M Vac100 (E15)

COLLATOR VAC-100
Important Information
- This manual is designed to help you to install, operate and maintain Collator, VAC-100.
Read, understand and keep this manual in a safe and convenient place.
- Do not operate VAC-100 until you read and understand the instructions in this manual.
- Horizon International Inc. shall not be liable for incidental consequential damages
resulting from : improper or inadequate maintenance by customer; unauthorized modifica-
tion 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.
070723/VAC100/15E/DV I UM201050-15
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 inad-
vertent operation when such operation could cause injury to personnel. Do not attempt to
operate any switch, valve, or other energy isolating device where it is locked or tagged out.
- Do not operate the machines when any covers are removed.
- Some of the drawings in this manual show the machine uncovered for explaining the
detail or inside of machine.
II
CONTENTS
Important Information ............................................................................................ I
Safety Precautions .................................................................................................... II
1. Before You Begin ..................................................................... 1
1-1 Specifications ...................................................................................................... 2
1-1-1 VAC-100 Series Specifications ...................................................................... 2

1-1-2 Receiving Tray (Option) Specifications ......................................................... 3
1-2 Machine Descriptions ........................................................................................ 4
1-2-1 Overview ........................................................................................................ 4

1-2-2 Feed Section ................................................................................................... 5
1-2-3 Operation Panel .............................................................................................. 6
[1] Main Page....................................................................................................... 6
[2] Set 1 Page ....................................................................................................... 8
[3] Set 2 Page ....................................................................................................... 9
[4] Program Page ................................................................................................. 10
[4] Program Page (Continued) ............................................................................. 11
[5] Memory Page ................................................................................................. 12
[6] Preset Input Page ............................................................................................ 13
1-2-4 Remote Controller .......................................................................................... 14
1-2-5 Receiving Tray (CCR).................................................................................... 15
1-2-6 Receiving Tray (CCR-DX) ............................................................................ 16
1-2-7 Stacker (ST-20) .............................................................................................. 17
1-2-8 Stacker (ST-20R)............................................................................................ 18
1-2-9 Stacker (ST-40) .............................................................................................. 19
1-2-10 Stacker (ST-60) ............................................................................................ 20
1-2-11 Hand Marry Unit (HMU-100) ...................................................................... 22
1-3 Accessories .......................................................................................................... 23
1-4 Consumables and Options ................................................................................ 25
2. Operation Procedures
2-1 Power ON ........................................................................................................... 28
2-2 Preparation for Operation ................................................................................ 29

2-2-1 Tower ON/OFF and Delivery Direction Setup .............................................. 29
2-2-2 Collating Sheet Preparation ............................................................................ 30
2-2-3 Small Size Sheet Setup ................................................................................... 32
2-2-4 Feed Height Adjustment ................................................................................. 34
III
2-2-5 Blower Adjustment......................................................................................... 34
2-2-6 Double Feed Stop Plate Height Adjustment................................................... 35
2-2-7 Separate Nose Adjustments ............................................................................35
2-2-8 Delivery Section Setup ................................................................................... 36
[1] Bulging Nose and Delivery Roller Setup ....................................................... 36
[2] Weight Setup ..................................................................................................37
[3] Delivery Air Adjustment ................................................................................38
2-2-9 Tray Unit Setup ..............................................................................................39
[1] When CCR or CCR-DX Is Used ....................................................................39
[2] When ST-20/ST-20R Is Used ........................................................................42
2-2-10 Setup in Main Page....................................................................................... 43
2-2-11 Hand Marry Unit Setup (HMU-100: Option)............................................... 44
2-3 Collating Operation ........................................................................................... 45
2-3-1 Sheet Thickness Calibration ........................................................................... 45

2-3-2 Collating Operation ........................................................................................46
2-4 Feed Error Indication and Remedy ................................................................. 47
2-5 Program Collation ............................................................................................. 49
2-5-1 Double Cycle ..................................................................................................49

2-5-2 Dual Cover Feed ............................................................................................. 51
2-5-3 Tab Insert ........................................................................................................53
2-6 Job Memory ....................................................................................................... 55
2-7 Right Side Delivery ............................................................................................56
2-8 Hand Marry ....................................................................................................... 57
2-9 Warming Up ....................................................................................................... 59
3. Troubleshooting
3-1 Error Indication and Remedy ..........................................................................62
3-2 When Misfeeding Occurs ..................................................................................63
3-3 When Double Feeding Occurs ..........................................................................63
3-4 Sheets Are Fed on the Skew ..............................................................................64
3-5 Paper Jam in Transport Conveyor ..................................................................64
3-6 Sheet from Hand Marry Unit Is Jammed ....................................................... 65
3-7 Collating Operation Does Not Start Even If Pressing Start Button ............. 65
3-8 Fuse and Breaker Check ................................................................................... 66
3-9 Pump Does Not Work ........................................................................................69
IV
4. Maintenance
4-1 Daily Cleaning .................................................................................................... 72
4-1-1 Feed Ring ....................................................................................................... 72

4-1-2 Transport Belt ................................................................................................. 73
4-2 Monthly Cleaning .............................................................................................. 72
4-2-1 Bin Sensor ...................................................................................................... 74

4-2-2 Delivery Sensor .............................................................................................. 74
4-3 Double Feed Stop Plate Replacement .............................................................. 75
4-4 Feed Error Sensor Cleaning ............................................................................. 76
4-5 Replacing the Air Filter ..................................................................................... 77
5. Move and Installation
5-1 Collator Installation ........................................................................................... 80
5-2 Blower Box Installation ..................................................................................... 81
5-3 System Switch Set Up ........................................................................................ 83
5-4 Cable Connection ............................................................................................... 84
5-5 Receiving Tray Installation ............................................................................... 85
5-5-1 CCR/CCR-DX ................................................................................................ 85

5-5-2 ST-20/ST20R.................................................................................................. 86
5-6 EAB-100 Extra Air Blower (Option) Installation ........................................... 88
5-7 VAC-100a Right Side Unit (Option) Attachment ........................................... 93
5-7-1 Accessories ..................................................................................................... 93

5-7-2 How to Attach ................................................................................................ 95
5-8 HMU-100 Hand Marry Unit (Option) Installation ......................................... 103
5-8-1 Accessories ..................................................................................................... 103

5-8-2 Hand Marry Unit (HMU-100) Installation ..................................................... 104
5-8-3 Cable Connection ........................................................................................... 107
V
VI
1. Before You Begin
1. Before You Begin
1-1 Specifications ........................................................................................... 2

1-2 Machine Descriptions .............................................................................. 4
1-3 Accessories ............................................................................................... 23
1-4 Consumables and Options ...................................................................... 25
1
1. Before You Begin
1-1 Specifications
1-1-1 VAC-100 Series Specifications
Module Type VAC-100a (Main Module)
VAC-100m (Extension Module)
VAC-100c (Rear Delivery Module)
Number of Bins 10, 20, 30, 40, 50, 60
Sheet Size 148 x 148 mm to 350 x 500 mm
(5.83" x 5.83" to 13.77" x 19.68')
Bin Pile Height 55 mm (2.2")
Paper Weight Range 52 gsm to 208 gsm
Collating Speed * Max. 9,900 sets/hr (10 Bins, A5LEF, Straight Receiving)
Max. 8,900 sets/hr (10 Bins, A4LEF, Straight Receiving)
Error Detection Miss, Double and Jam detection system (Photocell)
Error Monitor Eight sets of Feed Error Monitors
Power Single Phase 200 V 50/60 Hz
Single Phase 220/230/240 V 50 Hz
Rated Current 200 V 50/60 Hz: 9.9 A
220 V 50 Hz: 10.4 A
230 V 50 Hz: 10.4 A 60Hz: 8.7 A
240 V 50 Hz: 10.5 A
Power Consumption 200 V 1,400/1,500 W (50/60 Hz) / 220 V 1,700 W/230 V 1,800 W /
240 V 1,900W
Motors 1,200 W x 1 / 400 W x 1 / 200 W x 1 / 100 W x 1
60 W x 1 (only a, c towers)
Machine Weight VAC-100a : 290 kg (639.5 lb)
VAC-100m : 290 kg (639.5 lb)
VAC-100c : 290 kg (639.5 lb)
* Collating speed is limited by the type of finisher or sheet weight.
The machine design and specifications are subject change without any notice.
2
1. Before You Begin
1-1 Specifications
1-1-2 Receiving Tray (Option) Specifications
Model CCR CCR-DX ST-20 and ST-20R

Max. Sheet Size 318 x 470 mm (12.5" x 18.5") 320 x 450 mm (12.6" x 17.7")
Min. Sheet Size 148 x 210 mm (5.9" x 8.3") 128 x 185 mm (5.1" x 7.3")
Max. Pile Height A5 to A4 : 170 mm (6.7") 320 mm (12.6")
A4 to A3 : 100 mm (3.9")
Machine Weight 56 kg (123.5 lb) 64 kg (141.2 lb) 56 kg (123.5 lb)
Model HMU-100
Max. Sheet Size 350 x 500 mm (14" x 20")
Min. Sheet Size 120 x 148 mm (4.7" x 5.8")
Max. Sheet Height 80 gsm (21.3 lb) 50 sheets (5 mm)
Min. Sheet Height 80 gsm (21.3 lb) 1 sheets (0.1 mm)
The HMU-100 can be used with maximum of two-tower VAC-100.
The HMU-100 can not be connected with c-tower VAC-100.
The machine design and specifications are subject change without any notice.
3
1. Before You Begin
1-2 Machine Descriptions

1-2-1 Overview
Operation Panel (a-Tower)

This panel is used to operate or setup
collator. Feed errors and troubles are Operation Panel (c-Tower)
indicated on this panel. Sheets can be delivered to the right by
setting with this panel. Feed errors and
Transport Door troubles are indicated on this panel.
Belts, which transports sheets
Remote Controller
from each bin, are provided
Main operation can be performed
inside this door. This door can
with this remote controller.
be opened or removed.
Bin
Sheets are loaded on this bin.
Stop Button
Power Switch
Accessories
Receiving tray or stitcher & folder
(option) can be connected as Hand Marry Unit (Option)
finishing device. This unit is used to insert a sheet
on or under the collated sheets in
VAC-100. It can be attached to a -
Delivery Section tower or m-tower.
Sheets are transported from this section to
the accessory. Accessories (Option)
Receiving tray can be connected
as finishing device.
Stool
This stool is used to load sheets on the upper
bin. This stool is equipped with blower.
4
1. Before You Begin

1-2-2 Feed Section
Feed Rotor
This rotor sucks and feed sheets.
Feed Height Adjust Lever Feed Height Sensor

(White) This sensor determines the
This lever is used to adjust the sheet feed height.
height of feed height sensor.
Separation air Adjust

Lever (Blue)
This lever is used to adjust
separation air.
Front Plate Side Guide

This plate is the left register when This guide is the rear register
sheets are loaded on bin. when sheets are loaded on bin.
Bin
Blower Nozzle Sheets are loaded on this bin.
Blowing air comes out from this Double Feed Stop Plates
blower nozzle. These plates prevent double feeding.
Separate Nose Knob
Separate Nose
This separate nose supports to
separate sheets to prevent double
feeding.
5
1. Before You Begin

1-2-3 Operation Panel
[1] Main Page
Tabs
These tabs are used to select the page
on the screen. Error Monitor Button
This button is used to indicate
Total Counter feed error.
This counter counts sets of
collated sheets. This Delivery Air ON/OFF But-
counter can be reset with ton
clear button. When main This button is used to turn on/
power is turned off, this off delivery air.
counter is reset. 123 60 min.
Hand Marry Mode Indica-
C 60 min.
123
? tion
Preset Counter These icon indicate the se-
123
In case the required lected mode on HMU-100.

number of collated sets is 123
OFF
input in this counter with : Sheet(s) from hand marry
123 1
the right preset button, the unit is inserted under collated

collation stops when the sheets.
number of collated sets : Sheet(s) from hand marry
reaches the input number.
unit is inserted on collated
Tab Counter sheets.
This counter indicates the current : Hand marry unit is not
number of times of tab insert and
used.
the preset number of tab insert.
[Tab insertion] must be set on Stop Button
the program page. This button is used to stop the operation.
This button must be pressed three times
Double Cycle Preset Counter to stop the collator completely and lower
In case the [Double cycle mode] is bins. Refer to the chart below.
turned on and the number of [Double
cycle preset] is input in program screen Start Button
with the double cycle preset button, the This button is used to start the operation. The
collating section is automatically operation will not start before sheet calibra-
switched over when the number of tion is performed.
collated sets reaches the input number.
Feed Error Reject Function ON/OFF Button
This button is used to turn ON/OFF the function of
Dual Cover Feed Preset delivering errored sets, to the feed-error tray.
When the [Dual cover feed] is turned ON and (This button appears only if the ST-40/ST-60,
the [Dual cover feed pre-set number] is set on HOF-30 or BC-20 is connected with the VAC-100.)
the Program Page, preset collation number and
the dual cover feed pre-set number is indicated
here during the operation.
Stop Button Pressing Times Feeding Motor and Blower Bin
0 ON ON Up
1 OFF ON UP
2 OFF OFF UP
3 OFF OFF DOWN
6
1. Before You Begin
Feed Speed Indication

Feed speed can be set with triangle buttons
below. The speed can be changed during opera-
tion.
(When SPF-30 (StitchLiner) is connected, the
feed speed can not be changed with these
buttons.)
Automatic Setup Button
This button is used only when SPF-20A is
combined. When this button is pressed, the
collator speed is adjusted automatically to match
the SPF-20A speed.
Belt Speed Indication

The belt which transports collated sheets can be
123 60 min. adjusted on three scales with triangle buttons
C 60 min.
123
? below.
123
Suction Air Indication

123
OFF Suction air power can be adjusted on two scales
123 1
with triangle buttons below.1. When suction air
is set to Weak, the extra air blower (option)
cannot be used. Remove the hose of the extra air
blower, and plug the hose joint. Also, turn off the
power switch of the extra air blower. See Section
5-6 for details.
Program Indication
These icons indicate the
setup program function. Overlap between Towers Button
When the sheets are not arranged well at the
Overlap finisher, increase the overlap amount between
The sheet overlap can be adjusted on towers.
four scales with triangle buttons below. 1
Little Overlap (Normal)
2
Middle Overlap
3
Large Overlap
Vacuum Timing Select Button

When double feeding occurs frequently, turn ON
this button. Sheet will be vacuumed just before it
is fed, and the double feeding will be lessen.
(ON)
(OFF)
7
1. Before You Begin

[2] Set 1 Page
Tower Indication
The current used towers (collators) are
highlighted.
Finishing Device Button
This button is used to select
the finishing device combined.
When CCR-DX is used, CCR-
DX icon must be selected. The 1 2 3 4 5 6
standard icon ( ) must be used
for all the other devices.
Delivery Direction Button

This button is used to select delivery
direction. The c-tower is required to Finishing Device Button
deliver collated sheets to the right. This button is used to select the
finishing device combined. When
Tower Main Power Button CCR-DX is used, CCR-DX icon
The tower which is not used must be turned off. must be selected. The standard
icon ( ) must be used for all the
other devices.
8
1. Before You Begin

[3] Set 2 Page
Individual Calibration Buttons

These buttons are used to calibrate the sheet
thickness in the individual tower.
All Tower Calibration Button
This button is used to calibrate the
sheet thickness in all towers.
1 2 3
1 1 1
2 2 2
3 3 3
4 4 4
5 5 5
6 6 6
7 7 7
8 8 8
9 9 9
10 10 10 1
2
Sensor Button
This button is used adjust feed Page UP/DOWN Button
error sensor sensitivity on four This button is used to see the rest
scales. of tower indication when four
towers or more are combined.
: High
: Middle Bin Power Button
This button is used to turn on/off bin. The bin
: Low
where sheets are loaded during a sheet calibra-
: Double Feed Detect OFF tion is on. If sheets on the particular bin do not
require to be fed, the bin must be turned off.
Lamp Button : ON
This button is used to adjust the light intensity : OFF
on two scales according to the sheet thickness
and print darkness.
: for Normal to Thin
: for Thick or Dark Print Image
9
1. Before You Begin

[4] Program Page Tab Sheet Button Preset Button
Tab Insert Button This button is used to This button is used to set where tab
This button is used to turn on/off select one tab sheet or sheets are inserted.
the tab insert. two to be used.
Stop Button
Double Cycle Button This button is used to input
This button is used to turn number of tab insert to stop
on/off the double cycle 123
operation when the number of
123
mode. 1
tab insert reaches the input
Double Cycle Select 123
number.
Button Double Cycle Preset Button
This button is used to select 123
In case the number of double
which section is started in cycle preset is input, the
the double cycle program. 123 collating section is automati-
cally switched over when the
Dual Cover Feed Button number of collated sets
This button is used to turn Bin Select Button reaches the input number.
on/off the dual cover feed This button is used to select
mode. which bin is started in the
dual cover feed program.
Double Cycle : The VAC-100 system is divided into two sections. When any bin empties, the
VAC-100 immediately switches over to the second section and continues collating.
1 1 1 1 1 1 1 1 1
A 5
A 5
A
1 Tower 5
6 3 Towers A 6 B 5 Towers A A 6 B B
10
B 10 10
B 10 10 10 10
B 10 10
1 1 1 1 1 1 1 1 1 1 1 1
2 Towers A B 4 Towers A A B B 6 Towers A A A B B B

10 10 10 10 10 10 10 10 10 10 10 10
Dual Cover Feed : When one cover bin Tab Insert : Up to two tab sheets can be
empties, the VAC-100 inserted between preset collated
automatically switches over sets.
to the other cover bin.
Tab Sheets
Collated Sets
Cover Sheets
Collated Sets
Collated Sets Collated Sets
Collated Sets
Tab Sheets
NOTE
- Double cycle and dual cover feed programs can be operated together. The place of cover
sheets in the second section is the first two bins in the second section.
- Double cycle and tab insert programs can be operated together. The place of tab sheets in the
second section is the first bin in the second section.
10
1. Before You Begin

[4] Program Page (Continued)
Block Feed: Block feed function is used to divide each book block into several part. This function can
be used only when StitchLiner (Sticher) is combined. When the number of sheet for one
book is too many and the sheets cannot be scored sharply, use this function.
123 123
1
123
123
123
Block Feed ON/OFF

This button is used to turn Block Number Indication
on/off the block feed The value is calculated auto-
function. matically according to the
Block Pattern Setting block pattern.
Set the block pattern using
this icon.
11
1. Before You Begin

[5] Memory Page
Job No. Button

Up to nine collating setup patterns can be
stored with these buttons.
Current Setup Button Write Button

This button is used to indicate This button is used to memo-
the current setup condition of rize the collating setup pattern
collator. in the selected job No.
1 2 3 4 5 6 7 8 9
123 hr.
hr.
123
Read Button
Setup Indication This button is used to read the memo-
The setup condition is indicated when rized setup for the selected job No.
current setup button or job No. button is
pressed.
12
1. Before You Begin

[6] Preset Input Page
The preset input page is shown by pressing preset button on the main page or program page.
UP Key
This key is used to increase the number
indicated.
DOWN Key
This key is used to decrease the number
indicated.
71 81 91 10-number Keys
The required number can be input
41 51 61 with these keys.
11 21 31
C1 01 E1
Enter Key
This key is used to enter the number. The
page goes back after pressing this key.
Clear Key
The key is used to clear the input number.
13
1. Before You Begin

1-2-4 Remote Controller
Trouble Monitor
When collating operation stops, this monitor let
the operator know the cause with lamp lighting.
Speed Button
This button is used to adjust the collating speed.
The speed can be adjusted during the operation.
This button has the same function as the one on
the main page. While this button is being
pressed, the speed is increased rapidly.
(When SPF-30 (StitchLiner) is connected, the
123
feed speed can not be changed with this but-
ton.)
Inching Button
This button is used to inch roller and belt in the
transport and delivery sections. They can inch
during being pressed this button.
Start Button
This button is used to start the operation. The
operation cannot be started before sheet calibra-
tion is performed. This button has the same
function as the one on the main page.
Stop Button
This button is used to stop the operation. This
button has the same function as the one on the
main page. When this button is pressed with
error page shown on the screen, the screen goes
back to the main page. This function is the same
as the OK button in the error page.
14
1. Before You Begin

1-2-5 Receiving Tray (CCR)
Delivery Rollers
Tray These rollers transport collated
Tray for A5 to A4 sheet size or sets to receiving tray. Weights
for B4 to A3 sheet size can be correct sheet skew.
selected.
Air Adjust Knob
This knob is used to adjust the
delivery air.
Connecting Cable
This cable must be connected
Stopper to the collator connector.
This stopper must be set according to
the sheet size. Operation Panel
Tray Lock Knob

This knob is used to lock tray.
(Operation Panel)
L S
Off-set ON/OFF Switch Off-set Timing Knob

This switch is used to switch on/off This knob is used to adjust the side
off-set. guide delay after sheets are delivered
to CCR.
Single Motion Button

Tray rotation can be actuated
with this button.
15
1. Before You Begin

1-2-6 Receiving Tray (CCR-DX)
Tray Delivery Rollers

Tray for A5 to A4 sheet size or for B4 These rollers transport collated
to A3 sheet size can be selected. sets to receiving tray. Weights
correct sheet skew.
Full Tray Sensor
(Only for Small Receiving Tray) Air Adjust Knob
This sensor detects full tray. This knob is used to adjust the
delivery air.
Connecting Cable
This cable must be connected
Stopper to the collator connector.
This stopper must be set according to
the sheet size. Operation Panel
Tray Lock Knob

This knob is used to lock tray.
(Operation Panel)
L S
Off-set Timing Knob

Full Tray Detection Switch
This knob is used to adjust the side
This switch is used to switch on/off
guide delay after sheets are delivered
full tray detection.
to CCR-DX.
Off-set ON/OFF Switch Single Motion Button

This switch is used to switch on/off Tray rotation can be actuated
off-set. with this button.
16
1. Before You Begin

1-2-7 Stacker (ST-20)
Delivery Rollers
Stopper Adjust Knob
These rollers transport collated
This knob is used to adjust stop-
sets to receiving tray. Weights
per according to the sheet size.
correct sheet skew.
This knob can be locked with top
knob on this knob.
Operation Panel
Stop Button
Side Guide Adjust Knob

This knob is used to adjust side
Off-set Guide guide according to the sheet size.
This guide is for off-set This knob can be locked with top
receiving. knob on this knob.
Side Guide
This guide moves up and down
Tray every single cycle for off-set
Collated sets are loaded on receiving.
this tray. Stopper
Delivered collated-sets stops by
hitting this stopper.
(Operation Panel)
Tray UP Button
This button is used to raise Tray.
Off-set Timing Knob
Tray DOWN Button This knob is used to adjust the side
This button is used to lower Tray. guide delay after sheets are deliv-
Tray can be lowered only while ered to ST-20.
this button is being pressed.
Tray Lower Time Knob Off-set ON/OFF Switch

This knob is used to adjust the This switch is used to switch on/off
lowering length of tray every off-set.
single cycle.

Movable side guide can be
actuated with this button.
17
1. Before You Begin

1-2-8 Stacker (ST-20R)
Emergency Stop Button

Stopper Adjust Knob
This knob is used to adjust
Side Guide Adjust Knob stopper according to the sheet
This knob is used to adjust side size. This knob can be locked
guide according to the sheet with top knob on this knob.
size. This knob can be locked
with top knob on this knob.
Delivery Rollers
Stopper These rollers transport collated
Delivered collated-sets stops sets to receiving tray. Weights
by hitting this stopper. correct sheet skew.
Side Guide
This guide moves up and down
every single cycle for off-set Operation Panel
receiving.
Tray
Off-set Guide
Collated sets are loaded on this tray.
This guide is for off-set receiving.
(Operation Panel)
Tray UP Button
This button is used to raise tray.
Off-set Timing Knob
Tray DOWN Button This knob is used to adjust the side
This button is used to lower tray. guide delay after sheets are deliv-
Tray can be lowered only while ered to ST-20R.
this button is being pressed.
Tray Lower Time Knob Off-set ON/OFF Switch

This knob is used to adjust the lowering This switch is used to switch on/off
length of tray every single cycle. off-set.

Movable side guide can be
actuated with this button.
18
1. Before You Begin

1-2-9 Stacker (ST-40) Stopper A Adjust Knob
Feed Error Tray This knob is used to adjust stopper
All errored sets are A according to the sheet size. The Feed Error Lamp A
delivered to this tray. knob can be turn-locked into When the feed error occurs at the
position by the lock knob. collator, then the last set is deliv-
Delivery Section
Removing the feed error ered to the stack tray A, this lamp
tray and to bring will blink to alart the operator.
the transport
section to a level,
collated sets are
Stop Button
delivered to the
stitcher.
Delivery Section
Collated sets are
delivered to the
stitcher through this Side Guide A Adjust Knob
section. This knob is used to adjust side
Connector Section guide According to the sheet size.
Connect to the stitcher The knob can be turn-locked into
position by the rock knob.
Stopper
Delivered collated sets stop Side Guide
by hitting this stopper. This guide moves up and down with
every cycle for off-set receiving.
Folk
The stack tray is placed on this Off-set Guide
folk. Collated sets are accumu- This guide is for off-set receiving.
lated on the tray.
(Operation Panel) The movable side guide can
be actuated with this button.
Stack Tray UP Button
Depressing this button is
raises the stack tray. 123
123
Stack Tray Down Button

Depressing this button
lowers the stack tray.
Off-set ON/OFF Switch

This switch turns the off-set
function ON/OFF. This Off-set Delay Button
button is used to raise the This button is used to select a delayed time for
stack tray. the off-set function.
Lamp ON : Delayed time for off-set is 0.3
Stack/ Stitch Select Button second
Lamp ON : Stitch the collated sets at Lamp OFF : Delayed time for off-set is zero.
stitcher . Feed Error Reject Function ON/OFF Button
Lamp OFF : Stack the collated sets at This button is used to turn ON/OFF the function of
ST-40.
19 delivering errored sets, to the feed-error tray.
1. Before You Begin

1-2-10 Stacker (ST-60) Feed Error Tray
All errored sets are delivered to this tray.
Side Guide B
This guide moves up
and down every cycle Transport Unit
for off-set receiving. Collated sets are transported to side B
through this unit.
Stopper B
Delivered collated
sets stop by hitting Power Switch
this stopper.
Stack Tray B Stop Button

Collated sets are
accumulated on this
tray. Operation Panel A
Off-set Guide A
This guide is for off-set
receiving.
Stopper A
Collated sets are stopped Side Guide A Adjust Knob
by hitting this stopper. This knob is used to adjust side guide A
according to the sheet size. The knob
can be turn-locked into position by the
Stack Tray A rock knob.
Collated sets are loaded on this
tray. Feed Error Lamp A
When the feed error occurs at the
Side Guide A collator, then the last set is deliv-
This guide moves up and down with ered to the stack tray A, this lamp
every cycle for off-set receiving. will blink to alart the operator.
Stopper A Adjust Knob
This Knob is used to adjust stopper A
according to the sheet size. The knob can
be turn-locked into position by the rock
knob.
20
1. Before You Begin

(Operation Panel A) Single Motion Button
Counter Button Counter Input Button The movable side guide
This button is used to select can be actuated with
the mode of the counter. this button.
For further information,
refer to 2-3 in the ST-60
operation manual. 123
123
Stack Tray UP Button

Depressing this button is
raises the stack tray.
Stack Tray Down Button Off-set Delay Button

Depressing this button lowers This button is used to select a delayed
the stack tray. time for the off-set function.
Off-set ON/OFF Switch Lamp ON : Delayed time for off-set is
This switch turns the off-set function 0.3 second
ON/OFF. This button is used to raise the Lamp OFF : Delayed time for off-set
stack tray. is zero.
Stack Mode Select Button Feed Error Reject Function ON/OFF Button
Lamp ON : This button is used to turn ON/OFF the function of
The collated sets are alternately routed to the delivering errored sets, to the feed-error tray.
stack trays A/B one after the other. ON :
Lamp OFF : When a feed error occurs at the collator, the
The collated sets are alternately routed to one of errored set is delivered to the feed error tray with-
the stack trays only. When one stack tray is full, out stopping the collator. The collator will stop
the collated sets are routed to the other stack tray. after 4 consecutive errored sets are delivered to the
feed error tray.
(Operation Panel B) OFF:
When a feed error occurs at the collator, collating
Stack Tray Up Button
will stop. Errored sets will be delivered to the stack
This button is used to raise the
tray.
tray.
Stack Tray Down Button Single Motion Button

This button is used to lower the The movable side guide
stack tray. Stack tray can be can be actuated with
lowered only while this button this button.
is being pressed.
Stack Tray B Height Select Button Delivery Air ON/OFF Button

Lamp ON : 580 mm Maximum This button is used to turn ON/OFF the delivery
( 55 kg. about 700 sheets) air on the side B( left side).
Lamp OFF : 580 mm Maximum Lamp ON : Delivery air is ON
( 55 kg. about 430 sheets) Lamp OFF : Delivery air is OFF
21
1. Before You Begin

1-2-11 Hand Marry Unit (HMU-100)
Sheet Detection Sensor

When this sensor detects a sheet, collating
operation starts.
Sheet Registration Guide

Sheets to marry are registered with this
guide.
Sub-table
Hand Marry Table

Sheets to marry are placed on the table.
Sheet Guide
This guide is set according to sheet width.
Insert Mode Selecting Switch

This switch is used to select the mode to insert a
sheet on or under collated sheets from VAC-100
or to be off.
22
1. Before You Begin
1-3 Accessories
Connecting Plate (A920112-00) Detector (A924699-00) a:1 pc
m:1pc c:1 pc
Connecting Plate (A920111-00) Double Feed Stop Plate (A924697-01)
m:1 pc c:1 pc a: 10 pcs m: 10 pcs c: 10 pcs
Setting Plate (M000025-01) Grease (4-001272-00)
a: 3 pcs m: 3 pcs c: 3 pcs a:1 pc
Sheet Guide (A924698-01) Hose Band
a: 20 pcs m: 20 pcs a: 3 pcs m: 3 pcs

c: 20 pcs c: 3 pcs
Tool Box (4-003344-00) Reversible Screwdriver (4-005382-00)
a: 1 set a:1 pc
23
1. Before You Begin
1-3 Accessories
Allen Wrench a: 1 pc each
5 mm (4-000968-00) 4 mm (4-001439-00) 3 mm (4-001438-00) 2.5 mm (4-001437-00) 2 mm (4-001320-00)
Spanner a: 1 pc each
19 x 24 mm (4-005401-00) 13 x 17 mm (4-005400-00) 8 x 10 mm (4-005397-00)
Cleaning Brush (M072641-00) a: 1 pc Blower Box
;
@

À
a: 1 pc
m: 1 pc
À@;;À@;À@
;;
c: 1 pc
@@@

ÀÀÀ
;;;
Sheet Hold Plate (M072585-00) a: 5 pcs Air Filters
@@@

ÀÀÀ
;;;
a: 10 pcs
@@@

ÀÀÀ
;;;
m: 10 pcs
c: 10 pcs
@@@

ÀÀÀ
;;;
@@@

ÀÀÀ
;;;
24
1. Before You Begin
1-4 Consumables and Options
Consumables
Grease (4001272-00) Double Feed Stop Plate (A924697-01)
Fuse
;;;
@@@

ÀÀÀ
@@@

ÀÀÀ
;;;
Air Filters (M072647-00)
;;;
@@@

ÀÀÀ
1 A (4008911-00)
;;;

ÀÀÀ
@@@
2 A (4008912-00)
5 A (4008915-00)
Double Feed Stop Plate for Thin Paper

;;;
@@@

ÀÀÀ
(A924701-00)
Options
Support Guide(A924629-01) Extra Air Blower (EAB-100)
Sheet Guide (A924700-00) Hand Marry Unit (HMU-100)
25
1. Before You Begin
This page is intentionally left blank.
26
2-1 Power ON ................................................................................................. 28

2-2 Preparation for Operation...................................................................... 29
2-3 Collating Operation ................................................................................. 45
2-4 Feed Error Indication and Remedy ....................................................... 47
2-5 Program Collation ................................................................................... 49
2-6 Job Memory ............................................................................................. 55
2-7 Right Side Delivery .................................................................................. 56
2-8 Hand Marry ............................................................................................. 57
2-9 Warming Up ............................................................................................ 59
27
2-1 Power ON
NOTE
- When two towers or more are used, turn on
power from the right tower.
1. Turn on power switch.
NOTE
- When turning off main power, turn off a-
tower. Other towers can be turned off by
turning off only a-tower.
Power Switch
- The initial page as shown in the drawing

at right appears and 20 to 30 seconds later
the main page appears.
VAC-100
Now Loading....
123 60 min.
C 60 min.
123
?
123
123
OFF
123 1
NOTE
- When start button is pressed with inching
button pressed, the collator starts warming 123
up with " " indicated on the screen. Five

minutes later, warming up is stopped auto-
matically. Press stop button when stopping
Inching Button
warming up. Start Button
Stop Button
28
2-2 Preparation for Operation

2-2-1 Tower ON/OFF and Delivery Direction Setup
1. Select Set 1 page.
1 2 3 4 5 6
2. Turn on tower switch of collator which is
used, turn off tower switch of collator
which is not used.
: ON
: OFF
3. When the c-tower is combined, select the

delivery direction.
Delivery Direction Tower Switch
NOTE
- When the c-tower is not combined, the
delivery direction is only left side.
- When the right side delivery is required,
refer to "2-7 Right Side Delivery."
29

2-2-2 Collating Sheet Preparation
123 60 min.
C 60 min.
This section shows how to load sheets to be 123

?
collated. 123
123
1. Select the main page. OFF

123 1
2. When bins are raised, press stop button on

the main page or remote controller to lower
bins.
Stop Button
123
Stop Button
3. Place sheets against side guide and front

plate.
Front Plate
NOTE
- When collated sheets are delivered to the
left, load sheets from the top bin in page Collate Sheets Side Guide
order. When collate sheets are delivered to
the right, load sheets from the bottom bin in
The Page Number of Collate Sheets
page order.
P1 P10
P2 P9
- When the number of collate pages are few, P3 P8
it is efficient to load sheets from the bottom
bin.
P9 P2
P10 P1
- When two towers or more are used, it is
efficient to load sheets equally into each
tower. For example, it is more efficient to
load seven pages of sheets on both first and
[Left Side Delivery] [Right Side Delivery]
second towers than to load ten pages of
sheets into the fist tower and four pages of
sheets into the second tower.
30
NOTE
- Fan sheets well before loading them into
bins. Otherwise double feeding may occur. If
the sheets are bend, straighten then before
loading them into bins.
- Press firmly folded sheet edges when 4-page

signatures are collated to prevent misfeeding
or double feeding and to keep the sheet pile
height low level. Load sheets so the folded
edges touch front plate.
- The optional support guide allows collator

to collate 120 to 148 mm (4.7" to 5.8") width
sheets. (Refer to the next page.)
Support Guide
3. Set sheet guides so that they touch the

operation and right sides of sheet edges
respectively.
Sheet Guides
NOTE
- When handling acccordion-folded sheets or
NCR papers, set sheet hold plate on the right
sheet guide.
Sheet Hold Plate

Sheet Hold Plate
Right Sheet
Guide
Setting Direction of Accordion-folded Sheets
31

2-2-3 Small Size Sheet Setup
When small size sheets whose width is 120 to
148 mm (4.8" to 5.9") are handled, use
optional support guide.
1. Set support guide on bin where small size

sheets are loaded. Support Guide
Sheet
Bin
Support Guide
2. Raise feed height sensor and move it to the

operation side.
Feed Height Sensor
32
3. Place sheets against support guide and

front guide.
Front Guide
Sheets
Support Guide
4. Set sheet guides so that they touch the front

and right sides of sheet edges respectively.
Sheet Guides
33

2-2-4 Feed Height Adjustment
This section shows how to adjust the feed
height.
1. Adjust feed height adjust lever (White).

UP : High
DOWN : Low
3
NOTE
- The standard position of feed height adjust
lever is where lever is level.
Feed Height Adjust Lever (White)
- When feed height adjust lever is raised, the

feeding position is raised.
- When feed height adjust lever is lowered,
the feeding position is lowered.
- After test collating, raise feed height adjust Feeding Side
lever when thick sheets are handled and
misfeeding occurs. Lower feed height adjust
lever when thin sheets are handled and
double feeding occurs.
- When double feeding occurs on all bins,
weaken suction air on the main page.
2-2-5 Blower Adjustment

This section shows how to adjust blower air
on each bin.
1. Adjust separation air adjust lever (Blue).

UP : Strong
DOWN : Weak
3
NOTE
- Air is stronger where separation air adjust
lever is raised; weaker lowered.
- Normally, use blower with separation air
adjust lever on the top position.
- When sheets are blown up or pushed by air, Separation Air Adjust Lever
weaken air by lowering separation air adjust (Blue) Blowers
lever.
34

2-2-6 Double Feed Stop Plate Height Adjustment
This section shows how to adjust the double
Double Feed Stop Plates
feed stop plate height on each bin.
1. Adjust double feed stop plate adjust lever

by moving up and down.
Lever UP : Lower plate

Lever DOWN : Raise plate
NOTE
- Double feed stop adjust lever is usually used
in the lowest position.
- After test collating, raise double feed stop
plate adjust lever to lower double feed stop
plates when misfeeding occurs.
Double Feed Stop Plate Adjust Lever
2-2-7 Separate Nose Adjustments

When double feeding occurs because of thin
sheets, use separate nose. Separate Nose Knob
1. Move separate nose to the left and push out

separate nose.
NOTE
- Use separate nose only when double feeding
occurs because of thin sheets.
Separate Nose
35

2-2-8 Delivery Section Setup
WARNING
- Press stop button before setting up the
delivery section. Otherwise the delivery
section may hurt your hands.
Delivery Roller
[1] Bulging Nose and Delivery Roller Setup
Attach bulging nose and adjust delivery

rollers so that sheets are delivered smoothly
and jogged well.
1. Attach bulging nose so that it positioned in

the middle of the sheet.
Push here to lock.
Push here to remove.

Bulging Nose
NOTE
2 cm
- Sheets are delivered with 2 cm (0.8") dis-
(0.8")
tance from the rear side.
Delivery Rollers
2. Set delivery rollers by sliding so that
bulging nose is positioned in the middle of
delivery rollers according to the sheet size
and weight. Thick Sheet
4-page Signature
- Delivery rollers can be slid by raising the Bulging Nose
end of rollers.
NOTE
- When thick sheets or 4-page signature are Thin Sheet
handled, lower bulging nose. When thin Soft Sheet
sheets or soft sheets are handled, raise bulg-
ing nose. When large and thin sheets are
handled, use two bulging noses.
Large and Thin Sheet
36

[2] Weight Setup
1. Adjust the weight positions according to

the sheet thickness.
- Weights can be moved by turning counter- Weight

clockwise.
- The standard position of weight is the

middle.
NOTE
- When sheets are delivered on the skew, the
skew can be corrected by moving weight. A
- When sheets are skew in the (1) direction

shown in the drawing at right, move weights
in the A direction. UP
A
- When sheets are skew in the (2) direction (1)
MIDDLE
shown in the drawing at right, move weights
in the opposite direction of A. (2) DOWN
- Weight pressure is reduced in the UP direc-
tion. When thin sheets are handled, set
weights in the UP direction. Even if thick Weight Position
sheets are handled, you do not have to set UP : For thin sheets
weight in the DOWN direction if sheets are MIDDLE : For normal sheets
delivered smoothly. DOWN : For thick sheets
37

[3] Delivery Air Adjustment
1. Release stop button.
Stop Button
2. Turn on delivery air ON/OFF button.

123 60 min.
C 60 min.
123
?
123
123
OFF
123 1
Delivery Air ON/OFF Button
3. Adjust delivery air with delivery air knob.
Air Nozzles
Delivery Air Knob

NOTE
- When thin collated sets or sheets which are
difficult to be transported are handled, use Max.
delivery air.
- Turn delivery air knob within the range of
the arrow mark shown in the drawing at
right.
OFF
38

2-2-9 Tray Unit Setup
[1] When CCR or CCR-DX Is Used
1. Insert small or large tray into shaft.

Small Tray : A5 to A4
Large Tray : B4 to A3
Shaft
NOTE
- Two shafts project into tray. Insert these
shaft properly.
Insert Position
- The sheet set direction is different depend-

ing on the tray to be used.
Small Tray Large Tray

(The arrow direction is the feed direction.)
2. When using CCR-DX, insert full tray Full Tray Sensor Cable
sensor cable into main connector.
39
3. Place two sheets as shown with dotted lines

in the drawing at right and adjust stoppers (Small Tray)
and off-set bar to the sheet size in number Sheet Registers Off-set Bar
order. 3
Stopper
Stopper
1
(Large Tray)
Sheet Register
Off-set Bar
Stopper
Stopper
- Stoppers and off-set bar can be moved by
loosening lock knobs.
NOTE
- Provide 5 to 10 mm (0.2" to 0.4") between
the sheet edge and stoppers, and between the Lock Knob
sheet edge and off-set bar.
40
CAUTION
- Set receiving tray so that it does not Stopper
hit the collator delivery section when
turning receiving tray by 90˚.
4. Adjust the tray position.

- Move tray close to the collator where it Collator
does not touch collator delivery section
and lock the tray with tray lock knob.
Tray Lock Knob
NOTE
- Press single motion button to turn tray and
check the distance between tray and collator.
5. Set the operation mode. (CCR) Off-set Timing Knob
- When off-set receiving is required, turn

on off-set ON/OFF switch.
- Set off-set timing knob to the required

position. L S
- When using small tray of CCR-DX, turn Off-set ON/OFF Switch

on full tray detection switch. Single Motion Button
(CCR-DX)
L S
Full Tray Detection Switch

Off-set Timing Knob
41

[2] When ST-20/ST-20R Is Used
Tray UP Button Off-set Timing Knob
WARNING
- Press stop button before setting stop-
pers and guides on tray. Otherwise
personal injury may result.
(Off-set Receiving)
Guide Strip
1. Press tray UP button to raise tray. Off-set Guide
Support Stopper Sheet Registers
2. Press stop button.
3. Place a sheet as shown with dotted lines in
5 mm
the drawing at right and then adjust side
(0.2")
guide and stopper in number order. Stopper
Sheet
NOTE
- Provide 5 mm (0.2") gap between the sheet
edge and stopper, and between the sheet edge
and side guide. Side Guide
- When the sheet size is B4 or more, attach
5 mm 1 2
guide strip.
(0.2") Stopper Adjust Knob
4. Attach support stopper on the same posi- Side Guide Adjust Knob
tion as stopper's.
5. Set the operation mode. Tray Lower Time Knob Off-set Timing Knob
- Turn on off-set ON/OFF switch. (" "
position)
-Set off-set timing with off-set timing knob.
Turning knob clockwise makes off-set
time longer.
- Set tray lower time with tray lower time
knob according to the collated set thick-
Off-set ON/OFF Switch
ness. Tray lowers by turning knob clock-
wise.
(Straight Receiving)
Straight Receiving Guides
CAUTION
- Turn off off-set ON/OFF switch
(" " position) when straight receiving
is required.
1. Attach straight receiving guides and lock

them with lock knob.
Lock Knob
2. Adjust stoppers and side guide in the same
procedure as the step 3 above.
42

2-2-10 Setup in Main Page
This section shows how to set the feeding

condition in main page.
[Main Page]
1. Set the belt speed. (3 scales)
NOTE
-The belt speed can be adjusted on three 123
C
60 min.
60 min.
scales. Normally, set the middle speed. After 123
?
test collating, set the fast speed if sheets are 123
fed smoothly. On the contrary, if misfeeding

occurs, set the slow speed. 123
OFF
123 1
2. Set the feed speed.

NOTE
- The feed speed changes depending on the
belt speed and overlap used.
- The feed speed can be adjusted during the
operation.
- When SPF-20A is combined, the feed speed
is automatically adjusted by pressing auto-
CAUTION
matic set up button. - When SPF-30 (StitchLiner) is com-
3. Set air strength. (2 scales) bined, the feed speed can not be ad-
justed on VAC.
NOTE
- Air strength can be adjusted on two scales.
Normally, select strong. When double feeding
occurs because of thin sheets, select weak to
decrease the sucking force of the rotor. When
air strength is set to Weak, the extra air
blower (option) cannot be used. Remove the
hose of the extra air blower, and plug the
hose joint. Also, turn off the power switch of
the extra air blower. See Section 5-6 for
details.
4. Set overlap. (4 scales)
[Preset Input Page]
NOTE
- Overlap can be adjusted on four scales.
- After the actual collation, adjust the overlap
for good delivery to the receiving tray or
stitcher & folder.
5. When using total counter, press clear key
to reset the counter. 71 81 91
41 51 61
6. When using preset counter, press the
required number with 10-number keys, and 11 21 31
then press enter key to input the number. C1 01 E1
To clear the input number, press clear key.

After pressing enter key, the main page Clear Key Enter Key
appears.
43

2-2-11 Hand Marry Unit Setup (HMU-100: Option)
When using hand marry unit, set the sheet

guide and select the mode to insert a sheet on
or under collated sheets.
1. Select the mode with the insert mode

selecting switch.
: A sheet from hand marry unit is inserted on

collated sheets.
: Hand marry function is not used.
: A sheet from hand marry unit is inserted
under collated sheets.
- The selected mode on HMU-100 is indicated

by the icon on main page of VAC operation
panel.
123 60 min.
C 60 min.
123
?
123
123
OFF
123 1
(Main Page Of VAC Operation Panel)
2. Place sheets on hand marry table register- Place the sheets register-
ing with the sheet registration guide and set ing with this guide
the sheet guide according to sheet width.
Sheet Guide
44
2-3 Collating Operation

2-3-1 Sheet Thickness Calibration
Before actual collating operation, sheets
thickness must be calibrated and memorized. All Tower Calibration Button
Adjust sensor and/or lamp on each bin on the
Set 2 page with sheet calibration. Individual Calibration Buttons
1. Select Set 2 page.

NOTE
- When each bin power is off, sheets are not 1 2 3
fed even if sheets are loaded on the bin. 1 1 1

2 2 2
2. Set senor to middle sensitivity and lamp to 3

4
3
4
3
4
normal. 5 5 5
6 6 6
NOTE 7 7 7
- The initial setting of sensor is middle sensi- 8 8 8

9 9 9
tivity and lamp, normal. 10 10 10 1
- When sensor detects double feeding without 2
double feeding during the actual operating,

set sensor to low sensitivity. After that, sensor Sensor
still detects double feeding occurs, turn off
sensor. When sensor detects misfeeding : High Sensitivity
without misfeeding, set sensor to low sensitiv- : Middle Sensitivity
ity. : Low Sensitivity
- When sensor is turn off, sensor detects only : Double Sheet Detection OFF
misfeeding, not double feeding.
- Normally, set lamp to normal. When sensor Lamp
senses thick image on sheets or detects mis-
feeding without misfeeding, set lamp to : Normal
bright. : Bright
3. Press all tower calibration button. Bin

- Each bin on all used towers feeds one : ON
sheet. : OFF
NOTE
- When individual calibration button is
pressed, sheets only on the tower whose
button is pressed are fed once.
4. Check the number of collated sheets is

correct.
NOTE
- When the number of collated sheets is not
correct, press individual calibration button of
the tower which has a problem.
- When double feeding is monitored during a
sheet calibration, set lamp to bright and
check again.
- When double feeding of a collated set is
missed on receiving tray, misfeeding will be
detected during the actual operation.
45
2-3 Collating Operation

2-3-2 Collating Operation
This section shows how to operate the colla-
tor. 123 60 min.
C 60 min.
123
?
1. Select the main page.
123
2. Press start button either on the main page 123

OFF
or on remote controller. 123 1
NOTE
- The operation will not start before sheet
thickness calibration is completed. (Refer to
"2-3-1 Sheet Thickness Calibration.")
- When using the hand marry unit, refer to Start Button Stop Button
"2-8 Hand Marry"
3. Press stop button either on the main page

or on remote controller.
123
NOTE
- When stop button is pressed during opera-
tion, only feeding is stopped, not motor and
blower. When stop button is pressed again,
motor and blower are stopped, but bins are
not lowered. When stop button is pressed Start Button
again, bins are lowered.
Stop Button

0 ON ON Up
1 OFF ON UP
2 OFF OFF UP
3 OFF OFF DOWN
46
2-4 Feed Error Indication and Remedy

Feed Error Mark
When jam, misfeeding and double feeding
occur, the collator delivers the collated sets : Double Feed
and then stops with errors indicated on the : Jam
screen and remote controller. : Misfeed
OK
1. When the operation is stopped because of 1 2 3 4 5 6
feeding errors, the numbers 1 and 3 on 1 1 1
2 2 2 1
the right side on the screen mean that top 3 3 3
collated sets and 3rd collated sets from the 4 4 4 3
top on receiving tray have feed error. The 5 5 5
6 6 6
feed error icons indicate all errors when the 7 7 7
collator is stopped. 8 8 8
9 9 9
10 10 10
NOTE
- The feed error can be indicated on up to the
eighth collated set.
OK
1 2 3 4 5 6
1 1 1
2 2 2 1
2. Press the number 1 button on the right 3 3 3
side. Check the top collated set delivered 4 4 4 3
on receiving tray. 5 5 5
6 6 6
7 7 7
- Jam occurred on the second bin of the 8 8 8
9 9 9
second tower. 10 10 10
- Double feeding occurred on the first bin

of the fourth tower.
NOTE
- Jam may be monitored though sheets are 123
ejected. This is because feed timing is de-

Inching Button
layed. Check that sheets are not jammed.
When jammed, press inching button to trans-
port the sheet, open transport door and then
remove the sheet.
Transport Door
47
2-4 Feed Error Indication and Remedy

OK
3. Press the number 3 button on the right 1 2 3 4 5 6
side. Check the third collated set from the 1 1 1
2 2 2 1
top on receiving tray. 3 3 3
4 4 4 3
- Double feeding occurred on the first bin 5 5 5
6 6 6
of the sixth tower. 7 7 7
8 8 8
- Misfeeding occurred on the third bin of 9 9 9

10 10 10
the sixth tower.
NOTE OK
1 2 3 4 5 6
- When sheet feed timing is delayed, the 1 1 1
operation stops immediately with all tower 2 2 2 1
numbers and jam marks indicated on screen 3 3 3 2

4 4 4
as shown in the drawing at right. When this 5 5 5
3
4
occurs, eject the jammed sheet by pressing 6 6 6
5
inching button and check from the top to the 7 7 7
6
8 8 8
fifth collated sets on receiving tray. 9 9 9 7
10 10 10 8
NOTE Gray Icon

- If mis-collated sheets are not delivered to Feed Error OK
the mis-feed tray in ST-40/60, BC-20, and 1 2 3 4 5 6
ALL
1 1 1
HOF-20/30, an error indication icon is dis- 2 2 2
played in gray. See operation manual of each 3 3 3 2
machine for details. 4 4 4 3
5 5 5
6 6 6
7 7 7
8 8 8
9 9 9
10 10 10
4. Press O K button or stop button on

123 60 min.
remote controller to go back to the main C 60 min.
page.
123
?
123
NOTE 123
OFF
- When feed error monitor is required to see
123 1
again, press error monitor button on the

main page.
48
2-5 Program Collation

2-5-1 Double Cycle
The VAC-100 system is divided into two
sections. When any bin empties, the VAC-100
immediately switches over to the second
section and continues collating.
1 1 1 1 1 1 1 1 1
1 Tower 5
A 3 Towers 5
A 5 Towers 5
A
6 A 6 B A A 6 B B
10
B 10 10
B 10 10 10 10
B 10 10
1 1 1 1 1 1 1 1 1 1 1 1
2 Towers 4 Towers A
A B A B B 6 Towers A A A B B B
10 10 10 10 10 10 10 10 10 10 10 10
1. Load sheets on bins so that the first section

A and the second section B in the drawing
above have the same contents.
NOTE
- When using only 1 tower and 1 collated sets
use four bins, load sheets from the bins 1 to
4, and then load the same content sheets from
the bins 6 to 9, from the bins 7 to 10, or the
bins 6, 8 to 10.
- On the tower divided half of 1 tower, 3 or 5
towers, load sheets by 40 mm (1.5") height or
less because separation air may curl loaded
sheets.
2. Prepare for collating referring to the "2-2

Preparation for Operation."
Double Cycle Select Button
3. Select program page. Double Cycle Button
4. Turn on double cycle button. 123 123

1
5. Select which section is started first with

123
double cycle select button.

123
NOTE
- When sheets are delivered to the right, the A 123
and B sections are reversed.
49

Individual Calibration Buttons
6. Press all tower calibration button on the Set All Tower Calibration Button
2 page referring to the "2-3-1 Sheet Thick-
ness Calibration."
1 2 3
- All sheets on bins of all towers are col-
1 1 1
lated once. 2 2 2
3 3 3
4 4 4
5 5 5
6 6 6
7 7 7
8 8 8
9 9 9
10 10 10 1
2
7. Select the main page and press start button.

123 60 min.
C 60 min.
- When any bin empties in the first section, 123
?
the collator switches over to the second 123
section automatically and continues

collating. 123
OFF
123 1
NOTE
- Add sheets on bins which are paused.
- Double cycle and dual cover feed programs

can be operated together. Refer to "2-5-2
Dual Cover Feed" and "2-5-3 Tab Insert." Start Button Stop Button
- When the collating speed is too fast or some

bin empties in one section, misfeeding may be 123
indicated on screen. In this case, remove the

top collated set on receiving tray and press
start button. The collator switches over to the
other section automatically to start collating
operation.
Start Button
Stop Button
50

2-5-2 Dual Cover Feed
Normally, cover sheets are thicker than

inside sheets, so the bin loading cover sheets Cover Sheets
empties earlier than other bins. This dual
cover feed program enables operation to Inside Sheets
continue without interrupting by switching
over to the other bin loading cover sheets
when one bin loading cover sheets empties.
1. Load cover sheets into the top two bins,

and inside sheets into the rest bins. (Refer
to "2-2 Preparation for Operation.")
NOTE
- For example, when using the third to ninth
bins, load cover sheets into the third and
fourth bins.
123 123
1
2. Select the program page.
123
3. Turn on dual cover feed button. 123
123
4. Select which bin loading cover sheets is

used first with bin select button.
Dual Cover Feed Button Bin Select Button
5. Press all tower calibration button on the Set All Tower Calibration Button
2 page referring to "2-3-1 Sheet Thickness Individual Calibration Buttons
Calibration" and check the collating condi-
tion.
- All sheets of all towers are collated once. 1 2 3
Cover sheets on both bins are also col- 1 1 1
lated. 2 2 2
3 3 3
4 4 4
5 5 5
6 6 6
7 7 7
8 8 8
9 9 9
10 10 10 1
2
51

123 60 min.
C
- When one bin loading cover sheets emp- 123
60 min.
?
ties, the collator switches over to the other
123
bin automatically.
123
OFF
123 1
Start Button Stop Button
123
Start Button
Stop Button
NOTE
- Dual cover feed and double cycle programs
can be operated together. The position of
1 Cover Sheets
cover sheet loading in the second section is
the top two bins in the second section. (The first and second bins)
5
- Dual cover feed and tab insert programs can 6 Cover Sheets
not be operated together. (The sixth and seventh bins)
10
- When the collating speed is too fast or some
bin empties in one section, misfeeding may be
indicated on screen. In this case, remove the
top collated set on receiving tray and press
start button. The collator switches over to the
other section automatically to start collating
operation.
52

2-5-3 Tab Insert
Tab Sheets
Up to two tab sheets can be inserted between
Collated Sets
collated sets preset.
Collated Sets
1. When one tab sheet is inserted, load the tab Collated Sets
sheets into the top bin. When two tab
sheets are inserted, load the tab sheets into Collated Sets
the top two bins. And then load inside Tab Sheets
sheets into the rest bins. (Refer to "2-2
Preparation for Operation.") Tab Insert Button Preset Button
Tab Sheet Button Preset Stop Button
2. Select the program page.

123 123
1
3. Turn on tab insert button. 123
123
4. Select one or two with tab sheet button.

123
5. Input the required number of collated sets

between tab sheets with preset button.
6. When the operation is required to stop after

any tab inserting times, input the required 71 81 91
number of inserting times with preset stop 41 51 61
button.
11 21 31
C1 01 E1
All Tower Calibration Button

7. Press all tower calibration button on the Set Individual Calibration Buttons
2 page referring to "2-3-1 Sheet Thickness
Calibration" and check the collating condi-
tion. 1 2 3
1 1 1
- All sheets of all towers are collated once. 2 2 2
Cover sheets on both bins are also col- 3 3 3
lated. 4 4 4
5 5 5
6 6 6
7 7 7
8 8 8
9 9 9
10 10 10 1
2
53

123 60 min.
C 60 min.
- Tab sheets are inserted between the preset 123
?
number of collated sets and operation is 123
stopped with preset number of tab insert-

ing times. 123
OFF
123 1
NOTE
- When preset stop is used, the set number is
indicated in tab counter on the main page.
Tab Counter Start Button Stop Button
123
Start Button
Stop Button
NOTE
- Tab insert and double cycle programs can
be operated together. The position of tab
sheet loading in the second section is the top 1 Tab Sheets
bin or two in the second section.
(The first and second bins)
- Tab insert and dual cover feed programs 5
can not be operated together. 6 Tab Sheets
(The sixth and seventh bins)
10
54
2-6 Job Memory
The collation set up can be memorized and

used in the future operation. Up to nine jobs
can be memorized.
NOTE
- The following setups can be memorized.
Feed Speed
Belt Speed
Air Strength
Overlap
Using Bin Number
Preset Counter
Type of Program Collation
Delivery Direction
Sensor Lamp Adjustment
- The job memory function is not available

on c-tower. Current Setup Button
1. Select the main page. Job No. Button Write Button
2. When current setup button is pressed, the 1 2 3 4 5 6 7 8 9

current collator setup is indicated. When 123 hr.
job No. button is pressed, the memorized hr.
setup is indicated. 123
3. When the current set up is required to

memorize, press job No. button and then
write button.
- The former input set up is cleared and the Read Button

current set up is memorized.
4. When the memorized set up is required to

read, press job No. button and check the set
up indication. And then press read button.
- The set up of the collator is changed to

the memorized setup.
55
2-7 Right Side Delivery

When c-tower is combined, collated sets can
be delivered to the right.
1. Select the Set 1 page on a-tower operation

panel on the left end.
1 2 3 4 5 6
2. Select the delivery direction.

NOTE
- The delivery direction can be set as shown
in the drawing at right. While 1 and 2 towers
are delivering on the left side, 3 and 4 towers
can perform the right side delivery.
- The delivery direction can not be set on c- Delivery Direction Button

tower.
3. To change the delivery direction, select Page Order of Collated Sets

another page to determine the delivery
direction. P20 P10
P19 P9
P18 P8
4. Set up the collator referring to "2-2 Prepa-

ration for Operation" P12 P2
P11 P1
NOTE
- To deliver collated sets to the right, load
sheets from the bottom in order with the front [Right Side Delivery]
side down as shown in the drawing at right.
Collated sheets are delivered upside down.
5. Set the collating condition and start/stop

operation on c-tower.
NOTE
- The right side delivery operation can be
performed only on c-tower.
- Program collations are available in the

right side delivery operation.
56
2-8 Hand Marry

This section shows how to hand marry a
sheet on or under collated sheet with hand
marry unit. 123
C
60 min.
60 min.
123
?
1. Select the inserting mode with the switch 123
on the hand marry unit.

2. Select the main page. 123
OFF
3. Press start button either on the main page 123 1
NOTE
- The operation will not start before sheet
thickness calibration is completed. (Refer to
"2-3-1 Sheet Thickness Calibration.")
Start Button Stop Button
4. Place sheets on the hand marry unit.
-when the senser detects a sheet, collating
operation starts.
123
NOTE
- When selecting the mode with insert
mode selecting switch, sheets on hand marry
table are deliveried in a second after placing
sheets on the table and then the collating Start Button
operation starts.
When selecting the mode with insert mode
selecting switch, the collating operation starts Stop Button
in a second after placing sheets on the table
and then sheet on hand marry table is
deliveried.
-Even changing the mode with the insert
mode selecting switch after pressing start Put the sheets registering
buttom in VAC-100, the mode does not with this guide
change.When changing the mode, press stop
buttom to stop collating and change the mode
with the insert mode selecting switch.
ATTENTION
- When sheet from hand marry unit is
Sheet Guide
jammed on the mode , only collated sheets
in VAC are delivered to the finishing device.
The error is not indicated on the panel in
VAC-100.
- When sheet from hand marry unit is Insert Mode Selecting Switch
jammed on the mode , after the collated
sheets in VAC-100 are deliveried, the rollers : A sheet from hand marry unit is inserted on
continue to rotate and the finishing device collated sheets.
waits the sheet to be deliveried from hand : Hand marry function is not used.
marry unit. In this case, press stop buttom to
stop collating.When a sheet from the hand : A sheet from hand marry unit is inserted
marry unit is jammed, refer to "3-6 Sheet under collated sheets.
from Hand Marry Unit Is Jammed"
57
2-8 Hand Marry

5. Press stop button either on the main page
NOTE
- When stop button is pressed during opera-
tion, only feeding is stopped, not motor and
blower. When stop button is pressed again,
motor and blower are stopped, but bins are
not lowered. When stop button is pressed
again, bins are lowered.

0 ON ON Up
1 OFF ON UP
2 OFF OFF UP
3 OFF OFF DOWN
58
2-9 Warming Up
When feeding problems occur frequently
after startup in the morning, warm up the
machine.
1. While pressing the jog button on the re- Jog Button

mote controller, press the start button.
123
Start Button
- The control panel indicates the Warming Warminig Up Screen

Up mode, and the warming up process
begins.
- Warming up finishes automatically after

five minutes.
2. To cancel the warming up process, press

the stop button on the remote controller. 123
Stop Button
59
60
3. Troubleshooting
3. Troubleshooting
3-1 Error Indication and Remedy ................................................................ 62

3-2 When Misfeeding Occurs........................................................................ 63
3-3 When Double Feeding Occurs ................................................................ 63
3-4 Sheets Are Fed on the Skew ................................................................... 64
3-5 Paper Jam in Transport Conveyor ........................................................ 64
3-6 Sheet from Hand Marry Unit Is Jammed ............................................. 65
3-7 Collating Operation Does Not Start Even If Pressing Start Button ... 65
3-8 Fuse and Breaker Check ......................................................................... 66
3-9 Pump Does Not Work ............................................................................. 69
61
3. Troubleshooting
3-1 Error Indication and Remedy

When some error occurs during collation, the ? OK
cause is indicated on operation panel. 1 2 3 4 5 6
Feed Error
Double feeding, misfeeding or jam occurred. ? ? ? ? ? ?
Refer to "2-4 Feed Error Indication and Rem-
edy."
Bin Empty
Bin is empty. Add sheets.
? Operation Error System Error Code

Operation error occurs; (Refer to the table
- Start button is pressed before sheet thick- below for detail)
ness calibration. 101
- The number of used bins are different
between the first and second sections in
double cycle. System Error
- Bin power is off. System error happened. Turn off main power
Operate collator in the proper procedures. and five seconds later turn on power. If the
system error X51 or X52 (X:Number of tower
Door Open where the system error happened) happened,
Transport door is open. Close the door. press the "OK" Button on the operation panel
or the Stop Button on the remote controller to
Stop reset.
Stop button is being pressed. Release the
button. System Error Screen
Jam in the Delivery Section

Sheets are jammed in the delivery section.
Remove the jammed sheets.
SYSEM ERROR 02
Accessory Error
Some error happened in the finishing device.
Remove the cause from the accessory. When
stop button of the finishing device is being
pressed, this mark is indicated. And also, this A communication error occurred between the
mark is indicated when transport belt of board and the panel. Please call your local
stitcher & folder is not rotating. dealer.
System Error Code Table
Codes Causes Actions
X01 Communication Error with Operation Panel Turn off the power. Wait 10 sec. or more and turn on the power.
X02 Communication Error with Operation Panel Turn off the power. Wait 10 sec. or more and turn on the power.
X07 Internal Error Turn off the power. Wait 10 sec. or more and turn on the power. See how the condition improves for some time.
X25 Control Software Error Turn off the power. Wait 10 sec. or more and turn on the power.
X50 Inverter Error Turn off the power. Wait 10 sec. or more and turn on the power.
X51 Delivery Sensor Error Check the paper dust on the delivery sensor or the sensor position.
X52 Pulse Error Check the loading of the pulse encorder or the paper dust on the encorder.
X87 Communication Error between Towers Check the communication cable between towers and the dip switch on the P.C.B..
X88 Communication Error between Towers Turn off the power. Wait 10 sec. or more and turn on the power.
X89 Communication Error between Towers Turn off the power. Wait 10 sec. or more and turn on the power.
X99 Internal Error Turn off the power. Wait 10 sec. or more and turn on the power.
62
3. Troubleshooting
3-1 Error Indication and Remedy

Full Tray delivered to the left, this full tray indication
Receiving tray is full. Unload collated sets will appear. When the stacker ST-20 is con-
from tray. nected to the single VAC-100a and the col-
Or the setup of the stitcher is not completed. lated sets are also delivered to the left, this
full tray indication will appear. This error
NOTE indication can disappear by adjusting the
- When the stacker ST-20R is connected to volume on the printed circuit board. Contact
the single VAC-100a and the collated sets are with the dealer.
3-2 When Misfeeding Occurs

This section shows how to remedy misfeeding.
(Cause) (Remedy)
1. Sheets are too thick. (Out of specifications) 1. Use sheets within the specifications.
2. Sheets are not fanned well. 2. Fan sheets well.
Ink on sheets is not dry. Dry ink on sheets.
3. Double feed stop plates are too high. 3. Lower double feed stop plates.
4. Sheets are not loaded properly into bins. 4. Load sheets into bins properly referring
to "2-2-2 Collating Sheet Preparation."
5. Air strength is set to "weak" position. 5. Set air to "strong" position. When air
strength is set to Weak, the extra air
blower (option) cannot be used. Remove
the hose of the extra air blower, and plug
the hose joint. Also, turn off the power
switch of the extra air blower. See Sec-
tion 5-6 for details.
3-3 When Double Feeding Occurs

This section shows how to remedy double sheet feeding.
(Cause) (Remedy)
1. Sheets are too thin. (Out of specifications) 1. Use sheets within the specifications.
2. Sheets are loaded into bins too much. 2. Reduce the sheets.
3. Sheets are not fanned well. 3. Fan sheets well.
Ink on sheets is not dry. Dry ink on sheets.
4. Double feed stop plates are too low. 4. Raise double feed stop plates.
5. Air strength is set to "strong" position. 5. Set air to "weak" position.
6. Separation air is weak. 6. Strengthen separation air with separation
air adjust lever (Blue).
7. Sheets are porous. 7. Turn on the vacuum timing select button
so that sheet will be vacuumed just before
it is fed, referring to "1-2-3 Operation
Panel [1] Main Page."
63
3. Troubleshooting
3-4 Sheets Are Fed on the Skew

This section shows how to remedy sheet skew.
(Cause) (Remedy)
1. Sheets are not loaded properly into bins. 1. Reload sheets into bins referring to "2-2-2
Collating Sheet Preparation."
2. Sheet guides are not set properly. 2. Set guide by slightly hitting sheets, or
change the guide position.
3. Sheets are loaded too much. 3. Reduce the sheets.
4. Paper dust is collected in the feed and 4. Remove paper dust.

transport sections.
5. Double feed stop plates are worn out. 5. Replace double feed stop plates with new
ones referring to "4-3 Double Feed Stop
Plate Replacement."
6. Sheets are curling because of separation 6. Adjust separation air with separation air
air. adjust lever (Blue) on bin.
3-5 Paper Jam in Transport Conveyor

Transport
1. When the paper jam occurs in transport Conveyor
conveyor, pull the lever to left and lock
lever as shown in the drawing at right.
NOTE
- Normally, operate the machine without Lever
locking the lever.
64
3. Troubleshooting
3-6 Sheet from Hand Marry Unit Is Jammed

This section shows how to remedy jammed sheet delivered from hand marry unit.
(Cause) (Remedy)
1. Sheets on hand marry table are more than 1. Hand marry unit can accept 50 or less
50 sheets of 80 gsm (5 mm height). sheets at a time (5 mm).
2. The hand marry unit are not installed 2. Install the hand marry unit so that the
properly. positioning guide (arrow) of this unit fits
in the rear cover of VAC-100 completely.
Rear Cover
Hand Marry Unit

Positioning Guide
3-7 Collating Operation Does Not Start Even If Pressing Start Button
This section shows how to remedy the collating problem when the collating operation does not
start even if pressing start button.
(Cause) (Remedy)
1. Sheets thickness is not calibrated. 1. Calibrate sheets thickness before actual
collating operation referring to "2-3-1
Sheet Thickness Calibration".
2. The insert mode selecting switch is set 2. Turn OFF the insert mode selecting
either or on HMU-100. switch when hand marry function is not
used installing hand marry unit to VAC-
100. When using hand marry function,
the collating operation does not start until
sheets are put on hand marry table.
65
3. Troubleshooting
3-8 Fuse and Breaker Check
When one part of collator or whole does not Panel Cover

operate, check fuse and breaker.
WARNING
- Remove power cord before checking
fuse and breaker. Otherwise high volt-
age can cause sever personal injury.
Fix Screw
1. Remove power plug or power cord.
2. When the collator is locked, remove the

cause.
3. Loosen a fix screw on panel cover and

open panel cover.
Power Cord
4. Check fuses as shown in the drawing at

right. If fuse is cut, replace it with a new
one.
NOTE
- When fuses are cut, the collator has trouble
as follows.
F1 (5A) : The whole machine do not operate.
F2 (2A) : Delivery air does not come out.
F3 (1A) : Not used.
F4 (5A) : Receiving tray on the left side does
not operate.
F5 (5A) : Receiving tray on the right side of
c-tower does not operate.
F5
F4
F1
5. Close panel cover and fix it with a fix F2

F3
screw.
Fuses
66
3. Troubleshooting
The following procedures (steps 6 to 12)

Fix Screws
shows how to check breaker.
;
@

À
6. Remove top on blower box. (4 fix screws)
Fix Screws
À@;;À@;À@
;; Top
Blower Box
7. Remove 2 fix screws inside of blower box.
Fix Screws
8. Remove front cover. (3 fix screws)
Fix Screw
Front Cover
Fix Screws
67
3. Troubleshooting
9. Check breakers as shown in the drawing at

right. If some breakers trip, turn on break-
ers.
NOTE
- When breakers trip, the collator has trouble
as follows.
Q10 (16A) : The whole machine do not
operate.
Q01 (2A) : Receiving tray does not operate
and delivery air does not come
out.
10.Attach front cover. (3 fix screws)
Breaker Q10 Breaker Q01
11.Fix blower box on the collator. (2 fix

screws)
Fix Screws
Fix Screws
12.Attach top on blower box. (4 fix screws)
Top
Fix Screws
Blower Box
68
3. Troubleshooting
3-9 Pump Does Not Work
There is a function to prevent the inside

circuit from overheating in the pump and it
might work. The inside temperature might
increase because the air slits of blower box
are obstructed. Follow the steps to work
pump again.
Blower Box
1. Turn off the power switch.
;
@

À
2. Install the pump so that it does not obstruct
À@;;À@;À@
;;
the air slits of the blower box.
3. Wait until the inside temperature decrease

and turn on the power switch.
Air Slits
69
3. Troubleshooting
70
4. Maintenance
4. Maintenance
4-1 Daily Cleaning.......................................................................................... 72

4-2 Monthly Cleaning .................................................................................... 74
4-3 Double Feed Stop Plate Replacement .................................................... 75
4-4 Feed Error Sensor Cleaning ................................................................... 76
4-5 Replacing the Air Filter .......................................................................... 77
71
4. Maintenance
4-1 Daily Cleaning

4-1-1 Feed Ring
After operations, clean feed rings. If feed
rings are dirty, collated sheets may be
smeared.
WARNING
- Turn off main power before cleaning Feed Rings
feed rings. Otherwise personal injury
may result.
1. Wipe 4 gray feed rings on bin with alco-

hol-soaked cloth.
NOTE
- Feed rotor can be turned manually.
CAUTION
- Do not use thinner and benzine.
Otherwise roller or plastic may melt.
- Do not use rubber cleaner for roller
of the folder. Otherwise, the roller may
get swollen and be worn.
72
4. Maintenance
4-1 Daily Cleaning

4-1-2 Transport Belt
After operations, clean transport belt. If
transport belt and rollers are dirty, collated
sheets may be smeared.
WARNING
- Turn off main power before cleaning
transport belt. Otherwise personal Transport Door
injury may result.
1. Open transport door.

NOTE
- When transport door can not be opened
completely because a collator is combined on
the left side, remove transport door by open-
ing and lifting the door.
- Transport door weights 9 kg (19.9 lb). Take
utmost care when removing it.
Transport Belt
2. Wipe transport belt and rollers with alco-
hol-soaked cloth.
3. Close transport door. Transport Roller
73
4. Maintenance
4-2 Monthly Cleaning

4-2-1 Bin Sensor
Clean bin sensor monthly. If paper dust stick
on bin sensor, sensor determines that sheets
are loaded into bin without any sheets and
misfeeding is indicated.
Bin Sensor Cover

WARNING
bin sensor. Otherwise personal injury
may result.
1. Remove bin sensor cover by pulling to the

right.
2. Remove paper dust on bin sensor with

brush.
3. Attach bin sensor cover.
Bin Sensors
4-2-2 Delivery Sensor

Clean delivery sensor monthly. If paper dust
stick on delivery sensor, the machine may
stop due to jam in the delivery section.
WARNING
delivery sensor. Otherwise personal
injury may result.
1. Remove paper dust on delivery sensor with

brush. Delivery Sensor
74
4. Maintenance
4-3 Double Feed Stop Plate Replacement

When double feed stop plates are worn out
and double feeding occurs, replace double
feed stop plates with new ones.
WARNING
- Turn off main power before replacing Fix Screws
double feed stop plates. Otherwise
personal injury may result.
1. Loosen 2 fix screws on double feed stop

plate.
2. Remove double feed stop plate by sliding

upward.
Double Feed Stop Plate
Double Feed Stop Plate
3. Attach new double feed stop plate and fix

it with 2 fix screws. Fix Screws
NOTE
- Do not fasten screws too tight.
75
4. Maintenance
4-4 Feed Error Sensor Cleaning

When paper dust sticks to feed error sensors,
bins which require sensor cleaning are indi-
cated on the screen as soon as turning on
power switch.
1. Clean feed error sensor(s) indicated on OK

maintenance page of screen with cleaning 1 2 3 4 5 6
1 1 1
brush. 2 2 2
3 3 3
4 4 4
5 5 5
6 6 6
7 7 7
8 8 8
9 9 9
10 10 10
Paper dust sticks on the bins 2 and 7 of tower

1, and the bin 5 of tower 2.
NOTE
- Feed error sensors light inside the feed
section.
- Insert cleaning brush into the feed section
with the face down.
Feed Error Sensor
2. Turn off power switch and 10 seconds later

turn on power switch. When the main page
appears, feed error sensor has been
cleaned. When the maintenance page
appears again, clean feed error sensor
again.
Power Switch
76
4. Maintenance
4-5 Replacing the Air Filter

If the blower often stops, the air filter may be
clogged. If the whole surface of the air filter
is clogged or smeared, replace the air filter.
1. Turn off the power switch.
2. Open the air filter cover.
;;
@@

ÀÀ
@@

ÀÀ
;;
@@

ÀÀ
;;
@@

ÀÀ
;; Air Filter Cover
@@

ÀÀ
;;
3. Replace the air filter.
;;
@@

ÀÀ
@@

ÀÀ
;;
Air Filter
4. Close the air filter cover and turn on the

power switch.
77
4. Maintenance
78
5-1 Collator Installation ................................................................................ 80

5-2 Blower Box Installation .......................................................................... 81
5-3 System Switch Set Up .............................................................................. 83
5-4 Cable Connection .................................................................................... 84
5-5 Receiving Tray Installation .................................................................... 85
5-6 EAB-100 Extra Air Blower (Option) Installation ................................ 88
5-7 VAC-100a Right Side Unit (Option) Attachment ................................ 93
5-8 HMU-100 Hand Marry Unit (Option) Installation .............................. 103
79
5-1 Collator Installation
WARNING
- Do not turn on main power before
instruction.
CAUTION
- VAC-100 weights 298 kg (657.1 lb).
550 610 842
Install VAC-100 on rigid and level
floor. ST-20 VAC 65 CCR VAC 650
- Avoid direct sunlight and high humid-
Blower 302 Blower
ity.
506.6
610 842 810 810 810 810 914
1. Prepare space for installing VAC-100. (CCR) (a) (m) (m) (m) (m) (c)
Tray 1 Tower 2 Towers 3 Towers 4 Towers 5 Towers 6 Towers
952
NOTE Blower Blower Blower Blower Blower Blower
- Required space is shown as follows. 1517

1 Tower : 1517 x 952 mm (59.8" x 37.5") 2327
2 Towers : 2327 x 952 mm (91.7" x 37.5") 3137
3 Towers : 3137 x 952 mm (123.5" x 37.5") 3947
4 Towers : 3947 x 952 mm (155.4" x 37.5") 4757
5 Towers : 4757 x 952 mm (187.3" x 37.5") 5671
6 Towers : 5671 x 952 mm (223.3" x 37.5")
5 mm Connecting Plate (U) 3 mm

2. Position collator(s). When installing two (0.2") (0.12")
collators or more, attach connecting plates
(U) and (L).
3. Put setting plates under adjust bolts.
4. Raise collator(s) by turning adjusts bolts

until casters slightly separate from the
floor. Connecting Plate (L)
NOTE
- Collator must not tilt by 5 mm (0.2") or
more. Adjust Bolt
- The difference between tower heights must
be within 3 mm (0.12").
Setting Plate
80
5-2 Blower Box Installation
This section shows how to install blower box. Fix Screws
Fix Screws
2. Connect collator hose to blower through Top
hole and fix the hose.
3
2
1
3. Connect signal and power cords to terminal
board through cord bushes. 1
2 3
3
2
1
Signal Cord
Power Cord
Signal Cord Power Cord

(Thin) (Thick)
4. Fasten cord bushes to fix cords.
Cord Bushes
81
5-2 Blower Box Installation
5. Fix blower box on collator. (2 fix screws)

NOTE
- Do not obstruct the air slits of the blower
box.
Fix Screws
Fix Screws
6. Attach top on blower box. (4 fix screws)
Fix Screws
Top
82
5-3 System Switch Set Up
This section shows how to set up system

switches inside panel cover.
WARNING
- Remove power cord before setting up
system switch. Otherwise high voltage
can cause sever personal injury.
TOTAL ORDER
1. Loosen each fix screw on panel covers on

all towers and open panel cover.
1 1
2. Set "TOTAL" and "ORDER" with system

switches of all towers. 1 Tower
TOTAL:1
ORDER:1
2 Towers
TOTAL:2 TOTAL:2
ORDER:1 ORDER:2
3 Towers
TOTAL:3 TOTAL:3 TOTAL:3

ORDER:1 ORDER:2 ORDER:3
4 Towers
TOTAL:4 TOTAL:4 TOTAL:4 TOTAL:4

ORDER:1 ORDER:2 ORDER:3 ORDER:4
5 Towers
TOTAL:5 TOTAL:5 TOTAL:5 TOTAL:5 TOTAL:5

ORDER:1 ORDER:2 ORDER:3 ORDER:4 ORDER:5
6 Towers
TOTAL:6 TOTAL:6 TOTAL:6 TOTAL:6 TOTAL:6 TOTAL:6

ORDER:1 ORDER:2 ORDER:3 ORDER:4 ORDER:5 ORDER:6
3. Close panel cover and fasten each fix

screw on panel covers on all towers.
83
5-4 Cable Connection
This section shows how to connect signal and

power cords.
WARNING
- Turn off breakers in the building
before connecting power cord. Other-
wise high voltage can cause severe
personal injury.
1. When using two towers or more, connect

signal cord on the right tower to the left
tower.
NOTE
- The a-tower does not have signal cord.
Signal Cord
2. Connect power cords of all towers on

terminal in the building.
Power Cord
Ground
White
Red
Green
Power Cord
84
5-5 Receiving Tray Installation

5-5-1 CCR/CCR-DX
1. Loosen lock knob and set the angle of the Delivery

delivery unit on the collator at low posi- Direction
tion.
Lock Knob
Handle
2. Hold handle and raise it and insert pins into
holes.
Pin Pin
Holes
3. Connect connecting cable to connector (U) Handle
of collator.
Connecting Plate Connector (U)

Connecting Cable
4. Adjust CCR/CCR-DX with adjustor so that
CCR/CCR-DX is stable.
Adjustor
5. Select CCR with finishing device button on

the Set 1 page. 1 2 3 4 5 6
CCR

85

5-5-2 ST-20/ST20R
1. Loosen lock knob and set the angle of the
delivery unit on the collator at up position.
(Only for ST-20) Delivery
Direction
Lock Knob
2. Attach stacker guide on the delivery sec-

tion.
NOTE
- Attach stacker guide so that it does not
touch rollers.
Roller
Stacker Guide
3. Lift connecting plate on stacker and insert

stacker pins into holes on the collator.
4. Connect connecting cable to connector on

collator.
Small Cable ... Upper Connector

Large Cable .... Middle Connector
Holes
Connecting Plate Pin
86
5. Turn on collator power. Off-set Guide 5 mm (0.2")
- Press tray UP button. Tray will rise and

stop at the top.
- Load sheets into only one bin, press sheet Sheet

calibration button, and press stop button
immediately so that the sheet stops before
it reaches the delivery section.
- Press inching button on remote controller

to transport the sheet to the position
where it overlaps with stacker tray by 10
mm (0.4").
- Loosen thumb nuts, slide stacker back and

forth, and position stacker at the position
where the gap between off-set guide and
sheet edge is 5 mm (0.2") as shown in the
drawing at right.
- Fasten thumb nuts.
- Adjust stacker with four adjustor so that

stacker is stable.
Adjustors
Thumb Nuts
6. Select standard ( ) with finishing device

button on the Set 1 page.
1 2 3 4 5 6

87
5-6 EAB-100 Extra Air Blower (Option) Installation

This section shows how to install extra air
blower (option).
NOTE
- Extra air blower increases feed rotor suc- Fix Screws
tion. Separation air does not change by
installing it.
WARNING
- Remove power cord before installing Top
extra air blower. Otherwise high volt-
age can cause sever personal injury. Fix Screws
Blower Box
2. Remove 2 fix screws inside blower box
Fix Screws
Fix Screw
3. Remove front cover. (3 fix screws)
Front Cover
Fix Screws
88

Right Side Cover
4. Remove 2 right side covers on collator. (4
fix screws)
NOTE
- The cover can be removed by removing
upper 2 fix screws and loosening lower 2 fix
screws.
Fix Screws
5. Remove rear cover. (2 fix screws)

NOTE
Fix Screws
- Rear cover can be removed by loosing 2 fix
screws, tilting the cover to rear side, and
lifting cover. Rear Cover
6. Place extra air blower behind tower.
7. Remove plate on the rear side of collator.

(2 fix screws)
NOTE
- After removing plate, attach fix screws into
tow holes not to put air inside air pipe.
Fix Screws
Plate
89
8. Attach hose joint. (4 fix screws)
Fix Screws
Hose Joint
9. Put power and signal cables of extra air

blower inside collator through holes from
the right side as shown in the drawing at
right.
Power Cord Signal Cord
10.Connect power cord of extra air blower to

the collator as shown in the drawing at
right.
Green
Red
White
90
11.Connect signal cord of extra air blower to

the connector on the rear side of collator as
shown in the drawing at right.
Signal Cord
Connector
12.Attach front cover, 2 right side covers, rear
cover and blower box on the reverse order
of removal.
NOTE
- When attaching 2 right side covers, lead
power and signal cords of extra air blower on
the right side under the covers.
Extra Air Blower

Hose
Hose Band
13.Insert extra air blower hose into hose joint
and fix the hose with hose band.
- Do not obstruct the air hole of the blower

box.
Hose
91
NOTE
- When not using extra air blower, remove
extra air blower hose from hose joint and put
plug into hose joint. Hose Joint
- When using extra air blower, turn "on" the

switch. When not using extra blower, turn
"off" the switch.
ON: The switch is pressed.

OFF: The switch is not pressed.
Plug
Switch
92
5-7 VAC-100a Right Side Unit (Option) Attachment

5-7-1 Accessories
Delivery Unit C (A204602-00) 1 pc Connector 16S (A924631-00) 1 pc
Connector 10S (A924632-00) 1 pc Delivery Belt (M072683-01) 1 pc
Idler Shafts (A924633-00) 3 pc Cord Clamper (3N) 1 pc
Delivery Drive Pulley (M072319-00) 1 pc Pin (PP4-20h7) 1 pc
93
Snap Ring (STW-15) 1 pc Fix Screws
SB3-8:1 pcs
SB5-10:3 pcs B4-8ZP:4 pcs
B3-10ZP:4 pcs
Washers Flanged Nuts (N3F) 4 pc
W3:1 pcs W5S:3 pcs

W5(Extra-Large):1 pcs
94

5-7-2 How to Attach
WARNING
- Turn off breakers in the building Bins
before removing power cord. Otherwise Lamps
high voltage can cause severe personal Speed Buttons
injury.
123
1. Raise the bins following the procedures

below.
(1) Turn on power switch while pressing

both speed buttons simultaneously.
- Service mode page appears on the screen.
Power Switch
NOTE
- Keep on pressing both speed buttons until 3
lamps light as shown in the drawing of con-
troller at right.
Pressing this button
raise all bins.
(2) Press the right speed button on remote
controller or the bins UP button on the Bins UP Button
screen to raise all bins. 123
VAC-100 ROM Ver.

Life counter
Bins Bins
DOWN UP
Motor
ON/OFF
Blower
ON/OFF
Delivery Direction
front / rear
2. Turn off power switch and remove power

cord.
Power Switch
95

3. Remove front cover (3 fix screws) and rear
cover (2 fix screws). Fix Screw
Front Cover
Fix Screws
NOTE
- Rear cover can be removed by loosing 2 fix
screws and moving the upper part of the
cover to near side before lifting cover. Fix Screws
Rear Cover
4. Remove upper guide plate in the transport

conveyor.
Upper Guide Plate
96

NOTE
- The upper guide plate can be removerd by Upper Guide Plate
lifting up the right part of plate and moving
to the right.
Covers Right Side Cover

5. Remove right side cover (2 fix screws) and Cover
covers (2 fix screws each).
Fix Screws
6. Remove lower guide plate.
Lower Guide Plate
NOTE
- The lower guide plate can be removerd by
lifting up the right part of plate and moving
to the right.
97

7. Attach delivery unit C (4 fix screws:B4- Delivery Unit C
8ZP).
8. Remove side covers of delivery unit C (2

fix screws each) before removing fix screw
on front side cover.
Side Covers Fix Screws

Lock Screws
NOTE
- When delivery unit C fix screw is removed,
nut plate is also removed.
Nut Plate
9. Attach a delivery drive pulley to shaft as

(1) Insert a pin into hole of shaft.
(2) Attach the delivery drive pulley to shaft.
(3) Fit snap ring in the groove of shaft.
Pin
Delivery Drive
Pulley
Snap Ring
98

10.Attach 3 idler shafts as shown in the draw-
ing at right.
Fix Screws : SB5-10, W5S and W5

(extra-large) for the lowest
idler shaft.
SB5-10 and W5S for the
other two shafts.
NOTE
- Do not fasten the lowest idler shafts yet.
Idler Shafts
Do not fasten this shaft yet.
11.Attach a delivery belt to the pulleys as
Delivery Belt
12.Fix the lowest idler shaft pushing the arrow

direction in the drawing at right so that
delivery belt has tension.
Idler Shaft
99

13.Attach side covers (2 fix screws each ) and
secure the lock screw with nut plate before
attaching fix screw on nut plate.
Lock Screw
Side Covers
14.Connect connectors 10S and 16S (2 fix

screws each:B3-10ZP and N3F), cables
and ground wire as shown in the drawing
at right.
Ground Wire
Connector 10S
Connector 16S
Cables
100

15.Connect sensor connector on rear side.
NOTE
- Fix the sensor cord with cord clamper (fix
screw : SB3-8 and W3) on the delivery roller.
Connector
Cord Clamper
16.Insert air hose into hole on the right side of

tower.
NOTE
- Delivery unit C blows air when delivery air
knob is turned downward.
Air Hose Delivery Air Knob

Normal (Left Side Unit)
Right Side Unit

101

17.When the sirial number of your machine is
below 007001, replace the P.C.B. (QPW-
492C) on the back side of panel cover (1
fix screw).
P.C.B.(QPW-492C)
18.Attach the lower guide plate to the original

position.
19.Attach the upper guide plate to the original

position. Lower Guide Plate
20.Attach front cover (3 fix screws) and rear

cover (2 fix screws) to their original posi-
tions.
NOTE
- When the collated sets are delivered to the
right, turn off the power of the post-process-
ing equipment for the left paper ejection.
NOTE
- When the stacker ST-20R is connected to
the single VAC-100a and the collated sets are
delivered to the left, the full tray indication
will appear. When the stacker ST-20 is con-
nected to the single VAC-100a and the col- Upper Guide Plate
lated sets are also delivered to the left, the full Front Cover
tray indication will appear. The full tray
indication can disappear by adjusting the Rear Cover
volume on the printed circuit board. Contact
with the dealer.
102
5-8 HMU-100 Hand Marry Unit (Option) Installation

5-8-1 Accessories
Delivery Drive Pulley (M072319-00) 1 pc Idler Shafts AS(A924633-00) 2 pc
Delivery Belt (M120026-00) 1 pc Sheet Guide (A924698-01) 1 pc
Support table (M120031-00) 1 pc Delivery Drive Pulley Locking Snap Ring (STW-15) 1 pc
Idler Shafts Fixing Screws 1 pc Pin (PP5-20) 1 pc
(W5S) 2pc (W5Large)(For

(SB5-12) 2pc under idler shaft
AS) 1pc
103

5-8-2 Hand Marry Unit (HMU-100) Installation
When a-tower and m-tower are connected,

the hand marry unit is installed on the right
side of m-tower. It can be installed to maxi-
mum two towers.
WARNING
- Turn off breakers in the building
before disconnecting and connecting
power cord. Otherwise high voltage can
cause severe personal injury.
1. Turn off power switch and disconnect

power cord.
Power Switch
2. Remove the front cover of VAC-100

installed with hand marry unit.
Front Cover
Fix Screws
Cover For a-tower Or m-tower
3. Remove the right side cover of VAC-100, Hole Cover
the cover for a-tower or m-tower and the Fix Screws Right Side Cover
hole cover.
104

SB5-12
W5S
4. Insert a pin into a shaft and delivery drive
pulley and fix with a snap ring.
Idler Shafts AS
5. Fix a idler shafts AS(2pc) with fixing
screws (SB5-12, W5S, W5) from the
opposit side of the cover. (W5Large)
NOTE
- Fix the only lower idler shaft with the Shaft
fixing screw (W5 Large). Pin
Delivery Drive Pulley
Snap Ring
6. Reattach the right side cover.
7. Attach the hand marry unit on the right

side of VAC-100 on the following proce-
dures.
1. Hang the hook of the hand marry unit on Stay

the stay of VAC-100.
2.Attach the hand marry unit to VAC-100 Hook

so that the positioning guide (arrow
shows) fits closely to the rear cover of
VAC-100.
(Hand Marry Unit)
Rear Cover
Hand Marry Unit

Positioning Guide
105
8. Remove the front cover of the hand marry Front Cover

unit. (3 fixing screws)
NOTE
- Loosen the two fixing screws under-
neath the cover.
Delivery Belt
9. Draw 100 mm line on the delivery belt

with pen.
Idler Shaft Delivery Belt

Pully
10.Install the delivery belt on the pully of
VAC-100 and hand marry unit and idler
shaft. Arrow direction must be same as an
arrow in the drawing at right.
Pully
Idler Shaft
(VAC Front Side) (Hand Marry Unit Front Side)
Upper Idler Shaft

Idler Shaft AS
11.Adjust the upper idler shaft position of
hand marry unit so that the 100 mm line
marked on the delivery belt streches 101.5
to 102 mm.
Pully
12.Attach the front cover of hand marry unit
and VAC-100. Idler Shaft AS
Pully
Idler Shaft AS
(VAC Front Side) (Hand Marry Unit Front Side)
106

5-8-3 Cable Connection
Panel Cover
When a-tower is connected with m-tower, the
connecting cable is connected with m-tower.
WARNING
- Make sure the main power is turned
off before connecting the cable. Control Panel
(QPW-492C)
1. Open the panel cover of VAC-100. P.C.B.(QPW-492C)
2. Connect the thick cable (input signal) from

hand marry unit to the CON 8 and CON 9
on control panel QPM-119C inside of
panel cover.
NOTE
- It is the easy way to unplug the CON
8 connector and insert the cable pin
into the connector and connect the
connector at the original position.
- Make sure the inserting direction of
pin. When inserting to the proper direc-
tion, feel click.
a or c
tower only QPW502A
QPW506A
CON8
1
2
3
4
CON8
5
6 CON10
(Right Side)
7
CON11
CON9 8 R
1 C 9 W CON12
QPM119C
2 D 10 CON14
3 B 11 Y
CON15
4 12 G
5 13 CON16
6 14
CON17
CON18
CON4
1 CON2
2
3 QPW492C
4 CON4
5
CON13
6 CON11
CON16
7 CON7 CON14
8 CON17
9 W CON12 CON15
10 D CON9 CON18 CON20
CON10 CON19 CON21

(How To Insert Pin Into Connector)
107
3. Connect the thin cable (output signal) from

hand marry unit to the CON 4 on control CON4
CON5
CON1
panel QPM-492C inside of panel cover. CON2
NOTE CON9
QPM157A
- It is the easy way to unplug the CON
4 connector and insert the cable pin Image ROM
into the connector and connect the
connector at the original position.
CON1 CON2 CON5
QPM120C
4. Check the version of ROM. When the CON3
version is low, exchange it to a new one.

CON4 CON7
(The ROM coordinated with HMU-100)

Control ROM VAC Image ROM (IMG)
(Both a-tower and m-tower)
V1.20 (QPM-119C)
Image ROM (a-tower only)

V1.20J/E (the new panel QPM-157A)
V1.20E (the old panel QPM-120C)
NOTE
- When removing the ROM, it is recom-
mended to use IC puller.
Control ROM
IC Puller
Grip QPM119C
5. Turn off the breaker in the building and

connect the power cord.
6. Turn on the breaker in the building.
108

M Vac100 (E15)

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COLLATOR VAC-100

- Horizon International Inc. pursues a policy of continuing improvement in design and

- Do not operate the machines when any covers are removed.

Safety Precautions .................................................................................................... II

1. Before You Begin ..................................................................... 1

1-1 Specifications ...................................................................................................... 2

1-1-1 VAC-100 Series Specifications ...................................................................... 2

1-2-1 Overview ........................................................................................................ 4

1-4 Consumables and Options ................................................................................ 25

2-1 Power ON ........................................................................................................... 28

2-2 Preparation for Operation ................................................................................ 29

2-3-1 Sheet Thickness Calibration ........................................................................... 45

2-5 Program Collation ............................................................................................. 49

2-5-1 Double Cycle ..................................................................................................49

2-7 Right Side Delivery ............................................................................................56

2-8 Hand Marry ....................................................................................................... 57

2-9 Warming Up ....................................................................................................... 59

3-1 Error Indication and Remedy ..........................................................................62

3-2 When Misfeeding Occurs ..................................................................................63

3-3 When Double Feeding Occurs ..........................................................................63

3-4 Sheets Are Fed on the Skew ..............................................................................64

3-5 Paper Jam in Transport Conveyor ..................................................................64

3-6 Sheet from Hand Marry Unit Is Jammed ....................................................... 65

3-8 Fuse and Breaker Check ................................................................................... 66

3-9 Pump Does Not Work ........................................................................................69

4-1 Daily Cleaning .................................................................................................... 72

4-1-1 Feed Ring ....................................................................................................... 72

4-2-1 Bin Sensor ...................................................................................................... 74

4-4 Feed Error Sensor Cleaning ............................................................................. 76

4-5 Replacing the Air Filter ..................................................................................... 77

5. Move and Installation

5-1 Collator Installation ........................................................................................... 80

5-2 Blower Box Installation ..................................................................................... 81

5-3 System Switch Set Up ........................................................................................ 83

5-4 Cable Connection ............................................................................................... 84

5-5 Receiving Tray Installation ............................................................................... 85

5-5-1 CCR/CCR-DX ................................................................................................ 85

5-7 VAC-100a Right Side Unit (Option) Attachment ........................................... 93

5-7-1 Accessories ..................................................................................................... 93

5-8-1 Accessories ..................................................................................................... 103

1. Before You Begin

1-1 Specifications ........................................................................................... 2

Model CCR CCR-DX ST-20 and ST-20R

1-2 Machine Descriptions

Operation Panel (a-Tower)

1-2 Machine Descriptions

Feed Height Adjust Lever Feed Height Sensor

Separation air Adjust

Front Plate Side Guide

Separate Nose Knob

1-2 Machine Descriptions

In case the required lected mode on HMU-100.

the right preset button, the unit is inserted under collated

1-2 Machine Descriptions

Feed Speed Indication

Belt Speed Indication

Suction Air Indication

Vacuum Timing Select Button