. 9).
F I
190mm
10 20mm 11
H
Final adjustment fold programme with
filing border
• Press the programme button (F) (fig. 10) until the corresponding LED turns on (E) to activate the
function that creates the filing border on the left side of the drawing (fig. 11).
• Until the program vers.11 (visible on display at turn on of the machine)
The standard border measurement is 20 mm and can be changed only by a skilled technician.
Since the program vers.12, it is possible change it: press the button (I) for 5 seconds and can be
changed by using the adjustment buttons (H). After 3 seconds the value is memorize on the program.
• The set folding measurement is 190 mm and can be changed by using the adjustment buttons (H)
• Insert the sheet, positioning it with the front title block as shown (fig. 8).
The sheet will be folded as indicated in (fig. 11).
F
13 H 14
15
Parallel folding programme
• Press the programme button (F) (fig. 13) until the corresponding LED turns on (G) to make a fold without
intermediate partial folds, but with a random final border (fig. 15).
• The set folding measurement is 210 mm and can be changed by using the adjustment buttons (H) (FIG. 13).
• Check that the rear tray is open since the copy will be delivered randomly to one of the two delivery points.
• Insert the sheet, positioning it with the front title block as shown (fig. 14).
The sheet will be folded
NOTE
Since the final folded edge is completely random, the final fold may be made be aligned with the pack (fig. 15).
This occurs only in special circumstances related to the folding size and sheet length.
Fold sizes
The display (B) indicates the fold size in millimetres.
Press the adjustment buttons (H) to increase or decrease the digits displayed. With a single push the digit
varies 1 mm at a time. By continuing to push it for more than 2 seconds, the digits will change faster
(fig.20).
H
20
Min.
175mm
H 21
20
NOTE
The adjustment ranges from a minimum of 175 mm to a maximum of 215 (fig. 21).
These value can also be exceeded, but this may affect the folding operation.
The new data will remain stored in memory until the folding machine is turned off: therefore, it must be re-
inserted the next time the machine is turned on.
CROSS-FOLD USE
NOTE
This type of fold can be used only for sizes of max. A0 (841 x 1180 mm).
Programme automatic setting
When a copy is inserted that was previously accordion folded, the folding machine will automatically start the cross-
folding programme, setting the fold size to 297 mm.
The display will indicate 297 and the “parallel fold” LED will turn on (fig. 22).
23 297mm
297mm
H I 24 25
22
• Check that the rear tray is open to receive a copy.
• Insert the sheet, that was previously accordion folded, with the front title block as shown and position it toward
the feed entry of the folding machine (fig. 23).
• Pick up the folded pack from one of the two delivery points, front rack or rear tray, depending on the folds made
(fig. 24-25).
To change the standard cross-fold size, the “cross-fold” programme must be set manually.
Manual cross-fold setting

• Press the “Cross-fold” button (I) (fig.22) and make sure the display indicates the standard fold size setting 297.
• Use the buttons (H) to increase or decrease the fold size, if necessary.
• Insert the sheet, that was previously accordion folded, with the front title block as shown and position it toward
the feed entry of the folding machine (fig. 23).
• Pick up the folded pack from one of the two delivery points, front rack or rear tray, depending on the folds made
(fig. 24-25).
FRONT/REAR COPY DELIVERY

• The folding machine automatically selects the front or rear delivery point according to the following
procedures:
FRONT:
• all the copies are folded with the first two folding programmes with final adjustment fold with or without border.
FRONT/REAR:
• the copies are delivered randomly with the parallel and cross-fold programmes, depending on the position of the
last fold.
FOLD EJECT AND STOP BUTTON
26 27
• To stop the machine during the folding operation, briefly press the Eject/Stop button (C).
• To force the copy being folded to be ejected and allow the remaining paper to slide through, keep
pressing the Eject/Stop button (C) (fig. 26).
• When the button is released, the folding machine stops until a new sheet to fold is inserted.
• From the program 017:on Simulation Mode show on the display copies counter (1=1000 copies )
STOP
L C
28 29 30 31
• When emergencies occur, press the red mushroom button (L) (fig. 28). The machine stops and the power is cut
off.
• To restart the machine, turn the button (L) clockwise
(fig. 29).
• To stop folding when necessary, briefly press the Eject/Stop button (C) (fig. 30).
• At the end of the work shift, to turn off the machine, press the on-off switch (O) located in the rear and check
that its light turns off (fig. 31).
After the machine has turned off, wait at least 5 seconds before starting it again to avoid any damage to the
electronics
BLACK OUT
A power outage will not create particularly dangerous situations since the machine stops completely. When the
power is restored, the eject/stop fold button (C) must remain pressed in case any paper has remained inside the
folding machine.
SETTING KEY VALUES
DATA INPUT
DATA INPUT CARD
When you want to modify the parameters of the folding machine it is necessary to use the DATA INPUT CARD (P/N S2007L)
hereafter shown.
KEY display VALUE display
KEY
BUTTON
Blue
Red
VALUE
BUTTON
OPERATING PROCEDURE
To modify the parameters inside the program it is necessary to enter the KEY CODE and then modify the VALUE inside, with
following procedure:
11.. Switch OFF the machine
22.. Connect the Data Input Card to the electronic card of the RIG.805 into the connector –XS8 by means of the flat cable.
33.. Switch ON the machine
44.. Keep pressed down the KEY BUTTON (light blue).
a) The KEY display will flash to indicate that it is ready to receive the new data.
b) Enter the required KEY CODE by the numeric keyboard.
c) In case of wrong code insertion, release the KEY BUTTON and restart from origin.
55.. Release the KEY BUTTON
a) KEY DISPLAY will stop to flash.
b) VALUE DISPLAY will now show the value memorised inside this key.
66.. Keep pressed down the VALUE BUTTON (red)
a) The VALUE display will flash to indicate that it is ready to receive the new data.
b) Enter the required VALUE by the numeric keyboard.
c) In case of wrong code insertion, release the VALUE BUTTON and restart from origin.
77.. Release the VALUE BUTTON
a) VALUE DISPLAY will stop to flash.
b) VALUE DISPLAY will now show the new value memorised inside this key.
88.. DATA STORAGE
a) To save the new data values PRESS the T1 button on the electronic board of the RIG.805 folding machine.
b) A "beep" signal will confirm you that the data are stored and therefore they are not loose when you switch off the
machine.
c) ATTENTION: many key setting start to be effective immediately after the input of the new key value, BUT there are
many others that it is indispensable to store with "T1" button to be able to see their effect. Don't forget !
d) It is possible to modify many different key values before of final storage.
99.. Perform the modified functions on the folding machine to verify the correct settings. If necessary restart from point "4".
1100.. Remember to switch off the machine before to remove any flat cable from electronic board, to avoid possible damages
inside the electronic.
From EPROM 805-X

KEY VALUES TABLE
KEYS VALUES FUNCTION SCALE Eprom
vers.
1 20 Lenght border “DIN” mm.
2 210 Fold lenght of standard folding mm.
3 210 “Standard” folding size for program “G” Random final 3

185 “Standard” folding size for second program “G” Filing Border
4 190 Fold lenght of standard folding with “DIN” program mm.
5 297 Fold leng of standard on program “Cross-Folder”
6 25 Filing border size “DIN”for Progr.G mm. 07
9 1 Starting program whem switch on the folder: 07

Italy “0” for Random Final 297 mm.
“1” for Final Adjustament D
2 “2” for Filing Border E
Germany
“3” for Random Final or second Filing border G
13 0 Selection of program for “G” position: 07
or “0” for random fina (Italy standard)
1 “1” for second sizes Filing border folding (Germany standard)
60 1000 RESERVED
0 STANDARD “3” PROGRAM WIT RANDOM FINAL 21

66 -
135 SPECIAL “3” PROGRAM –RANDOM FINAL 21
70 330 Distance of first paper length from the inlet photocell (B4) till the folding roller stop 10=1mm.
71 400 Folding roller movement (10=1mm.) for guiding of first paper edge 10=1mm.
72 10 Stopped time of both motors 100=1sec
76 20 Magnet for CrossFolder system - Regulation start (after B4 photocell) 10=1mm.
77 90 Magnet for CrossFolder system-Time of works- 100=1sec
#78 500 Start delay of the inlet paper driving roller 1000=1sec
80 70 Minimum fold possible in the false fold mm.
#82 Trailing edge adjustnent for sheets loger than 560 mm. 10=1mm
5640+/-20 For machines S.N. since PQC0948 (INLET ROLLER WITH 11 RINGS)
6510+/-20 For machines S.N. antil PQD0948 (INLET ROLLER WITH 16 RINGS)
#83 4120+/-20 Trailing edge adjustnent for sheets from 420 to 560 mm. 10=1mm
#84 340 First fold setting distance (B4 photocell-virtual “folder point”) 10=1mm
85 1500 Packet ejection- distance from virtual “folder point” (Fan Folder) mm.
89 20 Restart motors delay 1000=1 sec.-
#90 3000 Folding machine maximum speed 10=1mm / sec.
#91 27000 RESERVED 10=1mm /sec.
97 10 RESERVED
98 1 RESERVED
99 0 for machine without B5 fotocell 03

135 for machine with B5 fotocell 05
100 500 RESERVED
#101 965+/-5 Setting feel roller measurement 10=1mm
102 1000 RESERVED
103 50 RESERVED
104 0 RESERVED
105 0 RESERVED
106 10 RESERVED
107 2000 RESERVED
115 500 RESERVED
#116 1415+/-10 Setting folder roller measurement 10=1mm.
117 1000 RESERVED
118 50 RESERVED
119 0 RESERVED
120 0 RESERVED
121 10 RESERVED
122 2000 RESERVED
155 Copy counter 1=10 copies 17

156 Meter counter 1=10 m. 17
Warning : At the first start of the machine, with the new eprom program PR801.018 please insert the value
0 (zero) on the new keys 156 and 155 (copy counter)
FROM THE PROGRAM PR801-021: NEW “KEY” 66 for special “3” program with value different from 135 (es. 0 or 1 )
the “3” program – Final Random – is the Standard program.
With key 66 at the value =135- the machine folded the paper with an final random
with the final chance to avoid any damage on the design, but in some cases
is forced to eject the sheet with the tail end is not bent.
In this way you will not have wrinkles but you'll most often the tail to fold a hand
FOLDS SETTING RIG.801
STACK MEASUREMENT ADJUSTMENT

Stack (X) measurement is defined as the distance between the opposite edges of the stack, without considering the first and the
last folds.
11.. Select the RANDOM FINAL FOLDING program "G" by operating push button F of controls panel.
X
22.. Operate FOLD SIZE button (H) to obtain a folding measure of 210 mm.
33.. Fold a paper sheet of at least 120 cm. in length which is introduced in the folding machine with TITLE
BLOCK on front side (drawing turned towards the work table); verify accurately the stack 'X' external measurement.
44.. If the stack measurement does not meet the requirement of 210 mm. then proceed as follows (column VALUES indicates
the standard data set-up by the manufacturer).
NOTE: Decrease N° value corresponds to an increase of the stack X folding measurement.
Change the two values with the same proportion, to avoid difference on synchronism.
KEY VALUE FUNCTION SCALE N X
101 965 ± 5 Stack X measurement setting of inlet roller Ð Ï
116 1415 ± 10 Stack X measurement setting of folding roller Ð Ï
LEADING EDGE ADJUSTMENT Y

Leading edge measurement is defined as the distance “Y” between the stack first edge and the first
fold.
11.. Select RANDOM FINAL FOLDING program "G" by operating push button F of controls panel.
22.. Operate FOLD SIZE button (H) to obtain a fold measure of 210 mm.
33.. Fold a paper sheet of at least 100 cm. in length which is introduced in the folding machine with TITLE BLOCK on front
side; using a pencil clearly mark-up the sheet side which will be introduced in the folding machine as first.
44.. If the first fold Y measurement does not meet the requirement of 210 mm. then proceed as follows.
NOTE: Increase of N° values corresponds to an increase of first fold Y.
KEY VALUE FUNCTION SCALE N Y

84 340 First fold setting 10=1mm Ï Ï
TRAILING EDGE ADJUSTMENT

55.. Select the folding program FOLD WITH FINAL ADJUSTMENT "D" by operating push button F
of control panel.
66.. Operate FOLD SIZE button (H) to obtain a fold measure of 190 mm. on the luminous display. Z
77.. Using a pencil clearly mark-up the sheet side which will be introduced in the folding machine as
last.
WARNING: Use calibration key 82 only for paper sheets longer than 56 cm.; use calibration key 83 only for paper sheets
length between 42-54 cm.
NOTE: Increase of N. values corresponds to a decrease of trailing edge Z.
KEY VALUES FUNCTION SCALE N° Z

82 Trailing edge adjustnent for sheets loger than 560 mm. Ï Ð
5640+/-20 For machines S.N. since PQC0948 (INLET ROLLER WITH 11 RINGS) 5640+/-20
6510+/-20 For machines S.N. antil PQD0948 (INLET ROLLER WITH 16 RINGS) 6510+/-20
83 4140 ± Trailing edge adjustment for sheets from 420 to 540mm 10=1mm Ï Ð
20
PAPER INLET SETTING

To address in the correct direction the leading edge of the paper sheet, when it enter the fan folding
machine, it is necessary to know the following setting procedure.
Normally the values set from manufacturer are good for any necessity, but it is necessary to modify them
in function of the maximum folding speed.
Before to start the procedure you must be sure that the leading edge of the paper sheet enter the fan-
folder perfectly parallel with the inlet roller.
If the paper cut of the printer is not perfectly square, may happen that (e.g.) the left side enter the
folder some millimetres before of the right side. In this situation you see the paper that, after about 20
cm from inlet, will turn abrupt on itself on left direction.
In this situation set the cutting device of printer before to modify any parameter inside folder.
If the paper arrive from the roll very curved (as it is bad quality) may happen that you see a very little fold
at only a few millimetres from leading edge. This means that the leading edge of the sheet was looking to
go in the opposite direction before to enter the folding press-roller.
To be able to see the modifications during setting of keys you must before enter a very high value in the
KEY 71: folding roller movement (10=1mm.) for guiding of paper edge (i.e. 9999). The standard one change from 380 to
400 in function of the speed.
In this way you have the possibility to look inside the “inspection holes” inside the fan-folder, as the copy
will stop for long time before to restart moving. Open the two side doors for a better view.
The leading edge must arrive as more possible near to position “A” and must stop there for a short time
before to be pressed from folding roller and restart moving.
To advance or move back the leading edge of paper it is necessary modify the values of:
KEY 70 Distance of paper length from the inlet photocell (B4) till the folding roller stop (10=1 mm.) (The standard is 330)
REMEMBER to return to the original values on the KEY 71 at the end of the procedure, and
SWITCH OFF/ON the machine to memorise the modifications.
DIAGNOSIS
DIAGNOSIS WITH SIMULATION

PHOTOCELL CHECK
To operate the Folding machine correctly, make sure the reflection photocells are operating correctly. In fact, over
time, the sensors may be obscured by dust, generating false signals and thus imperfect folds.
To check the operation of each photocell of the RIG. 801 and the Cross-fold machine, you must first enter the
“simulation mode”.
• Turn off the folding machine, wait at least 3 seconds and:
Since the program vers.12 continuing to press the “F” Program button and turn on the machine
Then identify the photocell on which to perform the operating check.

• Place a sheet of paper on which the entire surface is black with toner in front of the photocell sensors. The
photocells must be checked under the worst conditions. For this reason, use a sheet of paper with the black part
facing the photocell sensors.
• A brief acoustic signal should be heard each time the sheet is placed under the photocell and each time it is
removed.
• To
ATTENTION. If you repeat too many times this operation may be that you have no exit
more correct indication. the
“simulation” mode, turn off the folding machine and turn it on again after about 3 seconds.
MOTOR/ENCODER CONTROL
For the folding machine to operate correctly, the two motor/encoder units must operate perfectly. To check their
operation, you must first enter the “simulation mode”.
Turn off the folding machine, wait at least 3 seconds and:
Until the program vers.11 (see the display at the turn oo the machine)
then turn it back on while continuing to press the “I” Program button.
- Pressing the H button with the “-” sign will rotate Motor M1 that drives the entry roller to the RIG.801 folding
machine. Numbers that continue to increase will scroll on the display at the same time. This indicates that the
Motor/Encoder/Controller system is operating correctly.
- Pressing the H button with the “+” sign will rotate Motor M2 that drives the RIG.801 large folding roller.
Numbers that continue to increase will scroll on the display at the same time. This indicates that the
1a I
2
F 1b
PAPER JAM
If the paper should jam in the entry slot, the paper can be removed as follows:
• Briefly press the Eject/Stop button (C) to stop the folding machine (fig. 1).
• Remove the jammed paper, tearing off the part that remained outside the machine (fig. 2).
• Keep pressing the Eject/Stop button (C)
(Fig. 1) until all the paper that has remained inside the machine is delivered to the front rack (under
the table) (fig. 3).
3
2
C
1
NOTE
To restart the folding operation, just insert another sheet of paper.
TROUBLESHOOTING
This paragraph will make it easier to find and solve the problems that occur most frequently when using
the folding machine.
MACHINE OFF:
Pressing the on-off switch (O), the machine does not start (switch light off):
A. Make sure the power cord is properly connected to the mains and to the machine (fig. 1).
B. Make sure the red emergency button (L) has not been pressed (fig. 2); to release it, turn it clockwise
(fig. 3).
1
3
C. Check the fuses by doing the following:

- Turn off the machine using the on-off switch (O) (fig. 4) and disconnect the power cord first from the mains (fig.
5) and then from the machine (fig. 6).
- Remove the fuse holder (fig. 7) and check the condition of the fuses. If they have burned, replace them with new
ones rated at 3.15 Amp - Ø 5x20 mm (fig. 8).
- Insert the fuse holder in its compartment (fig. 9) and then the power cord.
- Connect the other end of the power cord to the mains and try to turn on the machine using the on-off switch (O)
(fig. 4).
4 5 6
7 9
ERROR CODES
The machine is programmed to display the main operating defects detected using a numeric code together
with an acoustic signal.
NOTE
When the machine is turned on, make sure there is no paper obstructing the photocells on the work
table to prevent the system from displaying an error signal.
Some error codes are caused by false readings of the photocells on the machine.
TO CHECK THE OPERATION OF THE PHOTOCELLS, SEE THE “PHOTOCELL CHECK” CHAPTER (10.2).
Code 001:
Positioning problem with the motor for the entry roller:
1. Press the Eject/Stop button (C) for about ten seconds.
2. Turn off the machine using the on-off switch (O) and turn it on again after at least 5 seconds.
If the code and acoustic signal disappear, the work cycle can be started
Code 002:
- Positioning problem with the motor for the fold roller.
- Follow the procedure described for error code 001.
Code 004:
Photocell B4 reading error - paper may be jammed inside the machine.
− Keep pressing the Eject/Stop button (C) for the time needed to eject any paper that has remained inside the
machine.
− Turn off the machine and turn it on again after at least five seconds.
Code 005-006:
Photocell B3-B2 reading error - paper may be jammed in the work table channel.
- Make sure there is nothing under the channel located on the left side of the work table.
CAUTION:
Do not use metallic objects but try to blow with force. If necessary, use paper sheets or thin cardboard.
− Press the Eject/Stop button (6) to check if the error has been cancelled.
Code 007-008:
Photocell B1 - B5 reading error.
Paper is probably present when the machine is turned on. Paper may be jammed in the entry channel.
Make sure nothing blocks the entrance to the entry channel. Do not use metallic objects but try to blow with force. If
necessary, use paper sheets or thin cardboard.
− Keep pressing the Eject/Stop button (6) for the time needed to eject any paper that has remained inside the
machine.
− Turn off the machine and turn it on again after at least five seconds.
Code 050:
Folded paper pack has not been delivered from the folding machine.
− Press the Eject/Stop button (C) and keep pressing it until the folded pack has been ejected
Code 051: (from the progr.20)

Faulty paper inlet in folding machine..
− Press the Eject/Stop button (C) and keep pressing it until the folded pack has been ejected.
Code 088:
Eprom not recognised.
− Turn off the machine using the on-off switch (O) and turn it on again after at least five seconds,
checking that the error signal has been cancelled.
Code 200-201:
Main board malfunction (controller).
− Turn off the machine using the on-off switch (O) and turn it on again after at least five seconds,
checking that the error signal has been cancelled.
NOTE
If any error code continues or repeats frequently, contact the Service Centre.
PHOTOCELL CHECK
If errors 004-005-006-007 occur, the photocells should be checked to make sure they are operating correctly since
they may just be obscured by dust, thus generating false signals
1a I
2
F 1b
− To check the operation of each photocell, do the following:
A. Enter the simulation mode

Turn off the folding machine, wait at least 3 seconds and:
then turn it back on while continuing to press the “I” Program button. (fig. 1a)
(fig.1b).
B. Use the legend and the drawings to find the photocell that should be checked (fig. 2).
- Place a sheet of black paper in front of the photocell. It is important to check the photocells under the
worst conditions. This is why a piece of paper with the black part facing up is used.
− Each time a sheet is placed under the photocell, or is removed, the machine should emit an acoustic
signal
If an operating fault should occur, contact the Service Centre.
To exit the “simulation” mode, turn of the folding machine and turn it on again.
MOTOR/ENCODER CONTROL
For the folding machine to operate correctly, the two motor/encoder units must operate perfectly. To check their operation, you
must first enter the “simulation mode”.
then turn it back on while continuing to press the “I” Program button.
- Pressing the H button with the “-” sign will rotate Motor M1 that drives the entry roller to the RIG.805 folding machine.
Numbers that continue to increase will scroll on the display at the same time. This indicates that the
- Pressing the H button with the “+” sign will rotate Motor M2 that drives the RIG.805 large folding roller. Numbers that
continue to increase will scroll on the display at the same time. This indicates that the Motor/Encoder/Controller system is
operating correctly.
FUSES CONTROL
EXTERNAL FUSES
2 fuses 3,15 Amps Diam.5x20mm. inside the socket outlet
INSIDE FUSES
Electronic Main board 1 fuse delayed 2 Amps diam. 5x20mm.
Motor Control board 1 fuse 6 Amps diam. 5x20mm.
Card for raising gummed axis 1 fuse 0,6 Amps diam. 5x20mm.
4 5 6
7 9
ELECTRIC DIAGRAM RIG.801 n. PR503
ELECTRIC DIAGRAM LEGEND PR503 until the machines s/n PQA0852

REF. DESCRIPTION Q.ty P/N
A1 Electronic Main Board 1 S2035L
Eprom RIG.801 for electronic main board 1 EP007L
A2 Electronic card Controller for 2 motors on RIG.801 1 S2036L
A3 Keyboard RIG.801/805 (assembly) 1 TA015L
A4 Rele card for to raising gummed axis 1 S2039L
B1 Photocell for delay on motors starting 1 FO006L
B2 Photocell for Trailing edge setting on copy over 560 mm 1 FO006L
B3 Photocell for Trailing edge setting on copy under 560 mm 1 FO006L
B4 Photocell starting the calculation of the length Fan Folder 1 FO006L
B5 Photocell starting the calculation of the length on Cross Folder 1 FO006L
BQ1 Encoder HP HEDS on motor M1 for inlet axis Fan Folder 1 EN048L
BQ2 Encoder HP HEDS on motor M2 for Folding Axis of Fan Folder 1 EN048L
FU1/FU2 Fuse on socket outlet of Fan Folder Diam. 5 x 20 mm. 3,15 Ampere 2 FU026L
FU3 Fuse on main board Diam. 5 x 20 mm. 2 A. delayed. 1 -
FU4 Fuse on controller 2 motors Diam. 5 x 20 mm. 6 Ampere 1 FU026L
F1=F2 R/C filter 0,47uF.630V.+ R=22ohm.3W. 2 RC040L
YA1 Electrom. 10W. 24Vdc. For raising gummed axis 1 EL005L
M1 Motor for Inlet axis RIG.801 WITH ENCODER 1 M6018E
M2 Motor for Folding axis RIG.801 WITH ENCODER 1 M6019E
SA1 General switch 220V. 1 I2012L
SB1 Emergency Red button 1 PU128L
Contact N.O. for emergency button 2 CO061L
TC1 Transformer 20 VA: 220/19-10 V. 1 T8013L
TC2 Transformer 250VA. 220/40 V. 1 T8009L
W1 Feeding electric cable 2x10A. + Earth and “euro” socket 1 C2045L
W2 Flat-cable 26 pin with 2 connectors – for keyboard 1 FL167L
W3 Flat-cable 26 pin Photocell connection on Fan Folder 1 FL168L
W4 Cable for encoder 100 cm. for Fan Folder 1 C2028L
W5 Cable encoder 25 cm. for Fan Folder 1 C2029L
W6 Flat-cable 10 pin 15 cm with connectors – for controller 1 FL165L
XP1 Plug CEE - panel type – with filter and fuse holder 1 SP041L
XP2 Connector on A1 board for keyboard
XP3 Connector on A1 board for Photocell signals
XP4 Connector on A1 board for encoder cable - 100 cm. motor M1
XP5 Connector on A1 board for encoder cable 25 cm. motor M2
XP6 Connector on A1 board for cable A2 controller
XP7 Connector on A1 board for board inlet 20V. a.c.
XP8 Connector on A1 board for Data Input Card
XP9 Connector for photocell B1
XP17 Connector on A2 board to controller
XP18 Connector on A2 board to connect folding motor M2
XP19 Connector on A2 board to connect Inlet motor M1

XP20 Connector on A2 board Inlet 40 V. a.c.
XS1 Plug CEE flying – feeding cable 1 PR034L
XS2 Connector on Flat-Cable W2 for keyboard
XS3 Connector on Flat-Cable W3 for Photocell
XS4 Connector on cable W4 for encoder
XS6 Connector on Flat-Cable W6 to controller
XS7 Connector “Phenix 3pins” for board inlet
XS8 Connector on A1 board for Setting Card
XS9 Connector on Flat-Cable W3 for photocell B1
XS15 Connector on cable W5 for encoder BQ2 (motor M2)
XS17 Connector on cable W6 to motor controller
XS18 Connector “Phenix 3poli” to M2 folding motor
XS19 Connector “Phenix 3poli” to M1 inlet motor
XS20 Connector “Phenix 3poli” inlet 40Va.c. controller A2
ELECTRIC DIAGRAM - PR503
ELECTRIC DIAGRAM RIG.801 n. PR504 – SINCE THE S/N. PQB0801

B1 Photocell new type GP2A25J for delay on motors starting 1 FO004A
B2 Photocell GP2A25J for Trailing edge setting on copy over 560 mm 1 FO004A
B3 Photocell GP2A25J for Trailing edge setting on copy under 560 mm 1 FO004A
B4 Photocell GP2A25J starting the calculation of the length Fan Folder 1 FO004A
B5 Photocell GP2A25J starting the calculation of the length on Cross 1 FO004A
Folder
W3 Flat-cable 26 pin Photocell connection on Fan Folder NEW TYPE 1 FL168A
FROM THE MACHINES s/n. PQB0804

ELECTRIC DIAGRAM RIG.801 n. PR505 – SINCE THE S/N. PQC0801

(new connectors XS22-XP22 for flat-cable photocells B2+B3)
B1 Photocell new type GP2A25J for delay on motors starting 1 FO004A
B2 Photocell GP2A25J for Trailing edge setting on copy over 560 mm 1 FO004A
B3 Photocell GP2A25J for Trailing edge setting on copy under 560 mm 1 FO004A
B4 Photocell GP2A25J starting the calculation of the length Fan Folder 1 FO004A
B5 Photocell GP2A25J starting the calculation of the length on Cross 1 FO004A
Folder
W3 Flat-cable 26 pin Photocell connection on Fan Folder NEW TYPE 1 FL168A
FROM THE MACHINES s/n. PQB0804

XP22 Connector female flat-cable 10 pin (on the cable for photocells B2-B3)
XS22 Connector male flat-cable 10 pin (on the cable for photocells B2-B3)
SPECIAL VOLTAGE ALIMENTATION
MACHINE with MULTI/VOLTAGE
Ref Description Code
TCS AUTOTRASFORM. 500 VA. V.In: 0-100-110-200 out:220 V. T8002M
XB3 Connectors strip for pin “fastons” for change the voltage
MACHINE with VOLTAGE 110V. 50/60 Hz.
COMPONENT PARTS
COMPONENTS MAP
ELECTR. COMPONENT MAP – RIG.801
B1 Photocell for delay on motors starting 1
B2 Photocell for Trailing edge setting on copy over 560 mm - on autom. Table 1
B3 Photocell for Trailing edge setting on copy under 560 mm - on autom. Table 1
B4 Photocell starting the calculation of the length Fan Folder 1
B5 Photocell starting the calculation of the length on Cross Folder 1

A2 Electronic card Controller for 2 motors on RIG.801/805 1 S2036L
A4 Rele card for to raising gummed axis 1 S2039 L
FU3 Fuse on main board Diam. 5 x 20 mm. 2 A. delayed. 1
M1 Motor for Inlet axis WITH ENCODER 1 M6018E

M2 Motor for Folding axis WITH ENCODER 1 M6019E


TC2 Transformer 250VA. 220/240-40 V.. 1 T8009L
RIG.801 COMPONENTS
ROLLERS
N° DESCRIZIONE Q.tà CODICE
1 Gummed folding axis, with groves for RIG801/107cm 1 RU013N
2 Neutral axis – copy exit for RIG801/107cm 1 RU011N
(excluded 2 roll bearing 608 2Z )
3 Polycord ring dia 4 x 525 mm 10 AN050L
4 Gummed axis to press for RIG801/107cm 2 RU014N
5 Supporting bar for inlet axis assembly 1
6 Guide supports for inlet rollers 7 SU010L
7 Inlet nylatron rollers d. 32x20mm. RU032L
UNTIL PQC09xx : with inlet roller 11 RUBBER RINGS 11
SINCE PQD0901 16
8 Inlet roller with rubber rings Large= 20 mm. for RIG801/107cm
2 TYPES
UNTIL PQC0948 : with 11 RUBBER RINGS large 20mm. 1 RU010N
SINCE PQD0901 : with 16 RUBBER RINGS large 20mm. (from 1 RU010P
dd. 02/09/09)
INLET-AXIS ASSEMBLY antil Series PQC0948

For machine with inlet roller with 11 rubber ring.

6 Support for short axis 7 SU010L
8 Inlet axis with rubber rings 1 RU010N
9 Nylatron Rollers paper pressing 11 RU032L
10A Short axis Ø 7 mm, x 130 mm. 1
10B Short axis Ø 7 mm x 190 mm. 1
10C Short axis Ø 7 mm x 201 mm. 1
10D Short axis Ø 7 mm x 226 mm. 1
10E Short axis Ø 7 mm x 295 mm. 1
11 Rod to press axis 12 PE001L
12 Spring for short axis Ø 5 x 30 mm 12 M4035L
13 Screw to press the spring
A B C D E
INLET-AXIS ASSEMBLY since New Series PQD0901

For machine with inlet roller with 16 rubber ring.
6 Support for short axis 9 SU010L
8 Inlet axis with16 rubber rings 1 RU010P
9 Nylatron Rollers d.33x20mm paper pressing 16 RU032L
10A Short axis Ø 7 mm, x 95 mm. for nylatron roller paper pressing 1
10B Short axis Ø 7 mm x 103 mm. for nylatron roller paper pressing 1
10C Short axis Ø 7 mm x 124 mm. for nylatron roller paper pressing 4
10D Short axis Ø 7 mm x 146 mm. for nylatron roller paper pressing 1
10E Short axis Ø 7 mm x 197 mm. for nylatron roller paper pressing 1
11 Rod to press axis 16 PE001L
12 Spring for short axis Ø 5 x 30 mm 16 M4035L
13 Screw to press the spring
A C D C C B C E
LEFT SIDE – Folding Motor

1 Geared motor EP70 48Vdc. WITH ENCODER 1 M6019E
2 Brush for motor EP70 mm.8x10 2 SP010L
3 Toothed pulley PDMT 27/T5 - Z40 1 PU090L
4 Toothed belt T5/16 575 1 CI071L
5 Toothed belt PDMT 27/T5/ Z60 1 PU084L
6 Gummed folding axis with groves for RIG801/107cm 1 RU013N
RIGHT SIDE – Inlet Motor

1 Geared motor EP65 48Vcc. WITH ENCODER 1 M6018E
2 Brush for motor EP65 mm. 6x6 2 SP009L
3 Toothed pulley T5/10 - Z18 1 PU087L
4 Toothed belt T5/10 - 420 1 CI067L
5 Belt tighten pulley - Nylatron 1
6 Inlet axis with rubber rings for RIG801/107cm 1 RU010N
7 Toothed pulley 10/T5 - Z40 1 PU082L
7 6
ROLL BEARINGS & HOLDERS

REF. DESCRIPTION Q.ty S/N
1 Roll-bearing holder 40 x 16 2 PO059L
Roll- bearing 4203/ATN9 2 C6050L
2 Screw 12x60 to support roll-bearing 2
Roll-bearing EL8 608 2 C6003L
3 Roll-bearing holder Round type 4 PO052L
Roll-bearing el15 6002 4 C6007L
4 Roll-bearing holder two pin type 2 PO051L
Roll-bearing EL15 6002 2 C6007L
RING TRANSMISSION
1 Polycord ring Dia. 5 x 830 mm. 2+2 AN063L
2 Aluminium pulley on folding axis 1+1
3 Aluminium pulley on pressing axis 2+2
4 Tighten pulley for polycord rings 2+2
Roll-bearing EL10 - 6000 – for tighten pulley 2+2 C6005L
Pivot to support roll-bearing 2+2
DEVICE TO IMPROVE THE CROSS FOLDER

With the BELT
Device to raising the gummed axis for to improve the cross folding
Device to raising the gummed axis for to improve the cross folding – with the belt

1 Copy feed table. 1
2 Supports for the copy feed table 2
3 Screws for to fix the supports 2
4 Aluminium plate of support electromagnet and elec.card 1
5 Elect. Card with rele 24 Vdc. 1 S2039L
6 Aluminium pulley of gummed folder axis diam.70mm. 1
7 Bush for friction beltFor belt large 20 mm.
8 Bolt to fix the bush 1
9 Belts for raising the axis large 20 mm. 1 NA007M
10 Screw for to fix the belt 1
11 Electromagnet 24 Vdc. 10 W. 1 EL005L
12 Plate for regulation maxim. position magnet core of electromagnet 1
With the ROPE

Device to raising the gummed axis for to improve the cross folding
Device to raising the gummed axis for to improve the cross folding – with the ROPE

1 Copy feed table. 1
2 Supports for the copy feed table 2
3 Screws for to fix the supports 2
4 Aluminium plate of support electromagnet and elec.card 1
5 Elect. Card with rele 24 Vdc. 1 S2039L
6 Aluminium pulley of gummed folder axis diam.70mm. 1
7 Bush for friction beltFor belt large 20 mm.
8 Bolt to fix the bush 1
9 ROPE for raising the axis 1 CO059L
10 Eye-bolt M6x60mm. for to fix the belt 1 V4050L
11 Electromagnet 24 Vdc. 10 W. 1 EL005L
12 Plate for regulation maxim. position magnet core of electromagnet 1

RIG801x107 - REV-08 InletR-16Ring - Tec Man Ingl

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RIG801x107 - REV-08 InletR-16Ring - Tec Man Ingl

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RIG.801x107cm.

TECHNICAL MANUAL Rev.08

GENERAL INFORMATION .......................................................................................................................................................... 5

CONTROL PANEL ....................................................................................................................................................................... 10

FOLDING PROGRAMME SELECTION .................................................................................................................................... 11

PAPER JAM .................................................................................................................................................................................. 22

ERROR CODES ............................................................................................................................................................................ 24

REVISION: Rev.3 : SINCE MACHINES – PQB0801 – NEW ELECTRIC DIAGRAM – PR-504

REVISION: Rev.4 : SINCE MACHINES – PQC0801 – NEW ELECTRIC DIAGRAM – PR-505

REVISION: Rev.5 -09/06/09

REVISION: Rev.6 02/09/09 – NEW INLET ROLLER with 16 RUBBER RINGS

WEIGHTS & DIMENSIONS

Paper width: max. 107 cm

SAFETY: conforms to EEC Machine Directive 89/392 and subsequent amendments.

FOLDING PROGRAMME SELECTION

Final adjustment fold programme

Manual cross-fold setting

FRONT/REAR COPY DELIVERY

FOLD EJECT AND STOP BUTTON

SETTING KEY VALUES

KEY display VALUE display

From EPROM 805-X

2 210 Fold lenght of standard folding mm.

3 210 “Standard” folding size for program “G” Random final 3

5 297 Fold leng of standard on program “Cross-Folder”

6 25 Filing border size “DIN”for Progr.G mm. 07

9 1 Starting program whem switch on the folder: 07

0 STANDARD “3” PROGRAM WIT RANDOM FINAL 21

72 10 Stopped time of both motors 100=1sec

76 20 Magnet for CrossFolder system - Regulation start (after B4 photocell) 10=1mm.

77 90 Magnet for CrossFolder system-Time of works- 100=1sec

80 70 Minimum fold possible in the false fold mm.

89 20 Restart motors delay 1000=1 sec.-

#90 3000 Folding machine maximum speed 10=1mm / sec.

#91 27000 RESERVED 10=1mm /sec.

99 0 for machine without B5 fotocell 03

102 1000 RESERVED

107 2000 RESERVED

115 500 RESERVED

#116 1415+/-10 Setting folder roller measurement 10=1mm.

117 1000 RESERVED

122 2000 RESERVED

155 Copy counter 1=10 copies 17

FOLDS SETTING RIG.801

STACK MEASUREMENT ADJUSTMENT

LEADING EDGE ADJUSTMENT Y

NOTE: Increase of N° values corresponds to an increase of first fold Y.

KEY VALUE FUNCTION SCALE N Y

TRAILING EDGE ADJUSTMENT

NOTE: Increase of N. values corresponds to a decrease of trailing edge Z.

KEY VALUES FUNCTION SCALE N° Z

PAPER INLET SETTING

DIAGNOSIS WITH SIMULATION

Then identify the photocell on which to perform the operating check.

C. Check the fuses by doing the following:

Code 051: (from the progr.20)

− To check the operation of each photocell, do the following:

A. Enter the simulation mode

If an operating fault should occur, contact the Service Centre.

ELECTRIC DIAGRAM RIG.801 n. PR503

ELECTRIC DIAGRAM LEGEND PR503 until the machines s/n PQA0852

REF. DESCRIPTION Q.ty P/N

ELECTRIC DIAGRAM - PR503