ES-TE Berlin GmbH

Zitadellenweg 34
D 13599 Berlin
Fon:
Fax:
030 369961-3
030 369961-59
es- te Ber
Berlin
eMail: [email protected]
Internet: www.es-te.de

estefold 2300
up to software version 3.08

Offline Folder

Technical Manual
Technical Manual estefold 2300

Contents

Operation ................................................................................................................ 3
Cross Fold............................................................................................................... 4
Maximum Paper length ........................................................................................... 5
Position of Light light barriers.................................................................................. 5
Service program...................................................................................................... 5
Panel adjust (panel width)....................................................................................... 5
First sheet adjust..................................................................................................... 6
1st light barrier adjust.............................................................................................. 6
2nd light barrier adjust.............................................................................................. 7
3rd light barrier adjust .............................................................................................. 7
Set fold type ............................................................................................................ 7
Default values ......................................................................................................... 7
Drive calibration (length conversion) ....................................................................... 8
Opto sensor calibration ........................................................................................... 9
Last sheet adjust (for all paper lengths) ................................................................ 10
Set test status ....................................................................................................... 10
Maximum fold limit (number of folds) .................................................................... 11
Motor..................................................................................................................... 11
Permanent operation ............................................................................................ 11
Light barrier check ................................................................................................ 11
Solenoid ................................................................................................................ 12
Copy counter......................................................................................................... 12
Beep on/off............................................................................................................ 12
Language .............................................................................................................. 12
Updating Firmware................................................................................................ 13
Setting Parameters in the Folder .......................................................................... 13
CBs ....................................................................................................................... 14
Error Messages..................................................................................................... 14
Technical data estefold 2300 ................................................................................ 15
Adjusting the Folder .............................................................................................. 16

Page 2
Technical Manual estefold 2300

Operation

| panel margin CF
1| 190 20 297

↑ ↓ ↵

select select mod/set

up down

As soon as you switch the folder on the following lines will be displayed for approximately
2 seconds.

Este Fold2300 V3.07

Prog. 7.03.2005 MCS

Current version and implementation date of the firmware in use are being displayed.
The power LED shines with an orange light indicating the the folder is running a self testing
routine. As soon as this routine has been run successfully the LED will turn green and the
currently selected folding program will be displayed:
Number of the selected program, panel width, margin, cross fold 297 (or 305 or off).
Programs can be selected by pressing buttons ↑ (select up) or ↓ (select down). Every press
on a button will be followed by a short beep (can be switched on and off). The number of the
selected folding program will be shown in the first column.
8 programs are available to the user. 1 - 4 are factory pre-programmed, the only option to be
selected from is cross fold 297 or 305 or off.

No. 1 2 3 4
Panel 190 mm 190 mm 198 mm 210 mm
Margin 20 mm 0 mm 0 mm 0 mm
CF off / 297 / 305 off / 297 / 305 off / 297 / 305 off / 297 / 305

Page 3
Technical Manual estefold 2300

In order to alter the cross-folder setting press button ↵ (mod/set) first. You now will notice the
figures below “CF” blink. Pressing button ↑ (select up) will change the setting. Pressing ↵
(mod/set) again will store the new setting. In case you do not press  (mod/set) within 5 sec
the setting will not be stored and the previous setting will be displayed.
The user may program programs 5 to 8 freely.

No. 5 6 7 8
Panel 180 - 210 mm 180 - 210 mm 180 - 210 mm 180 - 210 mm
Margin 0 - 30 mm 0 - 30 mm 0 - 30 mm 0 - 30 mm
CF off / 297 / 305 off / 297 / 305 off / 297 / 305 off / 297 / 305

Panel width may range from 180 mm to 210 mm; filing margin may range from 0 mm to 30
mm.
Pressing ↵ (mod/set) initiates the change of settings. All values of the currently selected
program will be blinking now.

Pressing ↑ (select up) will increase the panel width; pressing ↓ (select down) will decrease it.

Pressing ↵ (mod/set) again activates the margin setting. The margin value will be set in the
same way as the panel width. Pressing ↵ (mod/set) once again activates the cross fold
setting. Pressing ↵ (mod/set) stores all settings.
In case  (mod/set) has not been pressed within 5 sec none of the settings will be
stored and the previous settings will be displayed.

Cross Fold
Cross-folded packets may be either 297 mm or 305 mm long.
The cross fold mode will be activated as long as you have selected either 297 or 305 mm in
your folding program and the paper does not block light barrier 4 (which means the package
width does not exceed 239 mm).
If there is a remaining paper length of less than 110 mm after the first cross fold the folder
will not perform a second fold.
A maximum of two cross folds can be made.

rest > 110 mm rest < 110 mm

Adjustments of + 7.9mm can be made in the service mode.

Page 4
Technical Manual estefold 2300

Maximum Paper length

In the fanfold mode folding will be stopped after 30 folds; the remaining paper will be
delivered unfolded (can be adjusted in the service mode)
If the package is supposed to be cross-folded document length shall not exceed 1.500 mm
(paper weight 80 grams or less).

Position of Light light barriers

Position of light barriers (LB)

LB 1 LB2 LB3
LB4

LB0

Service program
The service program will be activated by keeping buttons ↑ (select up) and ↵ (mod/set)
pressed simultaneously while you turn the folder on. As soon as „Service” is displayed you
may release the buttons.

Pressing ↑ (select up) or ↓ (select down) helps you to select the desired service mode.

Pressing button ↵ (mod/set) activates the service menu.

Service menu subroutines:

Panel adjust (panel width)

Display panel: +0,00mm
+ - Next

Page 5
Technical Manual estefold 2300

By pressing m (select up) or m (select down) the panel width will be either in- or decreased in
the range from –7.9 mm to + 7.9 mm. Pressing button ↵ (mod/set) will store the new setting.
Example:

-7,9 ±0,0 +7,9

First sheet adjust

Display 1. sheet +0,00mm
+ - Next

The width of the first sheet can be adjusted in the range from -7,9 to +7,9 mm. The
procedure equals the one described above.
Example:

-7,9 ±0,0 +7,9

1st light barrier adjust

(Paper length from 400 mm to 530 mm)

Display 1. LB.: +0,00mm

+ - Next

This subroutine lets you vary the distance of the first light barrier to the virtual folding point
from –7.9 mm to +7.9 mm. Changing the values will be done as described under adjustment
of panel width.

Example:

-7,9 ±0,0 +7,9

Page 6
Technical Manual estefold 2300

2nd light barrier adjust

(Paper length from 530 mm to 740 mm)
Adjustments see above.

3rd light barrier adjust

(Paper length more than 760 mm)
Adjustments see above.

Cross fold adjustment

The width of the cross fold can be altered in the range from -7,9 to +7,9 mm.The value can
either be de- or increased by pressing either button ↓ (select down) or m (select up).
Alterations effect both package widths 297 and 305 mm. Button ↵ (mod/set) terminates the
subroutine sounding a beep.

Set fold type

Display Set fold typ:

Prog.no : + - start : ←

By pressing “select up” you may toggle between “standard” and “uncalc”. As soon as the
setting is “uncalc” folding program 5 will be set to be a fold style without compensation fold.
The documents will be folded without compensation fold and filing margin.

Default values
Attention All values will be replaced by default values !

This subroutine replaces all formerly set values by default values, which enable the folder to
fold documents. All stored values in the system memory will be set to “0”

Display reset all value ?

+ 5sec +

As soon as this routine has been entered both buttons m (select up) and ↵ (mod/set) need to
be pushed within 2 sec otherwise the subroutine will be terminated. A beep will sound for 5
sec. During that period of time the two buttons have to be pressed down otherwise the
routine will be terminated. When the folder has been reset the display will show:

OK, release

The parameters have been reset to the following settings:

Page 7
Technical Manual estefold 2300

• Conversion motor steps - length = 0,0851

• conversion length – motor steps = 11,75
• distance of light barriers from virtual folding point:
LS0 = 132,0 mm LS1 = 259,0 mm LS2 = 406,3 mm, LS3 = 616,5 mm
• Corrected values of panel width, first page width will be set to 0
• Maximum number of folds is set to 25
• Values of programs 5-8 (panel=190 mm, margin = 20 mm)

The default settings deliver acceptable fold result, but need to be corrected to deliver
optimised results.

Drive calibration (length conversion)

Display
Drive calibration :
Prog. no: + - start:←

The subroutine calculating the conversion factor starts running.

1. Enter length of the calibration sheet.
2. Prepare the calibration sheet.
3. The calibration sheet will be pulled into the folder at a slow speed. After the sheet has
been transported through the folder completely the display shows the length of the
sheet and the conversion factor for one step of the stepping motor in 1/10 mm. The
tested length of the measuring sheet is stored. Button ↵ (mod/set) ends the
subroutine with a beep.
The conversion factor helps to calculate the length of a document by counting the steps of
the stepping motor driving the fold rollers. It is calculated by counting the steps that are
necessary to transport a sheet of defined length through the folder.
Calibration sheet

real length Adjustment

hole

In order to estimate the length of the sheet the leading edge of the sheet and the trailing
edge of the adjustment hole are being used.
The adjustment hole must not decrease the sheet’s stability and must be positioned in a way
that allows the light barriers to look through the hole. When the sheet is moved out of the

Page 8
Technical Manual estefold 2300

folder it still has to be held by the fold roller when trailing edge of the adjustment hole is still
at LS0.

Opto sensor calibration

Display Opto sensor calibration

Prog. no: + - start:←

A subroutine that estimates the distance between the light barriers starts running.
1. Enter the length of the calibration sheet.
2. Insert the measuring sheet.
3. The measuring sheet will be pulled into the folder at a slow speed. After that the
distances are shown on the display.

0132,1 0259,2 0406,0 0616,5 (Example)

Which means: Delta 0 Delta 1 Delta 2 Delta 3

The entered length of the calibration sheet is stored. Button ↵ (mod/set) terminates the
subroutine with a beep.

Virtual folding point

Paper movement
LS LS LS LS
0 1 2 3

DELTA0 DELTA3

DELTA2

DELTA1

Calibration sheet (dimensions)

Lenght calibration

Light barrier calibration

Page 9
Technical Manual estefold 2300

Minimum length: distance between LS0 and LS3 (920 mm)

Adjustment hole: Width: min 30mm,
Height: min 40mm,
Distance from lower edge: max. 20 mm
Distance from trailing edge: min 200 mm

The leading edge of the adjustment hole will be used to estimate the distances of the light
barriers.
The adjustment hole must not decrease the sheet’s stability and must be positioned in a way
that allows the light barriers to look through the hole. When the sheet is moved out of the
folder it still has to be held by the fold roller when trailing edge of the adjustment hole is still
at LS0.

Last sheet adjust (for all paper lengths)

Display: Last sheetadjust :

Prog.no:+ - Start:←

The last sheet’s width can be altered in the range from -7,9 to +7,9 mm. The procedure of
alteration is the same as described in “first sheet adjust”.

Example:

-7,9 ±0,0 +7,9

Set test status

Display: set test status
fold:0 meas:0

Button m (select up) sets the stepping motor to only one rotating direction (fold:+ )so that
the paper will be transported through the folder without folding. All calculations will still be
performed as if the paper is being folded.
Button n (select down) effects the calculation and indication of different folding parameters in
the lower row of the display.
Display:

panel margin CF
1234,5mm R K3 L2 620,5mm

Page 10
Technical Manual estefold 2300

When covering LB1 the line will be deleted and updated at the end of the folding process..
The display shows:
Total length, type (R,H), folding class, light barrier (1-3) and distance covered from the last
fold up to the moment when the end of the paper is recognized.

Maximum fold limit (number of folds)

Display: Maximum fold limit :

Prog.no:+ - start :←

The maximum number of completed folds can be altered in the range of 1 to 30. Button m
(select up) increases the number, button n (select down) decreases the number. Button ↵
(mod/set) stores the value.

Motor
Display: Motor End:←
on off

Button m (select up) switches fold motor on, button n (select down) switches it off. Button ↵
(mod/set) terminates the routine.
The subroutine helps to measure speeds.

Permanent operation
Display: permanent operation
Prog.no: + - start:←

The folder starts running with a transport distance of 190 mm in one direction and 180mm in
the other direction.The lower row in the display shows the feed of paper in metres. Keeping
button ↵ (mod/set) pressed terminates this routine.

Light barrier check

Display: Light barrier check end:←
0:2√ 1:2√ 3:2√ 4:2√

Opto sensors are operated in pulse mode. The subroutine tests the operation of the opto
sensors.

Page 11
Technical Manual estefold 2300

The first figure indicates the sensor’s number (0 to 4) .

The left semi byte shows the time the phototransistor needs to recognize the emitter’s light in
µsec.
The average value is 2 – 4 µsec. Maximum value is 6 µsec.
The values are displayed hexadecimal ( 0-9, A, B, C, D, E, F).
The right semi byte checks the time the phototransistor needs to recognize light off.
√ = ok
X = error in sensor.
Button ↵ (mod/set) terminates this program..

Solenoid
Display Solenoid end:←
on off

Button m (select up) switches the rake solenoid on, button n (select down) switches the
solenoid off. Button ↵ (mod/set) terminates the program.

Copy counter
Display Copy counter end:←
00.000.000

Shows the total number of folded copies. This counter only shows the number of folded
copies, but neither the total length nor the total area. This counter cannot be reset.

Beep on/off
Display Beep on/off end:←

Beep: +

The beep that sounds every time you press a key on the folder’s keyboard can be switched
off using this subroutine.

Language
Display: Language
Deutsch Englisch USA

Button ↑ (select up) selects the German, button ↓ (select down) selects the English language.
The subroutine terminates automatically after a button has been pressed. When the folder
has been set to “USA” all folding programs will calculate inches.

Page 12
Technical Manual estefold 2300

Updating Firmware
If the firmware needs to be updated the folder needs to be connected to a PC by the serial
interface on printed circuit M 1307. Please ensure that computer and folder are switched
off when you are connecting the transfer cable to the serial ports as, otherwise, the
ports might be damaged.
Program “PTR.EXE” shows the new firmware version in a separate window. The firmware
has to be of “xxx.HEX” type. As soon as the COM port has been selected and the button
“TRANSFER” has been pressed the new firmware will be transferred into the folder’s CPU.
The program will indicate whether the transmission has been completed without any fault.
As long as the transfer cable is connected the folder the LED “Power” will shine red. As long
as the transfer process is underway it will glow orange and turn to green as soon as the
software transfer has been completed successfully.

Transfer Cable

Setting Parameters in the Folder

Page 13
Technical Manual estefold 2300

After the main PCB has been replaced, it will be necessary to set the folder parameters to
their proper settings… In order to do so properly a certain routine has to be gone through.
First of all the service menu has to be started and then the following routine has to be
performed:

1. Set Default Values

2. Drive Calibration
3. Light barrier Calibration
4. Adjust Panel Width
5. First Sheet Adjust
6. 3. Opto Sensor Adjust
7. 2. Opto Sensor Adjust
8. 1. Opto Sensor Adjust
9. Cross Fold Adjust

CBs
Mains CB in plug T1,6A
Motor Control Board T10A
Transformer 8 Volts T 0,5A
Transformer 28 Volts T 8A

Error Messages
A long beep will sound as soon as an error occurs.
Following errors may occur:

Paper jam
The stepper motor will stop if there is still paper at LB0 20 sec after a folding process has
been completed or terminated

Top Cover is open!

This error will be displayed when the machine cover has been opened or if it is not closed
properly.
The folder needs a “Power off – Power on” after the top cover is closed.

End stage not ready

The message will be displayed when there is an error on the motor PCB or if the PCB is not
supplied with sufficient power.

Light barrier cut x

When the folder is switched on, all opto sensors are being tested. If one of them is covered
(e.g. by paper) the error message “ light barrier cut x “ will be displayed.

LB0 paper ejection

LB1-3 paper length estimation transfer table
LB4 paper intake, automatic distinction between fan and cross fold

Light barrier defective x

Light barriers are switched on and off permanently. A self-test procedure checks if all sensor
receivers receive no light before the sensors are switched on (x is number 0-4).

Page 14
Technical Manual estefold 2300

If an error occurs button ↑ (select up) rotates the folding motor upwards, button ↓ (select
down) rotates the folding motor downwards.
Elimination of an error has to be completed by pressing button ↵ (mod/set). The folder will
restart then.

Technical data estefold 2300

Paper length: 420 – 4000 mm
Paper width: 275 - 930 mm
Paper weight: 60 - 110 g/m²
Package width: 180 - 210 mm
Filing edge: adjustable from 0 – 30 mm
Folding programmes: 8 longitudinal / 2 cross
Fold: according to DIN 824

Power supply: 115/230 V, 50/60 Hz, 6/3 A

Weight: 145 kg

Dimensions:
Width: 1350 mm
Height: 1010 mm
Depth: 1315 mm
Table height: 860 mm

Page 15
Technical Manual estefold 2300

Adjusting the Folder

Malfunctions such as:

• Damaged documents
• Paper jams
• Poor fold results
• Variations in the filing edge

may be caused by a not properly adjusted rake in the fan fold unit.
________________________________________________________________

• There has to be at least a gap of 1 mm between the rake in the lowest position and
the lower fold roller. This gap allows a document to pass without any problems. The
gap can be checked visually by any field engineer and should be consistently the
same at any position between lower fold roller and rake.

• The rake edge marked with a red arrow has to be covered by the fold roller all time in
order to avoid the document’s leading edge from jamming.

• The gap between rake and lower fold roller is adjusted by

screwing the upper rubber stop either in or out .

• The gap between main fold roller and rake should be about 4 mm.
You may have trouble folding long plots in case the gap is smaller since there will not
be enough room for the folded package.
The rake’s curve has to be parallel to the fold roller.

Page 16
Technical Manual estefold 2300

• You have to loosen the two screws that fix the rake to the mounting plate in order to
adjust the gap size.

• The fingers circled red keep the documents leading edge away from the rubber rollers
as these rotate clockwise when the document enters the folder. Especially the leading
edge of curly documents might be damaged otherwise. The fingers should be aligned
with the rubber rollers’ surface. For very curly documents the fingers may be bent
downwards slightly causing them to stick out of the rollers’ surface 1mm (this is the
maximum).

• When the rake is not in use its leading edge has to be inside the rubber roller always.
The edge marked with the red arrow must not be seen from the side otherwise the
fan folds may be very inaccurate ( especially the filing edge). The rake’s position can
be adjusted by screwing the lower rubber stop in or out.

The pressure between the fold rollers has been adjusted very lightly. Thus the springs that
adjust the pressure between rubber rollers and main fold roller have been hung on the
smaller diameter tap.

Page 17
Technical Manual estefold 2300

high pressure

low pressure

Some coated papers have a slippery surface either on one or on both sides. The slippery
surface may cause a relative movement between the single layers of the fan folded package
resulting in a so called double fold. The double fold is parallel to the intended folded edge
(this is contrary to the double fold that occurs in the cross folder and which has a triangular
shape).

Important:

• Low pressure between fold rollers reduces the danger of the folded document being
wrinkled during the fan fold process
• High pressure reduces the danger of double folds occurring when documents with
slippery surfaces are folded.

Page 18