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Important safety instructions

H Observe the general and press-specific safety instructions in the operating manual. H At first start-up or after the exchange of equipment or components check the correct functioning of all safety equipment. H Control cabinet and machine housing have to be locked while the press is in operation. They may only be opened for repair purposes. H Make sure that the main power switch is turned off and that there is no voltage applied to the press before you open the control cabinet or the machine housing. H If it is necessary to repair the press while it is connected to the mains supply, please pay attention to general safety precautions. H Never exchange components and units while the press is connected to the mains supply. H Safety equipment must not be modified. Do not remove earth conductors. If it is necessary to disconnect these conductors, please remember to reconnect them after you are finished. H If extra accessories not corresponding to Heidelberg specifications are installed or mounted, Heidelberg does not accept any liability whatsoever. In each case these accessories must be controlled or locked in a way that no hazards can arise when the press and its devices are operated.

Attention:

Observe these handling instructions when you replace electronic boards with electrostatically sensitive devices (ESDs)!

Handling and replacing electronic boards


+80C

25C Storage: NEVER below 25C NEVER above +80C ALWAYS pack into the protective container for ESDs. NEVER replace when power is on. NEVER use force to insert.

Protective measures for ESDs to be observed when replacing electronic boards

DISCHARGE static charges.

UNPACK from the protective container for ESDs.

REPLACE electronic boards.

PACK into the protective container for ESDs.

2. Speedmaster CD102

Table of contents

2. Speedmaster CD 102
7 7 12 17 17 19 21 28 31 31 39 39 45 45 47 53 59 67 77 85 96 104 110 Main drive M1 Direct-current main motor M1 Brushless main motor Pile centering Block diagram 11B10 Pile centering 11M9 Pile centering 11B55 Inactivating pile centering Pile merging 11M8 Adjustment of pile support plate Suction head height control 11M5 Suction head height adjustment Size adjustment Block diagram 11M4 Adjustment of format wheels 11M6 Suction head/format adjustment 11M11/11M12 Pile stops D.S./O.S. 1M4 Cover guide height adjustment 1M2/1M3 Print-free margin D.S./O.S. 1...nM5 Adjustment of printing pressure 1M7/1M8 Adjustment of pull lays 12M5 Sheet slowdown/format adjustment 12M6/12M7 Sheet joggers D.S./O.S.

1 438

2. Speedmaster CD102

Table of contents

119 119 121 124 127 140 143 146 149 152 155 158 161 161 163 166 170 186 189 192 195 198 201 204 207 207 210 223 231 238 241 247 251

Feeder pile control Block diagrams Layout Overview of components Function 11M1 Main pile motor (Preset) 11M1 Main pile motor (standard) 11M2 Auxiliary pile motor 11B11 Auxiliary pile detection 11B33 Upper main pile limitation 11B35 Automatic pile transport 11S34 Bottom main pile limitation Delivery pile control Block diagrams Layout Overview of components Function 12M1 Main pile motor (Preset) 12M1 Main pile motor (standard) 12M2 Auxiliary pile motor 12B65 Changeover fast/slow 12B69 Pile height control 12B129 Delivery upper edge of pile 12S34 Bottom main pile limitation Sheet alignment Block diagram 1B13/ 1B49 Sheet alignment control 1B9/1B10 Pull lay control 1B11 Double-sheet detector 11M3 Automatic sheet arrival control 11M3 Automatic sheet arrival control (standard version) 11M3 Automatic sheet arrival control (Preset version) 11M7 Automatic misalignment control

2. Speedmaster CD102

Table of contents

259 259 267 267 271 275 275 276 278 281 286 292 296 297 301 303 305 305 308 311 314 317 318 321 321 322 323 325 328

Sheet monitoring 1...nB48/ 1...nB48a Sheet travel monitor Plate clamping device Autoplate 1...nB53 Coarse register monitoring Washup devices Control by command Washup Messages Service display Washup Blanket washup device (GTW) Inking roller washup device (FWW) Impression cylinder washup device (DZW) M43, M50 ... M56 Washup brush motors E9 Washup solution container B1, B54, B55 Sensors at the washup solution container 1...nB43 Monitoring the ink blade Inking unit Servo-drive ink fountain roller Servo-drive diagonal register 1...nM6 Servo-drive lateral register Servo-drive circumferential register Inking unit temperature control E39 Inking unit temperature control Dampening 1...nM1 Pan roller motors 1...nM45 Blower motor for dampening system 1...nB32 Sensor Dampening solution control E40 Central dampening solution supply / cooling and circulating unit E41 Dampening solution mixing unit

2. Speedmaster CD102

Table of contents

329 329 330 332 333 338 343 345 346 347 348

Central lubrication Basic concept Service display Fault messages Grease lubrication Oil lubrication M44 Oil pump 12M47 Motor for grease lubrication 1F33 Pressure monitoring oil lubrication 1 bar 1F34 Pressure monitoring oil lubrication 12 bars 12B47 Lubrication monitoring 1 and 12B77 Lubrication monitoring 2

351 351 353 355 357 357 369 369 371 373 377 379 380 381 382 383 386 388

Pneumatic system 15Y11 Admission of pressure, pneumatic system 15B14 Pressure sensor Pneumatic system E4 Pneumatic system compressor Suction and blast air 1M9 Blast air regulation at the feeder Other components E4a Varnish supply unit L-B32 Level in coating pan 12E2 Powder spray unit 12M35 Blower motor for powder spray device 12S68 Switch Powdering cycle 12S9, -a, -b, -c Monitoring the IR slide-in dryer E8 Air supply cabinet E39 Inking unit temperature control 12E3 Static electricity eliminator WSA Intercom IDS Encoder

2. Speedmaster CD102

Table of contents

393 393 408 409 411 413 415 417 423 429 431 435 437

Location diagrams ZSG Central control cabinet ZSP Central control console Position switches Solenoid valves Motors Sensors Control panels Operators controls ZSP Control panel of control console Abbreviations Equipment identification Position codes

2. Speedmaster CD102

Table of contents

Main drive

M1 Direct-current main motor

Main drive
M1 Direct-current main motor Layout
The dc main motor is a dc shunt motor. Its layout varies depending on the manufacturer, motor power and type of construction. The illustration below shows one example of the components of the main motor M1.

Representation of a dc main motor M1

1 2 3 4 5 6 7 8

Installation area of fan impeller Ventilation cover Terminal box for main motor M1 ( contains all connections for M1 ) Hoop for manual release of brake Terminal box of brake Brake Y1 Installation area of carbon brushes and commutator Motor support rails or motor baseplate

Main drive

M1 Direct-current main motor

Attention:

Make sure the motor is disconnected from the power supply before working on it! Make certain to leave a minimum gap of 6 mm in the terminal box between neighbouring conducting parts carrying different potentials! Shut the terminal box tight! Terminal box of SIEMENS main motor

1 2 3 4 5 6 7 8 9
Terminal box of a SIEMENS main motor

Entries for motor connecting cables Connection PE conductor Connection armature circuit + / A1 Connection armature circuit / A2 Connection field circuit + / F1 Connection field circuit / F2 Connector X1 / connection to optocoupler module 15U5 (monitoring of carbon brushes) and brake control module BAM ( BAM-X1) Connector X2 / connection to interference suppressor module ESM ( motor coding ) Connecting cable to brake Y1

Terminal box of BAUMLLER main motor

1 2 3 4 5 6 7 8
Terminal box of a BAUMLLER main motor

Connection PE conductor Connector X1 / connection to optocoupler module 15U5 (monitoring of carbon brushes) and brake control module BAM ( BAM-X1) Connector X2 / connection to interference suppressor module ESM ( motor coding ) Connection field circuit / F2 Connection field circuit + / F1 Connection armature circuit + / A1 Connection armature circuit / A2 Entries for motor connecting cables

Main drive

M1 Direct-current main motor

Removal and installation of brake 1 2 3 4 1 2 3 4


Brake at main motor
Connecting cable of brake Terminal box of brake Fixing bolts of brake Brake of main motor M1

Removal of defective brake Turn off the main switch on the central control cabinet ZSG and make sure no-one can turn the power back on. Disconnect the connecting cable terminal box 2 of the brake. Loosen the fixing bolts

1 from the

3 of the brake.

Pull the brake off the main motor shaft.

1 2 3 4 5 1 2 3

Connecting cable of brake Terminal box of brake Fixing bolts of brake Brake of main motor M1 Square driver of motor shaft

Installation of the new brake Place the new brake on the square driver the motor shaft. Tighten the fixing bolts

5 of

3 uniformly. Connect the connecting cable 1 of the brake to the terminal box 2.

Main motor with brake removed

Main drive

M1 Direct-current main motor

Removal/installation of carbon brushes 1 2 3 4 5


Ventilation covers of main motor Terminals of carbon brushes Carbon brushes Clamp-type carbon brush holder Brush-rocker ring

Removal of carbon brushes

Note: Always replace all carbon brushes of the main motor.


All carbon brushes should be from the same set of spare parts to guarantee that they are all from the same material.

Ventilation covers of main motor

1 2 3

Turn off the main switch on the central control cabinet ZSG and make sure no-one can turn the power back on. Remove all ventilation covers installation side of the brake.

1 on the

Disconnect the wires of the carbon brushes from the terminals 2.

Note: With certain motors it is necessary to turn the brush-rocker ring 5 for brush removal. Before turning the brush-rocker ring 5, mark its position in relation to the stator ( e.g. colour line ) if no markings exist so far.

Loosen the retaining screws 6 ( but do not turn them out completely ) and turn the brush-rocker ring 5 ( see illustration on next page). Flip up the clamp-type brush holder 4 and take out all used carbon brushes 3.

5
Layout of brush-rocker ring (example)

10

Main drive

M1 Direct-current main motor

2 3 4 5 6

Carbon brush connections Carbon brushes Clamp-type carbon brush holder Brush-rocker ring Fixing bolts for brush-rocker ring

Installation of new carbon brushes When replacing a set of carbon brushes, clean all the cooling-air paths, e.g. with dry, oil-free compressed air. Any deposits of carbon dust on the insulating parts of the commutator and the brush-rocker ring must be removed completely, e.g. by cleaning these parts with a non-linting cloth.

1
Fastening the brush-rocker ring (example)

Insert the new carbon brushes 3 and connect them to the terminals. Close the clamp-type brush holder 4.

Note: The carbon brushes must rest correctly on the commutator and run smoothly in the brush boxes.

If the brush-rocker ring 5 was turned before, it must be brought back in its initial position and locked after replacement of the carbon brushes. Pay attention to the markings! Screw down the covers

1 again.

Note: The ventilation slots in the ventilation covers must point downward to maintain the type of protection.

11

Main drive

M1 Brushless main motor

M1 Brushless main motor Construction with terminal board (from 37kW)

Main motor M1 with terminal box

1 2 3 4 5 6

Motor shaft Terminal box of main motor Terminal box of brake Rotor position encoder Plug of rotor position encoder Lever for manual release of the brake

12

Main drive

M1 Brushless main motor

Rotor position encoder


The rotor position encoder consists of three components: sensor, rotating part, adjusting ring.

Attention:

Do not loosen the safety screws of the adjusting ring of the rotor position encoder! Displacement of the adjusting ring results in displacement of the rotor position encoder in relation to the actual position of the rotor of the main motor. If the adjusting ring is not in its normal position or defective, the main motor must be replaced!

Layout


Front view of rotor position encoder

1 2 3 4

Pin base X2 / connection to BLT4 Safety screws of adjusting ring Sensor Adjusting ring

X2
1

Pin assignment 2 3 7 6 4 5 6 7 X2 Plug connection to ZSG (BLT4) Function DC +15 V 15 V

Pin

Pin base X2, 7-pole

13

Main drive

M1 Brushless main motor


Rotor position encoder of main motor M1

1 2 3 4 5 6 7 1 2 3 4

Motor casing / brake Adjusting ring End-float washers (not always provided) Motor shaft Rotating part Connector M1-X2 Sensor part

Removal Turn off the main switch and make sure no-one can turn the power back on. Remove connector X2. Remove the sensor (four fixing bolts). Replace the sensor or rotating part.

Note: Put the end-float washers back in place between the rotating part and motor.
Installation

Reinstall all parts and connect the rotor position encoder.

14

Main drive

M1 Brushless main motor

Connection
Main motors with < 37 kW are connected by means of prefabricated plugs. For EMC reasons, main motors with 37 KW or more are connected via a terminal board.

1 2 3 4 5 6

PE conductor connection Motor winding W (threaded bolt M12) Motor winding V (threaded bolt M10) Motor winding U (threaded bolt M8) PE conductor connection Plug for motor code, brake and temperature sensor

Terminal box of main motor BAUMLLER 37KW Please note: The terminal studs of the motor terminal board and the eye rings of the connecting cables have different diameters. Thus the cables cannot be mixed up.
Terminal N is used for measuring purposes only.

Pin assignment
X1 1 5 2 6 1 2 3 2 6 1 5 4 5 Plug connection in motor terminal box Function Motor code 0 Motor code 1 Motor code Temperature sensor Brake + Brake Pin

Pin and socket bases, 6-pole

15

Main drive

M1 Brushless main drive

16

Pile centering

Block diagram

Pile centering
Block diagram
The pile centering function comprises:
Pile centering 11B10 Inactivating pile centering 11B55

the sensor Pile centering 11B10, the sensor Inactivating pile centering 11B55, the servo-drive Pile centering 11M9.

Pile centering 11M9

SSM1

SSM1

The pile centering function compensates for the lateral displacement of the paper pile at the feeder. The sensor Pile centering 11B10 senses the lateral edge of the pile. The required distance between the sensor and the lateral pile edge is 130 " 2 mm. If the difference between the required and actual distance exceeds the tolerance limits, the electronic control system corrects the position of the paper pile through the servo-drive Pile centering 11M9. If the pile support plate reaches the sensor Inactivating pile centering 11B35 during its upward movement, the electronic control system stops the automatic control. Automatic control is resumed as soon as the pile support plate is below the sensor 11B35 and the sensors 11B10 and 11B35 detect paper or the pile support plate lies on the floor (position switch 11S34 actuated).

SSK

EAK 1

SAK

ESK

REK1

REK386

DSK

DNK

SVM

ZID Displays

MID11

MID12

Legend:

Data line Control lines

Block diagram for pile centering


17

Pile centering

Block diagram

Activating and inactivating pile centering

Selecting the display

Symbol Pile centering on / off

Activating and inactivating pile centering: in the preselection display, by means of the function button.

If the symbol is lit, pile centering is active.

Preselection/coarse display, pile centering

18

Pile centering

11B10 Pile centering

11B10 Pile centering


The sensor 11B10: senses the lateral pile edge (actual distance), with the required distance = 130 2 mm.

11B10

Where? approx. 25 mm below the upper edge of the pile.

Automatic control through the electronic control system: 130 2 mm if the difference between the required distance and actual distance exceeds the tolerance limits, by activating the servo-drive Pile centering 11M9.

Required distance for pile centering

No automatic control: within the tolerance limits of the required distance.

Output signal of sensor 11B10: analog voltage, digitization on the SSK1.

Signal flow: Sensor 11B10 Servo-drive distributor module (11LVT: 2SSM1) backplane SSR: X14 servo-drive control board SSK1.

19

Pile centering

11B10 Pile centering

Place of installation

11B10

PU1 and Preset feeder

Removal and installation

black

11LVT1
2SSM1 X5: D4 X2: +8 X2: 8

blue brown

Check


130  2 mm

1646 70

20

Pile centering

11M9 Pile centering

11M9 Pile centering Automatic positioning


Condition: Automatic pile centering is switched on in the preselection display.
The servo-drive 11M9 positions the pile support frame at the feeder. The sensor 11B10 senses the lateral edge of the pile. If the difference between the required distance and the actual distance exceeds the tolerance limits, the servo-drive control board SSK regulates the servo-drive 11M9. If the pile support plate reaches the sensor 11B35 while moving up, the electronic control system stops the automatic control.

Manual positioning for feeder without NON-STOP facility:


Condition: Automatic pile centering is switched off in the preselection display.
Pushbuttons Main pile centering Plus button Minus button The pushbuttons "Main pile centering" control the servo-drive 11M9. Maximum positioning range: +/ 30 mm in relation to the centre of the feeder. Plus button Minus button = movement towards D.S. = movement towards O.S.

21

Pile centering

11M9 Pile centering

NON-STOP feeder
The positioning of the pile support plate by means of pushbuttons depends on the position of the toggle switch Auxiliary pile on/off.

Toggle switch Auxiliary pile on / off

Toggle switch in position "Off": ON OFF Main pile control activated. The pushbuttons Main pile centering control the servodrive. Maximum positioning range: 35mm in relation to the centre of the feeder. movement towards D.S. movement towards O.S.

Pushbuttons Main pile centering Plus button Minus button

Plus button = Minus button =

The pile support frame and pile support plate can move max. 35 mm in the same direction together. Toggle switch in position ON: Toggle switch Auxiliary pile on / off Pushbuttons Auxiliary pile centering Plus button Minus button ON OFF Auxiliary pile control activated. The pushbuttons Auxiliary pile centering control the pile support frame. Maximum positioning range: 35mm in relation to the centre of the feeder.

The pile support frame and pile support plate can move max. 35 mm in the same direction together.

Indication of position in MID


During manual positioning, the electronic control system indicates the present position of the pile support frame in the press display MID. The displayed value represents the absolute position in relation to the centre of the feeder.

11

2 0

Indication of position of pile support frame

1 2

Present position Position code

22

Pile centering

11M9 Pile centering

Place of installation

11M9

Operator side

Technical data
Motor data U P = = DC 24 V 5 W

Potentiometer data U R = = DC 10 V 10 KW

23

Pile centering

11M9 Pile centering

Interconnection diagram
X10 X5

SSR

SSR X10
X11 X12 X3 X13 X14 X4

SSR X14

11 11LVT1 2SSM1: X2
X3 X4 X1 X2 X5

Backplane of servodrive plug-in unit SSR

2SSM1: X4

2SSM1

Servo-drive distributor module 2SSM1

11M9: X1

3 2

4 5 1

11M9

Servo-drive 11M9
11M9:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 2SSM 1 X5: C1 X5: C2 X5: C3 X5: C4 X5: C5 SSR X10: X10: X14: X14:

+ 10V 0V

X2: X2: X4: X4:

1 2 3 4

B14 D14 3 4

X4: 5

X14: 5

24

Pile centering

11M9 Pile centering

Removal and installation

1
1

ON OFF

2
2

06

2048 2

Set the toggle switch Auxiliary pile ON/OFF to OFF. Select the service display SSK1. Bring the pile support plate into its central position (set to 20482 inc).

Remove the servo-drive Pile centering 11M9.

Set the distance between the side frame and the pile support frame to 83 mm. 25

Pile centering

11M9 Pile centering

4
4)

07

2048 2 1M9: X1

Fit the motor baseplate and gear wheel. Connect plug 11M9: X1. Set to 20482 inc.

Install the servo-drive.

26

Pile centering

11M9 Pile centering

Checking the operating range 1


Servo-drive Pile centering 11M9

Condition: The pile support plate is in its central position (2048 inc).
Input 35 mm + 35 mm Incremental value 3686 " 23 inc 409 " 23 inc

Service display Values, incremental values servodrives

27

Pile centering

11B55 Inactivating pile centering

11B55 Inactivating pile centering


If the pile support plate reaches the sensor 11B55 during 11B55 Production run or Paper run,

the electronic control system switches the pile centering function off. The remaining sheets on the pile are still printed. For the pile change, the operator lowers the pile support plate and places paper on it. If the sensors Automatic pile transport 11B35 and Inactivating pile centering 11B55

detect the paper, the preselected pile centering function is active again.

Sensor 11B55

28

Pile centering

11B55 Inactivating pile centering

Place of installation

11B55

Adjustment

black
FAM64 XE: 55 +1 1

brown blue

11LVT1

Check

0010

29

Pile centering

11B55 Inactivating pile centering

30

Pile merging

11M8 Adjustment of pile support plate

Pile merging
11M8 Adjustment of pile support plate
The servo-drive 11M8 is only installed at the NONSTOP feeder of Preset presses. The servo-drive 11M8 positions the pile support plate at the feeder. The positioning of the pile support plate depends on the position of the toggle switch Auxiliary pile on/off.

Toggle switch Auxiliary pile on / off

Toggle switch in position Off ON OFF Main pile control activated. The pushbuttons Auxiliary pile centering control the servodrive 11M8. Maximum positioning range: 30 mm in relation to the centre of the feeder. Plus button Minus button = movement towards D.S. = movement towards O.S.

Pushbuttons Auxiliary pile centering Plus button Minus button

The pile support frame and pile support plate can move max. 35 mm in the same direction together. When the pile support plate reaches the position switch 11S39 Pile support plate limitation while moving down, the electronic control system positions the pile support plate (through 11M8) the pile support frame (through 11M9)

Pushbutton Main pile down

relative to the centre of the feeder. During positioning, the function Main pile down is blocked. Approx. 30 seconds after the beginning of positioning, the electronic control system releases the function Main pile down again.

31

Pile merging

11M8 Adjustment of pile support plate

Toggle switch Auxiliary pile on / off

Toggle switch in position ON ON OFF Auxiliary pile control activated. The pushbuttons Auxiliary pile centering control the servodrive 11M8. Maximum positioning range: 30 mm in relation to the centre of the feeder. Plus button Minus button = movement towards D.S. = movement towards O.S.

Pushbuttons Main pile centering Plus button Minus button

The pile support frame and pile support plate can move max. 35 mm in the same direction together. During the downward movement, the servo-drive 11M8 positions

Pushbutton Main pile down

the pile support plate

relative to the centre of the feeder. As soon as the pile support plate lies on the ground (position switch 11S34 actuated), this function is stopped. The pile support plate cannot be positioned anymore. NON-STOP mode: When pile centering is active, the electronic control system regulates the pile support frame. To ensure that the pile support plate keeps its position on the floor, it is displaced by the same value as the pile support frame, however in the opposite direction.

32

Pile merging

11M8 Adjustment of pile support plate

Place of installation

11M8

Operator side

Technical data
Motor data U P = = DC 24 V 5 W

Potentiometer data U R = = DC 10 V 10 KW

33

Pile merging

11M8 Adjustment of pile support plate

Interconnection diagram
X10 X5

SSR

SSR X10
X11 X12 X3 X13 X14 X4

SSR X13

11 11LVT1 2SSM1: X1
X3 X4

Backplane of servodrive plug-in unit SSR

X2 X1 X5

2SSM1: X3

2SSM1

Servo-drive distributor module 2SSM1

11M8: X1

3 2

4 5 1

11M8

Servo-drive 11M8
11M8:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 2SSM 1 X5: B1 X5: B2 X5: B3 X5: B4 X5: B5 SSR X10: X10: X13: X13:

+ 10V 0V

X1: X1: X3: X3:

3 4 8 7

B12 D12 8 7

X3: 6

X13: 6

34

Pile merging

11M8 Adjustment of pile support plate

Removal and installation

1
1

ON OFF

2
2

07

2048 2

Set the toggle switch Auxiliary pile ON/OFF to OFF. Select the service display SSK1. Bring the pile support frame into its central position (set to 20482 inc).

Remove the servo-drive Adjustment of pile support plate 11M8.

Frame .

Guide Set the distance between the pile support plate guide and the pile support frame to 31.5 mm. 35

Pile merging

11M8 Adjustment of pile support plate

4
4)

06

2048 2 1M8: X1

Mount the servo-drive on the motor baseplate. Fit the gear wheel. Connect plug 11M8: X1. Set to 2048 inc.

Tighten the chain.

36

Pile merging

11M8 Adjustment of pile support plate

Checking the operating range 1


Servo-drive Adjustment of pile support plate 11M8

Condition: The pile support frame is positioned in the centre of the feeder.
Off-centre position: 00 Input 30 mm Incremental value 3461 " 23 inc 634 " 23 inc

Service display Values, incremental values servo-drives

+ 30 mm

37

Pile merging

11M8 Adjustment of pile support plate

38

Suction head height control

11M5 Suction head height adjustment

Suction head height control


11M5 Suction head height adjustment
The servo-drive 11M5 positions the suction head vertically. The servo-drive can be controlled with the pushbuttons Suction head height. Pushbuttons Suction head height Plus button Minus button Actuation of one of the pushbuttons: suction head positions vertically, positioning range +/ 20 mm, indication of position in feeder MID. = suction head moves up (+ 20 mm). = suction head moves down ( 20 mm).

Plus button Minus button

39

Suction head height control

11M5 Suction head height adjustment

Place of installation

11M5

Preset feeder

Technical data
Motor data U P = = DC 24 V 5 W

Potentiometer data U R = = DC 10 V 10 KW

40

Suction head height control

11M5 Suction head height adjustment

Interconnection diagram
X10 X5

SSR

SSR X10
X11 X12 X3 X13 X14 X4

SSR X12

11 11LVT1 1SSM1: X1
X3 X4

Backplane of servodrive plug-in unit SSR

X2 X1 X5

1SSM1: X4

1SSM1

Servo-drive distributor module 1SSM1

11M5: X1

3 2

4 5 1

11M5

Servo-drive 11M5
11M5:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 1SSM 1 X5: C1 X5: C2 X5: C3 X5: C4 X5: C5 SSR X10: X10: X12: X12:

+ 10V 0V

X2: X2: X4: X4:

1 2 3 4

B6 D6 3 4

X4: 5

X12: 5

41

Suction head height control

11M5 Suction head height adjustment

Removal and installation

20 mm

Remove the servo-drive Suction head height adjustment 11M5.

Set the distance (20 mm) at the suction head guide rail.

3
4)

03

2456 2

11M5: X1

42

Connect plug 11M5: X1. Set to 2456 2 inc.

Suction head height control

11M5 Suction head height adjustment

Install the servo-drive.

Checking the operating range 1


Servo-drive Suction head height adjustment 11M5 Input 20 + 20 Incremental value 880 " 4 inc 3215 " 4 inc

Service display Values, incremental values servodrives

43

Suction head height control

11M5 Suction head height adjustment

44

Size adjustment

Block diagram

Size adjustment
Block diagram
Adjustment of format wheels 11M4 M Suction head/ format adjustment 11M6 M Pile stop D.S. 11M11 SSM M Pile stop O.S. 11M12 SSM M Sheet jogger D.S. 12M6 SSM M Sheet jogger O.S. 12M7 SSM M SSM M SSM M Cover guide height adjustment 1M4 SSM M Adjustment of printing pressure 1...nM5 Sheet slowdown/ format adjustment 12M5 M Adjustment of pull lay D.S. 1M7 SSM SSM M Adjustment of pull lay O.S. 1M8

SSM

SSM

SSK1/2/3

Displays

SAK

ESK

SVM

MID11

MID12

REK1

REK386

DSK

DNK

ZID

Legend:

Data line

Control lines

Block diagram size adjustment


45

Size adjustment

Block diagram

Command: PRESETTING Attention:


To avoid damage to the press, make sure nothing is in the way of the following servo-drives when the command Presetting is active: suction head, pile stops D.S. and O.S., format wheels, pull lays D.S. and O.S., sheet slowdown, sheet joggers D.S. and O.S.

Selecting the command


As a result of the inputs in this command mode, various servo-drives on the press are positioned automatically.
1020

After command enabling the electronic control system positions the following servo-drives: On the feeder

720 1.00

Suction head/format adjustment Pile stops D.S. and O.S. Adjustment of format wheels

Command in control console display ZID

On printing unit / coating unit Adjustment of pull lays D.S. and O.S. Cover guide height adjustment Adjustment of printing pressure

On the delivery Sheet slowdown/format adjustment Sheet joggers D.S. and O.S.

46

Size adjustment

11M4 Adjustment of format wheels

11M4 Adjustment of format wheels


The servo-drive 11M4 positions the format wheels on the feeder. Automatic positioning Automatic positioning: is effected through the command Presetting; depends on inputs into CPTRONIC, such as: paper length, paper thickness, front lay adjustment (smallest value); depends on inputs into CPC1-04, such as: coating unit register. Positioning accuracy: 0.25 mm. End of automatic positioning: Pushbuttons Format wheels Plus button Minus button when the new desired position has been reached, when one of the pushbuttons Format wheels is actuated.

Manual positioning Actuation of one of the pushbuttons Format wheels: the format wheels are repositioned irrespective of the preset format, indication of the position in the feeder MID, when the command Presetting is active, automatic positioning is stopped immediately. = movement towards maximum format.

Plus button

Minus button = movement towards minimum format.

Fault message in the ZID


Adjustment of format wheels The symbol appears in the display Feeder/Warning. The symbol appears: during positioning while the press is on Run.

The symbol goes off: when positioning is over and the press is on Run, when one of the pushbuttons Format wheels is actuated and the press is on Run.

47

Size adjustment

11M4 Adjustment of format wheels

Place of installation

11M4

Operator side

Technical data
Motor data U P = = DC 24 V 5 W

Potentiometer data U R = = DC 10 V 10 KW

48

Size adjustment

11M4 Adjustment of format wheels

Interconnection diagram
X10 X5

SSR

SSR X10

X11

X12 X3 X4

SSR X11
X13 X14

11 11LVT1 1SSM1: X1
X3 X4

Backplane of servodrive plug-in unit SSR

X2 X1 X5

1SSM1: X3

1SSM1

Servo-drive distributor module 1SSM1

11M4: X1

3 2

4 5 1

11M4

Servo-drive 11M4
11M4:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 1SSM 1 X5: B1 X5: B2 X5: B3 X5: B4 X5: B5 SSR X10: B4 X10: D4 X11: 8 X11: 7 X11: 6

+ 10V 0V

X1: X1: X3: X3:

3 4 8 7

X3: 6

49

Size adjustment

11M4 Adjustment of format wheels

Removal and installation

9.00 9.00

1020

720 1.00

Set the print-free margin to 9 mm.

Enter the paper thickness Enter the paper width Enter the paper length Enable the command Paper

(1.0 mm). (1020 mm). (720 mm). size adjustment.

Remove the servo-drive Adjustment of format wheels 11M4.

Bring the format wheels into their central position.

50

Size adjustment

11M4 Adjustment of format wheels

. Format wheels

. Sheet of paper

Set the distance ( 722.5 mm ) between the front lays and format wheels.

02

3871 2

11M4: X1

Attach the gear wheel to the motor shaft. Connect plug 11M4: X1. Set to 3871 " 2 inc.

51

Size adjustment

11M4 Adjustment of format wheels

Install the servo-drive.

Checking the operating range 1


Servo-drive Adjustment of format wheels 11M4

SM102: Print-free margin: 10.00 mm Paper length: Paper thickness: 720 mm 1.50 mm 8.00 mm 280 mm 1.50 mm 288 2 inc

Incremental value: 3876 2 inc CD102:

Service display Values, incremental values servo-drives

Print-free margin: 10.00 mm Paper length: Paper thickness: 720 mm 2.00 mm

8.00 mm 280 mm 2.00 mm 288 2 inc

Incremental value: 3886 2 inc

52

Size adjustment

11M6 Suction head/format adjustment

11M6 Suction head/format adjustment


The servo-drive 11M6 positions the suction head to the entered paper length. Automatic positioning Automatic positioning: is effected through the command Presetting; depends on the entered sheet length.

Positioning accuracy: 0.30 mm. Automatic positioning range: max. 720 mm, min. 500 mm because of danger of collision with the lateral pile stops, in the case of sheet lengths below 500 mm, the suction head stops at the lower limit (500 mm), manual positioning if the sheets are shorter (less than 500 mm).

End of automatic positioning: when the new desired position has been reached, when the lower limit (500 mm) of the positioning range has been reached, when one of the pushbuttons Suction head format is actuated.

Manual positioning Pushbuttons Suction head format Plus button Minus button Actuation of one of the pushbuttons Suction head format: the servo-drive Suction head/ format adjustment 11M6 is controlled, the suction head positions irrespective of the preset format, indication of the position in the feeder MID, automatic positioning is stopped immediately. = to max. 730 mm.

Plus button

Minus button = to min. 280 mm.

53

Size adjustment

11M6 Suction head/format adjustment

Fault message in the ZID


Suction head/format adjustment The symbol appears in the display Feeder/Warning. The symbol appears: during positioning while the press is on Run, when the lower limit is reached during automatic positioning.

The symbol goes off: when positioning is over and the press is on Run, when one of the pushbuttons Suction head format is actuated and the press is on Run.

54

Size adjustment

11M6 Suction head/format adjustment

Place of installation

11M6

Preset feeder

Technical data
Motor data U P = = DC 24 V 5 W

Potentiometer data U R = = DC 10 V 10 KW

55

Size adjustment

11M6 Suction head/format adjustment

Interconnection diagram
X10 X5

SSR

SSR X10

X11

X12 X3 X4

SSR X12
X13 X14

11 11LVT1 1SSM1: X2
X3 X4

Backplane of servodrive plug-in unit SSR

X2 X1 X5

1SSM1: X4

1SSM1

Servo-drive distributor module 1SSM1

11M6: X1

3 2

4 5 1

11M6

Servo-drive 11M6
11M6X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 1SSM 1 X5: D1 X5: D2 X5: D3 X5: D4 X5: D5 SSR X10: X10: X12: X12:

+ 10V 0V

X2: X2: X4: X4:

3 4 8 7

B8 D8 8 7

X4: 6

X12: 6

56

Size adjustment

11M6 Suction head/format adjustment

Removal and installation

Front sheet stop

Governor foot Marking

3 2
Remove the servo-drive Suction head/format adjustment 11M6. Set the distance between the front sheet stop and the marking on the governor foot to 720 mm.

Note: To compensate for the backlash, the 720 mm must be set from the max. possible distance.

2
4)

11M6: X1
04

462 2

11M6: X1 Connect plug 11M6: X1. Set to 462 2 inc. 57

Size adjustment

11M6 Suction head/format adjustment

Install the servo-drive.

Checking the operating range 1


Servo-drive Suction head/format adjustment 11M6 Incremental value 3634 " 2 inc 389 " 2 inc

Paper length 280 mm 730 mm

Service display Values, incremental values servo-drives

58

Size adjustment

11M11/11M12 Pile stops D.S./O.S.

11M11/11M12 Pile stops D.S./O.S.


The servo-drive 11M11 positions the pile stop on the D.S. The servo-drive 11M12 positions the pile stop on the O.S. Automatic positioning Automatic positioning: is effected through the command Presetting, depends on the inputs into CPTRONIC, such as: sheet width, off-centre position, preselected pull direction. Positioning accuracy: 0.3 mm. End of automatic positioning: when the new desired position has been reached, when one of the pushbuttons Pile stops larger format or Pile stops smaller format is actuated.

Manual positioning Pushbutton Pile stops larger format Actuation of pushbutton Pile stops larger format: Control of servo-drives Pile stop D.S. 11M11 and Pile stop O.S. 11M12, irrespective of the preset format, the pile stops position to a larger format.

Actuation of pushbutton Pile stops smaller format: Pushbutton Pile stops smaller format Control of servo-drives Pile stop D.S. 11M11 and Pile stop O.S. 11M12, irrespective of the preset format, the pile stops position to a smaller format.

Actuation of one of the pushbuttons: indication of the position in the feeder MID, the off-centre position can be up to 50 mm, automatic positioning is stopped immediately. = to max. 1040 mm.

Plus button

Minus button = to min. 420 mm.

59

Size adjustment

11M11/11M12 Pile stops D.S./O.S.

Fault message in the ZID


Pile stop D.S. The symbols appear in the display Feeder/Warning. The symbols appear: Pile stop O.S. during positioning while the press is on Run.

The symbols go off: when positioning is over and the press is on Run, when one of the pushbuttons Pile stop D.S. or Pile stop O.S. is actuated and the press is on Run.

Prepiling
This function can only be activated in the preselection display. To inactivate it, press the corresponding button once more.

Selecting the display

The lateral pile stops move together when the pile support plate moving down is stopped by means of the button Pile stop and the pile support plate is in front of the position switch Pile support plate limitation 11S39.

The distance between the stops is: sheet width entered + 5 mm O.S., + 5 mm D.S. The 5 mm O.S. + 5 mm D.S. are added to the entered value by the electronic control system. Preselection/coarse display, prepiling The lateral pile stops move apart when the pile is raised.

The distance between the stops is: sheet width entered + 25 mm O.S., + 25 mm D.S. The 25 mm O.S. + 25 mm D.S. are added to the entered value by the electronic control system.

Symbol Prepiling

60

Size adjustment

11M11/11M12 Pile stops D.S./O.S.

Place of installation

11M12 11M11

Operator side

Technical data
Motor data U P = = DC 24 V 5 W

Potentiometer data U R = = DC 10 V 10 KW

61

Size adjustment

11M11/11M12 Pile stops D.S./O.S.

Interconnection diagram 11M11


X10 X5

SSR

SSR X10
X15 X16 X3 X17 X18 X4

SSR X15

11 3SSM2: X1 11LVT1

Backplane of servo-drive plug-in unit SSR

3SSM1: X2
X2 X1

X3

3SSM2

Servo-drive distributor module 3SSM2

11M11: X1

3 2

4 5 1

11M11

Servo-drive 11M11
11M11:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 3SSM 2 X5: A1 X5: A2 X5: A3 X5: A4 X5: A5 SSR X10: X10: X15: X15:

+ 10V 0V

X1: X1: X3: X3:

1 2 3 4

B18 D18 3 4

X3: 5

X15: 5

62

Size adjustment

11M11/11M12 Pile stops D.S./O.S.

Interconnection diagram 11M12


X10 X5

SSR

SSR X10
X15 X16

SSR X15
X17 X18

X3

X4

11 3SSM2: X1 11LVT1

Backplane of servodrive plug-in unit SSR

3SSM2: X2
X2 X1

X3

3SSM2

Servo-drive distributor module 3SSM2


11M12: X1

3 2

4 5 1

11M12

Servo-drive 11M12
11M12:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 3SSM 2 X5: B1 X5: B2 X5: B3 X5: B4 X5: B5 SSR X10: X10: X15: X15:

+ 10V 0V

X1: X1: X2: X2:

3 4 8 7

B20 D20 8 7

X2: 6

X15: 6

63

Size adjustment

11M11/11M12 Pile stops D.S./O.S.

Removal and installation

11M11


Remove the servo-drive Pile stop D.S. 11M11 or Pile stop O.S. 11M12.

11M12

D.S.

O.S. O.S. D.S.

D.S./O.S. = 180 mm Set the distance between the side frame D.S. (or side frame O.S.) and the pile stop D.S. (or pile stop O.S.) to 180 mm.

64

Size adjustment

11M11/11M12 Pile stops D.S./O.S.

09

3015 2

10

1072 2 11M11: X1 11M12: X1

Fit the motor baseplate and gear wheel. Connect plug 11M11: X1 (or 11M12: X1). 11M11 (D.S.) = set to 30152 inc. 11M12 (O.S.) = set to 10722 inc.

1020

720 1,00

Install the servo-drive.

Select the command Presetting. Press the button Input. The servo-drives position to the displayed format.

65

Size adjustment

11M11/11M12 Pile stops D.S./O.S.

Checking the operating range 1 2


Servo-drive Pile stop D.S. 11M11 Servo-drive Pile stop O.S. 11M12

Position the pile stops manually to the maximum format (press the button Pile stops larger format). Incremental value for 11M11: 3231 2 inc Incremental value for 11M12: 856 2 inc Position the pile stops manually to the minimum format (press the button Pile stops smaller format).

Service display Values, incremental values servo-drives

Incremental value for 11M11: 783 2 inc Incremental value for 11M12: 3304 2 inc

66

Size adjustment

1M4 Cover guide height adjustment

1M4 Cover guide height adjustment


For cover guide height adjustment a servo-drive is installed on the operator side of the 1st printing unit. With this servo-drive the cover guides (gripper opening) on the transfer gripper are adjusted. By means of a mechanical device (eccentric bush) gripper opening can be adjusted within a range from 0.1 mm to 1.9 mm.

Positioning
The new desired position is always approached from the direction of the widest gripper opening (1.9 mm). Actual position Reversal point Example 1: The new desired position is larger than the actual position. When the new desired position has been entered, the servo-drive first positions to the reversal point 1 and then to the new desired position 2. Example 2: New desired position Actual position The new desired position is smaller than the actual position. When the new desired position has been entered, the servo-drive moves to the new desired position.

New desired position 1.9mm

Example 1

1.9mm

Example 2
Automatic positioning Entering the paper thickness When the command Presetting has been enabled, the electronic control system positions the cover guides on CD102 and SM102 (only with REK386): to twice the paper thickness entered plus 0.1 mm (max. 1.9 mm),

SM74 and SM52: to twice the paper thickness entered (max. 1.9 mm).

67

Size adjustment

1M4 Cover guide height adjustment

Manual positioning After actuating the button Cover guide height adjustment, the operator can make adjustments with the left-hand +/ buttons.

Selecting the display

Indication of the present value of the cover guide height adjustment

Actual value/coarse display, cover guide height adjustment

68

Size adjustment

1M4 Cover guide height adjustment

Place of installation

Printing unit 1 and feeder

Technical data
Motor data U P = = DC 24 V 5 W

Potentiometer data U R = = DC 10 V 10 KW

69

Size adjustment

1M4 Cover guide height adjustment

Interconnection diagram
X10 X5

SSR

SSR X20

X21

X22 X3 X4

X23

X24

SSR X23

1 2SSM1: X2
X3 X1 X2 X5 X4

Backplane of servo-drive plug-in unit SSR


1LVT1

2SSM1: X4

2SSM1

Servo-drive distributor module 2SSM1

1M4: X1

1M4

Servo-drive 1M4
1M4:X1 1 2 4 5 6 2SSM 1 X5: D1 X5: D2 X5: D3 X5: D4 X5: D5 SSR X20: X20: X23: X23:

+ 10V 0V

X2: X2: X4: X4:

3 4 8 7

B12 D12 8 7

X4: 6

X23: 6

70

Size adjustment

1M4 Cover guide height adjustment

Removal and installation of motor

1
1
0 1

2
15Q66


1M4

1M4

1M4

71

Size adjustment

1M4 Cover guide height adjustment

brown blue

red
1 2

2
black

1M4


1 2

3
1M4 0 1

15Q66

72

Size adjustment

1M4 Cover guide height adjustment

Removal and installation of potentiometer

1
2
310 . 0

3 1
0 1

15Q66

1M4

73

Size adjustment

1M4 Cover guide height adjustment

defective

new

5
1 M4: X1

2 1
0 blue black red 15Q66 1

beige yellow black

4 5 6

08

1016 4

74

Size adjustment

1M4 Cover guide height adjustment

1M4

75

Size adjustment

1M4 Cover guide height adjustment

Checking the operating range


Preset version:

Servo-drive Cover guide height adjustment 1M4 Paper thickness 0.01 mm 1.00 mm Incremental value 676 " 4 inc 3260 " 4 inc

Service display Values, incremental values servo-drives


Standard version:

Servo-drive Cover guide height adjustment 1M4 Paper thickness 0.01 mm 1.00 mm Incremental value 676 " 4 inc 3260 " 4 inc

Service display Values, incremental values servo-drives

76

Size adjustment

1M2/1M3 Print-free margin D.S./O.S.

1M2/1M3 Print-free margin D.S./O.S.


Running direction of paper The print-free margin on the sheet is adjusted by means of two servo-drives. These servo-drives change the position of the front lay stop. The front lays are fitted on a shaft which, for adjustment of the print-free margin, can be adjusted parallel or at an angle (to the feed table). For this purpose, one servo-drive is installed on the drive side and one on the operator side. With these two servo-drives the front lays can be influenced in such a way that the print-free margin measures between 10 mm and 12 mm. The adjustment is made at the central control console.

Front lays 2mm Adjustment of front lays to change the "Printfree margin"

Graphical representation in the ZID

Selecting the display


Graphical representation Print-free margin Minimum value Maximum value Current value D.S. Current value O.S.

Actual value/fine display Print-free margin


Print-free margin O.S.

To adjust the print-free margin, press the corresponding function button. Then make the adjustment within a range from 10.0 mm to 12.0 mm by means of the left-hand +/ buttons.

Print-free margin D.S. and O.S. Print-free margin D.S.

77

Size adjustment

1M2/1M3 Print-free margin D.S./O.S.

Place of installation

1M2 = D.S. 1M3 = O.S.

Printing unit 1 and feeder

Technical data
Motor data U P = = DC 24 V 5 W

Potentiometer data U R = = DC 10 V 10 KW

78

Size adjustment

1M2/1M3 Print-free margin D.S./O.S.

Interconnection diagram
X10 X5

SSR

SSR X10
X15 X16 X3 X17 X18 X4

SSR X18

1 1LVT1
X3 X4

Backplane of servodrive plug-in unit SSR


1SSM1: X1

1SSM1 X3
X2 X1 X5

1SSM 1

Servo-drive distributor module SSM 1

X3 X1

SSM3
X2

X3 X1

SSM3
X2

1M2

1M3

Servo-drives 1M2 and 1M3


1M3 SSM3 X3: 1 X3: 2 X3: 3 X3: 4 X3: 5

+ 10V 0V

1M2 SSM3 X3: 1 X3: 2 X3: 3 X3: 4 X3: 5

SSM 1 X5: A1 X5: A2 X5: A3 X5: A4

X1: X1: X3: X3:

1 2 3 4

SSR X10: X10: X18: X18:

B30 D30 3 4

SSM1 X5: B1 X5: B2 X5: B3 X5: B4

X1: X1: X3: X3:

3 4 8 7

SSR X10: B32 X10: D32 X18: 8 X18: 7 X18: 6

X5: A5 X3: 5

X18: 5

X5: B5 X3:6

79

Size adjustment

1M2/1M3 Print-free margin D.S./O.S.

Removal and installation of motor

1
1
0 1

4
15Q66 1M2 (1M3)

24

1
1M2 (1M3)

2 3

24

80

Size adjustment

1M2/1M3 Print-free margin D.S./O.S.

Removal and installation of potentiometer

1
1
216 . 0

2
0 1 15Q66

3
1M2 (1M3)

2 1

24

2 1
81

Size adjustment

1M2/1M3 Print-free margin D.S./O.S.

4
2
. Pull rail

1
Front lay

defective

new

6
2
0 1 15Q66

82

Size adjustment

1M2/1M3 Print-free margin D.S./O.S.

05

1M2 2048 6

06

1M3 2048 6

1
1M2 (1M3)

224 3

83

Size adjustment

1M2/1M3 Print-free margin D.S./O.S.

Checking the operating range


Preset version:

1 2

Servo-drive Print-free margin D.S. 1M2 Servo-drive Print-free margin O.S. 1M3 Input 8 mm 10 mm Incremental value 3850 " 4 inc 246 " 4 inc

Service display Values, incremental values servo-drives


Standard version:

1 2

Servo-drive Print-free margin D.S. 1M2 Servo-drive Print-free margin O.S. 1M3 Input 8 mm 10 mm Incremental value 3850 " 4 inc 246 " 4 inc

Service display Values, incremental values servo-drives

84

Size adjustment

1...nM5 Adjustment of printing pressure

1...nM5 Adjustment of printing pressure


The servo-drive Adjustment of printing pressure changes the gap between blanket cylinder and impression cylinder. The rotation of the drive is transmitted to the blanket cylinder via a worm gear and a gear segment. The operator thus influences the pressure exerted on the print sheet during the printing process. Automatic positioning When the paper thickness is entered under the command Presetting, the servo-drive automatically positions to the value: paper thickness 0.1 mm = pressure.

Examples: 0.07 0.1 = 0.50 0.1 =

0.03 ! 0.03 x 1 = 0.03 0.40 ! 0.40 x 1 = 0.40

The correction factor (1) ensures that the result is shown correctly in the Actual value display.

1 2 3

Paper thickness entered Symbol for the paper thickness entered Upper adjustment limit for the printing pressure (max. gap between blanket cylinder and impression cylinder). SM102 = 0.75 mm, CD102, CU on SM102 = 1.20 mm. Graphical representation of the printing pressure Present value of the printing pressure 0 position of the printing pressure Lower adjustment limit (0.3 mm) for the printing pressure (min. gap between blanket cylinder and impression cylinder)

4
Explanation of the display

5 6 7

85

Size adjustment

1...nM5 Adjustment of printing pressure

Manual positioning

Selecting the display


Graphical representation of the adjustment of the printing pressure The servo-drive can be positioned manually with the right-hand +/ buttons. If no printing unit has been selected in the Printing unit/actual value display, all drives respond. If only one drive is to be positioned, the corresponding printing unit must be selected before.

Actual value/coarse display, adjustment of printing pressure

Note: The software limits the maximum pressure to 0.55. The max. pressure is composed of
the automatic positioning value (0.10) and the manual positioning value (max. 0.45).

86

Size adjustment

1...nM5 Adjustment of printing pressure

Place of installation

1...nM5

L-M5

1...8M5

Operator side

Technical data
Motor data U P = = DC 24 V 5 W

Potentiometer data U R = = DC 10 V 10 KW

87

Size adjustment

1...nM5 Adjustment of printing pressure

Interconnection diagram for printing unit 1...nM5


PU1, PU3, PU5 PU2, PU4 PU6, PU7, PU8 PU1 PU2 PU3 PU4 PU5 PU6 PU7 PU8 = = = = = = = = SSR SSR SSR SSR SSR SSR SSR SSR X24 X25 X26 X27 X28 X31 X32 X33
X5

SSR X20 SSR X30

X20

X30

SSR

X25

X26 X3 X4

X27

X28

1...8

Backplane of servo-drive plug-in unit SSR

1SSM2: X1

1...8LVT1

1...8M5: X1

1SSM2 X2
X1 X2 X3

1...8M5: X1

1SSM2

Servo-drive 1...8M5 Servo-drive distributor module 1SSM2

1...8M5:X1 1SSM 2 + 10V 0V 1 2 4 5 X3: X3: X3: X3: A1 A2 A3 A4 X1: X1: X2: X2: 1 2 3 4

SSR PU1 X20: B14 X20: B14 X24: 3 X24: 4 X24: 5 SSR PU5 X20: B30 X20: D30 X28: 3 X28: 4 X28: 5

PU2 X20: X20: X25: X25:

B18 D18 3 4

PU3 X20: X20: X26: X26:

B22 D22 3 4

PU4 X20: X20: X27: X27:

B26 D26 3 4

6 X3: A5 1...8M5:X1 1SSM 2 1 2 4 5 6 X3: X3: X3: X3: A1 A2 A3 A4

X2: 5

X25: 5 PU6 X30: X30: X31: X31:

X26: 5 PU7 X30: X30: X32: X32:

X27: 5 PU8 X30: X30: X32: X32:

+ 10V 0V

X1: X1: X2: X2:

1 2 3 4

B2 D2 3 4

B6 D6 3 4

B10 D10 3 4

X3: A5

X2: 5

X31: 5

X32: 5

X32: 5

88

Size adjustment

1...nM5 Adjustment of printing pressure

Interconnection diagram for coating unit 2...nM5


PU3, PU5 PU2, PU4 PU6, PU7, PU8 PU2 PU3 PU4 PU5 PU6 PU7 PU8 PU9 = = = = = = = = SSR SSR SSR SSR SSR SSR SSR SSR X25 X26 X27 X28 X31 X32 X33 X34
X5

SSR X20 SSR X30


X25 X26

X20

X30

SSR

X3 X27 X28

X4

Backplane of servo-drive plug-in unit SSR


2..9 1SSM2: X1 2...9LVT1

2...9M5: X1

1SSM2 X2
X1 X2 X3

2...9M5: X1

Servo-drive 2...9M5
1SSM2

Servo-drive control module 1SSM2


2...9M5:X1 1SSM 2 + 10V 0V 1 2 4 5 X3: X3: X3: X3: A1 A2 A3 A4 X1: X1: X2: X2: 1 2 3 4 SSR PU2 X20: X20: X25: X25: X25: SSR PU6 X30: X30: X31: X31:

B18 D18 3 4 5

PU3 X20: X20: X26: X26:

B22 D22 3 4

PU4 X20: X20: X27: X27:

B26 D26 3 4

PU5 X20: X20: X28: X28:

B30 D30 3 4

6 X3: A5 2...9M5:X1 1SSM 2 1 2 4 5 6 X3: X3: X3: X3: A1 A2 A3 A4

X2: 5

X26: 5 PU7 X30: X30: X32: X32:

X27: 5 PU8 X30: X30: X32: X32:

X28: 5 PU9 X30: X30: X34: X34:

+ 10V 0V

X1: X1: X2: X2:

1 2 3 4

B2 D2 3 4

B6 D6 3 4

B10 D10 3 4

B14 D14 3 4

X3: A5

X2: 5

X31: 5

X32: 5

X32: 5

X34: 5

89

Size adjustment

1...nM5 Adjustment of printing pressure

Removal and installation of motor

1
1
0 1

1...8M5 X1

Switch off the press. Open the guard on the O.S.

Disconnect 1...8M5 X1.

4
1

2 3

90

Loosen the fixing bolts on the motor.

Remove the defective motor.

Size adjustment

1...nM5 Adjustment of printing pressure

3 2 1

Install the new motor.

Tighten the fixing bolts.

7
1
brown 1 2 blue blue brown

2
0 1

1...8M5 X1

... 0.30 ...-1.20

Connect the motor. Start the press.

The value on the display changes in positive direction (0.30). The value on the display changes in negative direction (1.20).

91

Size adjustment

1...nM5 Adjustment of printing pressure

Removal and installation of potentiometer

1
1
0 1

1...8M5 X1

Switch off the press. Open the guard on the O.S.

Disconnect the potentiometer from 1...8M5 X1.

1
Turn the mechanism to the 0 value of the scale by means of the hexagon.

Loosen the stud on the gear wheel. Pull the gear wheel off the potentiometer. Loosen the nut on the potentiometer. Replace the potentiometer.

92

Size adjustment

1...nM5 Adjustment of printing pressure

1...8M5 X1

1
blue black red 4 5 6 beige yellow black

2
0 1

Connect the new potentiometer. Start the press.

Select service display 2.

1
PU1 ... PUn = 1234 8 inc

2 3 4

Set the potentiometer to 1234 8 inc.

Fasten the potentiometer. Put the gear wheel back in place and fasten it with the stud.

93

Size adjustment

1...nM5 Adjustment of printing pressure

... 0.30

Check the operating range: 0.30 = 616 8 inc

10

...-1.20

Check the operating range: 1.20 = 3550 8 inc

94

Size adjustment

1...nM5 Adjustment of printing pressure

Checking the operating range


Preset version

Servo-drive Adjustment of printing pressure 1M5 Input + 0.30 1.20 Incremental value 616 " 8 inc 3550 " 8 inc

Service display Values, incremental values servo-drives

95

Size adjustment

1M7/1M8 Adjustment of pull lays

1M7/1M8 Adjustment of pull lays


The servo-drive 1M7 positions the pull lay on the D.S. The servo-drive 1M8 positions the pull lay on the O.S.

Automatic positioning
Automatic positioning: is effected through the command Presetting, depends on the inputs into CPTRONIC, such as sheet width, off-centre position, pull direction, precision adjustment of pull lay.

After actuation of the input button, the electronic control system positions: the pull lay in use to the sheet width entered, the pull lay not in use 15 mm outside the entered sheet width.

1M7 1M8

A pneumatic clamping mechanism locks the pull lay in position. The pneumatic clamping mechanism opens after actuation of the input button for the command Presetting. The pneumatic clamping mechanism closes: when the pull lay is in the new position, if the new position is not reached in less than 4 minutes (fault message 7FFF in Dyn-test).

The electronic control system determines the position of each pull lay via two potentiometers: Potentiometer for precision adjustment during coarse positioning through the potentiometer in the servo-drive, during precision positioning through the potentiometer near the servo-drive.

Servo-drives Adjustment of pull lays

96

Size adjustment

1M7/1M8 Adjustment of pull lays

Precision adjustment of pull lay

Selecting the display

Symbol and indication of the current value for the precision adjustment of the pull lay

The symbol shows the active pull lay: Arrow pointing up = pull lay on D.S. active

Arrow pointing down = pull lay on O.S. active With the right-hand +/ buttons the active pull lay can be precision-adjusted. Adjustment is possible within a range of 5 mm in relation to the preset format.

Actual value/coarse display, Adjustment of pull lays

97

Size adjustment

1M7/1M8 Adjustment of pull lays

Place of installation

1M7 1M8

1Y47

Potentiometer for precision adjustment

Operator side

Technical data
Motor data U P = = DC 24 V 5 W

Potentiometer data U R = = DC 10 V 10 KW

98

Size adjustment

1M7/1M8 Adjustment of pull lays

Interconnection diagram 1M7


X20 X5

SSR

SSR X20
X21 X22 X3 X23 X24 X4

SSR X21

1 11LVT1 1SSM1: X2
X3 X4

Backplane of servodrive plug-in unit SSR

X2 X1 X5

1SSM1: X4

1SSM1

Servo-drive distributor module 1SSM1


3 2 4 5 1

1M7: X1

1M7

Servo-drive 1M7 (with potentiometer for coarse adjustment)


+ 10V 0V Pin Pin Pin Pin 1 2 3 4 X5: X5: X5: X5: C1 C2 C3 C4 X2: X2: X4: X4: 1 2 3 4 X20: X20: X21: X21: B2 D2 3 4

Potentiometer (for precision adjustment)

X5: D3 X5: D4 X5: D5

X4: 8 X4: 7 X4: 6

X21: 8 X21: 7 X21: 6

Pin 5

X5: C5

X4: 5

X21: 5

99

Size adjustment

1M7/1M8 Adjustment of pull lays

Interconnection diagram 1M8


X20 X5

SSR

SSR X20

X21

X22 X3 X4

SSR X22
X23 X24

1 11LVT1 2SSM1: X1
X3 X4

Backplane of servo-drive plug-in unit SSR

X2 X1 X5

2SSM1: X3

2SSM1

Servo-drive distributor module 2SSM1


3 2 4 5 1

1M8: X1

1M8

Servo-drive 1M8 (with potentiometer for coarse adjustment)


+ 10V 0V Pin Pin Pin Pin 1 2 3 4 X5: X5: X5: X5: A1 A2 A3 A4 X1: X1: X3: X3: 1 2 3 4 X20: X20: X22: X22: B6 D6 3 4

Potentiometer (for precision adjustment)

X5: B3 X5: B4 X5: B5

X3: 8 X3: 7 X3: 6

X22: 8 X22: 7 X22: 6

Pin 5

X5: A5

X3: 5

X22: 5

100

Size adjustment

1M7/1M8 Adjustment of pull lays

Removal and installation

1Y47

Remove the servo-drive Adjustment of pull lay D.S. 1M7 (or Adjustment of pull lay O.S. 1M8).

Actuate the solenoid valve 1Y47 manually and hold it in this position (pneumatic clamping mechanism is open).

3
2 1
O.S.

1 3

D.S.

2 3

Set the distance between the side frame D.S. (or O.S.) and the inside of the pull lay stop to 55 mm. Let go of the solenoid valve 1Y47.

Note: Because of the backlash, the distance between the side frame and pull lay stop must first be smaller than 55 mm. Then the correct value of 55 mm must be set.

101

Size adjustment

1M7/1M8 Adjustment of pull lays

01

3055 2

03

3055 2

1M7: X1 1M8: X1 Fit the gear wheel. Connect plug 1M7: X1 (or 1M8: X1). 1M7 (D.S.) = set to 30552 inc. 1M8 (O.S.) = set to 30552 inc.

1020

1,00

720

Install the servo-drive.

Select the command Presetting. Press the button Input. The servo-drives position to the displayed format.

102

Size adjustment

1M7/1M8 Adjustment of pull lays

Checking the operating range 1 2


Servo-drive Adjustment of pull lay D.S. 1M7 Servo-drive Adjustment of pull lay O.S. 1M8

Only compare the new servo-drive with the indicated values. Maximum sheet width Precision adjustment: 0.00 mm (2048 inc) Sheet width: 1040 mm Off-centre position: 00

Service display Values, incremental values servo-drives

For 1M7: pulling towards D.S. Incremental value: 3155 4 inc For 1M8: pulling towards O.S. Incremental value: 3155 4 inc Minimum sheet width Precision adjustment: 0.00 mm (2048 inc) Sheet width: 420 mm Off-centre position: 00 For 1M7: pulling towards D.S. Incremental value: 933 4 inc For 1M8: pulling towards O.S. Incremental value: 933 4 inc

103

Size adjustment

12M5 Sheet slowdown/format adjustment

12M5 Sheet slowdown/format adjustment


The servo-drive 12M5 positions the sheet slowdown at the delivery to the entered sheet length. Automatic positioning Automatic positioning: is effected through the command Presetting, depends on the entered sheet length.

Positioning accuracy: 0.50 mm. Positioning range: max. 720 mm, min. 500 mm (because of danger of collision with the sheet joggers), in the case of sheet lengths below 500 mm, the suction head stops at the lower limit (500 mm), manual positioning if the sheets are shorter (less than 500 mm).

End of automatic positioning: when the new desired position has been reached, when the lower limit (500 mm) of the positioning range has been reached, when one of the pushbuttons Sheet slowdown format is actuated.

Manual positioning Pushbuttons Sheet slowdown format Plus button Minus button Actuation of one of the pushbuttons Sheet slowdown format: the sheet slowdown positions irrespective of the preset format, indication of the position in the delivery MID, automatic positioning is stopped immediately. = to max. 730 mm.

Plus button

Minus button = to min. 270 mm.

104

Size adjustment

12M5 Sheet slowdown/format adjustment

Fault message in the ZID


Sheet slowdown/format adjustment The symbol appears in the display Delivery/ Warning. The symbol appears: during positioning while the press is on Run, when the lower limit is reached during automatic positioning.

The symbol goes off: when positioning is over and the press is on Run, when one of the pushbuttons Sheet slowdown format is actuated and the press is on Run.

105

Size adjustment

12M5 Sheet slowdown/format adjustment

Place of installation

12M5

Operator side

Technical data
Motor data U P = = DC 24 V 5 W

Potentiometer data U R = = DC 10 V 10 KW

106

Size adjustment

12M5 Sheet slowdown/format adjustment

Interconnection diagram
X10 X5

SSR

SSR X10
X15 X16 X3 X17 X18 X4

SSR X16

12 12LVT1 1SSM1: X1
X3 X4

Backplane of servo-drive plug-in unit SSR

1SSM1: X3
X2 X1

X5

1SSM1

Servo-drive distributor module 1SSM1


3 4 5 1

12M5: X1

12M5

Servo-drive 12M5
12M5:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 1SSM 1 X5: B1 X5: B2 X5: B3 X5: B4 X5: B5 SSR X10: X10: X16: X16:

+ 10V 0V

X1: X1: X3: X3:

3 4 8 7

B24 D24 8 7

X3: 6

X16: 6

107

Size adjustment

12M5 Sheet slowdown/format adjustment

Removal and installation

Rear paper stop

3 2

Front paper stop

Set the distance between the front and rear paper stops to 600 mm.

Remove the servo-drive Sheet slowdown / format adjustment 12M5.

Note: To compensate for the backlash, the 600 mm must be set from the max. possible distance.

12M5: X1

12

1370

Coupling part 108 Mount the coupling part. Connect plug 12M5: X1. Set to 1370 inc.

Size adjustment

12M5 Sheet slowdown/format adjustment

Install the servo-drive.

Checking the operating range 1


Servo-drive Sheet slowdown / format adjustment 12M5 Paper length Incremental value 280 mm 720 mm 730 mm 3540 " 3 inc 556 " 3 inc 498 " 3 inc

Service display Values, incremental values servo-drives

109

Size adjustment

12M6/12M7 Sheet joggers D.S./O.S.

12M6/12M7 Sheet joggers D.S./O.S.


The servo-drive 12M6 positions the sheet jogger on the D.S. The servo-drive 12M7 positions the sheet jogger on the O.S. Automatic positioning Automatic positioning: is effected through the command Presetting, depends on the inputs into CPTRONIC, such as: sheet width, off-centre position.

Positioning accuracy: 1.0 mm. End of automatic positioning: when the new desired position has been reached, when one of the pushbuttons Sheet jogger D.S. or Sheet jogger O.S. is actuated.

Manual positioning Pushbuttons Sheet jogger D.S. Plus button Minus button Pushbuttons Sheet jogger O.S. Plus button Minus button Actuation of one of the pushbuttons Sheet jogger D.S.: the servo-drive Sheet jogger D.S. 12M6 is controlled, the sheet jogger on the D.S. positions irrespective of the preset format.

Actuation of one of the pushbuttons Sheet jogger O.S.: the servo-drive Sheet jogger O.S. 12M7 is controlled, the sheet jogger on the O.S. positions irrespective of the preset format.

Actuation of one of the pushbuttons Sheet jogger: indication of the position in the delivery MID, the off-centre position can be up to 50 mm, automatic positioning is stopped immediately.

Plus button = to max. 1040 mm. Minus button = to min. 420 mm.

110

Size adjustment

12M6/12M7 Sheet joggers D.S./O.S.

Fault message in the ZID


Sheet jogger D.S. The symbols appear in the display Delivery/ Warning. The symbols appear: Sheet jogger O.S. during positioning while the press is on Run.

The symbols go off: when positioning is over and the press is on Run, when one of the pushbuttons Sheet jogger D.S. or Sheet jogger O.S. is actuated and the press is on Run.

111

Size adjustment

12M6/12M7 Sheet joggers D.S./O.S.

Place of installation

D.S. = 12M6 O.S. = 12M7

Delivery

Technical data
Motor data U P = = DC 24 V 5 W

Potentiometer data U R = = DC 10 V 10 KW

112

Size adjustment

12M6/12M7 Sheet joggers D.S./O.S.

Interconnection diagram 12M6


X10 X5

SSR

SSR X10
X15 X16 X3 X17 X18 X4

SSR X17

12 12LVT1 1SSM1: X2
X3 X4

Backplane of servo-drive plug-in unit SSR

1SSM1: X4
X2 X1 X5

1SSM1

Servo-drive distributor module 1SSM1


3 4 5 1

12M6: X1

12M6

Servo-drive 12M6
12M6:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 1SSM 1 X5: C1 X5: C2 X5: C3 X5: C4 X5: C5 SSR X10: X10: X17: X17:

+ 10V 0V

X2: X2: X4: X4:

1 2 3 4

B26 D26 3 4

X4: 5

X17: 5

113

Size adjustment

12M6/12M7 Sheet joggers D.S./O.S.

Interconnection diagram 12M7


X10 X5

SSR

SSR X10
X15 X16 X3 X17 X18 X4

SSR X17

12

Backplane of servo-drive plug-in unit SSR

12LVT1 1SSM1: X2
X3 X4

1SSM1: X4
X2 X1 X5

1SSM1

Servo-drive distributor module 1SSM1


3 4 5 1

12M7: X1

12M7

Servo-drive 12M7
12M7:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 1SSM 1 X5: D1 X5: D2 X5: D3 X5: D4 X5: D5 SSR X10: X10: X17: X17:

+ 10V 0V

X2: X2: X4: X4:

3 4 8 7

B28 D28 8 7

X4: 6

X17: 6

114

Size adjustment

12M6/12M7 Sheet joggers D.S./O.S.

Removal and installation

Cam follower

Control cam

Remove the servo-drive Sheet jogger D.S. 12M6 (or Sheet jogger O.S. 12M7).

Inch the press until the cam follower of the sheet jogger has reached the highest point of the control cam.

Set the distance between the sheet jogger D.S. (or O.S.) and the side frame D.S. (or O.S.) to 55 mm. 115

Size adjustment

12M6/12M7 Sheet joggers D.S./O.S.

4
4)

12M6: X1 12M7: X1

13

704 2

14

704 2

Fit the gear wheel. Connect plug 12M6: X1 (or 12M7: X1). 12M6 (D.S.) = set to 7042 inc. 12M7 (O.S.) = set to 7042 inc.

1020

720 1.00

Install the servo-drive.

Select the command Presetting. Press the button Input. The servo-drives position to the displayed format.

116

Size adjustment

12M6/12M7 Sheet joggers D.S./O.S.

Checking the operating range 1 2


Servo-drive Sheet jogger D.S. 12M6 Servo-drive Sheet jogger O.S. 12M7

The indicated values are valid for both servodrives. Sheet width: 1040 mm Incremental value: 704 3 inc Sheet width: 420 mm Incremental value: 3392 3 inc

Service display Values, incremental values servo-drives

117

Size adjustment

12M6/12M7 Sheet joggers D.S./O.S.

118

Feeder pile control

Block diagrams

Feeder pile control


Block diagrams Block diagram (Preset)

Pile height

Switches and sensors

Controls

Safety circuit

SEK

EAK_11

Press control

REK2

ESK

Auxiliary drive control

A A A

HAK_01 B LTK500 BAK

C B B

HAK_02 B

STK1

Main pile

M 11M1

M 11M2

Auxiliary pile

Preset feeder with auxiliary pile

119

Feeder pile control

Block diagrams

Block diagram (Standard)

Pile height

Switches and sensors

Controls

Safety circuit

SEK

EAK_11

Press control

REK2

ESK

Auxiliary drive control

HAK_01 B

HAK_02 B

STK1

STK2

Main pile

M 11M1

M 11M2

Auxiliary pile

Standard feeder with auxiliary pile

120

Feeder pile control

Layout

Layout Overview
The pile control of the feeder is used to control the main pile and auxiliary pile. It consists of the following functional units: Press control: Detection and evaluation of input signals for controlling the pile drives Safety circuit: Detection and evaluation of safety signals for the emergency shutdown of pile drives Auxiliary drive control: Control of pile motors

The following components are part of the pile control: SEK Safety input board

EAK_11 Input/output board on board slot 11 (signal acquisition feeder) REK2 ESK Processor board on board slot 2 (press control) Input/output control board

HAK_01 Auxiliary drive board on board slot 1 HAK_02 Auxiliary drive board on board slot 2 STK1 STK2 BAK LTK500 Pile control board on board slot 1 Pile control board on board slot 2 Brake control board Power part board 500W

121

Feeder pile control

Layout

Press control
The press control detects the signals of the switches and sensors on the feeder via the inputs of EAK_11. REK2 evaluates these signals and generates control signals for the pile motors. The control signals for pile motors are passed on to the auxiliary drive control via the ESK. The ESK is provided with the following operation set for controlling the individual pile motors: REK2 ESK Auxiliary drive control Pile stop (pile height control off) Pile up (slow) Pile down (slow) Pile up, fast (at main pile only) Pile down, fast (at main pile only) Pile height control on Rack mode (parameter: rack height)

Inputs

EAK_11

Press control

Safety circuit
The SEK registers the signals of those switches on the feeder which are relevant to safety. It evaluates these signals and if necessary it generates control signals for the emergency shutdown of the pile drives. These control signals are directly passed on to the auxiliary drive control. The signals of the safety circuit always take priority over the signals of the press control. Auxiliary drive control The ESK is provided with the following operation set for controlling the individual pile motors: Pile drive enabled Pile up blocked Pile down blocked

Inputs

SEK

Safety circuit

122

Feeder pile control

Layout

Auxiliary drive control


The auxiliary drive control conditions the control signals of SEK and ESK and regulates the individual pile drives. Each drive is assigned with a control section (component of a HAK) and a power part (dependent on the motor used). Depending on the press version, the assignments listed in the following are possible - see also block diagrams. Control section HAK01 Part A HAK01 Part A HAK01 Part C

Safety circuit

Press control

HAK_01

HAK_02

LT

LT

Drive Main pile (Preset) Main pile (standard) Auxiliary pile

Power part BAK+LTK500 Part A STK1 Part A STK2 Part A

M 11M1

M 11M2

Auxiliary drive control

The signal of the governor foot for controlling the pile heights is conditioned in the power parts of the main pile and of the auxiliary pile. Both power parts pass the conditioned signal to the relevant control section. See chapter Control systems / auxiliary drive control for further information on auxiliary drive control.

123

Feeder pile control

Overview of components

Overview of components Preset feeder

11M1

11S56

11M2 11B35

11S34 11S37 11S31

11S65

11S32

11S36

11B33 11B11 11S39

Components on the Preset feeder

124

Feeder pile control

Overview of components

Standard feeder
11M1

11S33

11M2 11S34 11S37 11S36 11S32 11S65 11S31

11S35

11S39

Components on the standard feeder

125

Feeder pile control

Overview of components

Motors
Equipment Function with nonstop D D Preset without nonstop D Standard with nonstop D D without nonstop D Brushless motor Three-phase a.c. motor Remarks

11M1 11M1 11M2

Main pile drive (Preset) Main pile drive (standard) Auxiliary pile drive

Switches and sensors


Equipment 11B11 11S31 11S32 11S33 11B33 11S34 11B35 11S35 11S36 11S37 11S39 11S56 11S65 Function with nonstop D D D D D D D D D D D D D Preset without nonstop D D D D D Standard with without nonnonstop stop D D D D D D D D D D D D D D Remarks

Auxiliary pile detection Suction head limitation Upper pile safety Upper main pile limitation Upper main pile limitation Bottom main pile limitation Automatic pile transport Automatic pile transport Upper limitation of auxiliary pile Bottom limitation of auxiliary pile Pile support plate limitation Switching off the auxiliary pile Pile height control (governor foot)

D D

126

Feeder pile control

Function

Function Pile height control of main pile (Preset)


The automatic pile height control of the main pile on the feeder is activated as soon as one of the following conditions is met:
11S65 11B35

The sensor automatic pile transport (11B35) detects paper when raising the main pile (actuation of the button main pile up, 11S24) The press turns, the feeder is engaged and the sensor automatic pile transport (11B35) detects paper

Switching points of main pile height control


Pile height control
Governor foot is positioned vertically 11S65 detects too little paper Pile up (by the value set)

With the automatic pile height control, the pile is controlled so that the upper edge is always at the level of the governor foot (11S65) - with governor foot in vertical position. As soon as the sensor detects too little paper on the pile, the pile is moved upwards by a presettable height (the pile lift increment at the feeder can be adjusted between 0.5 mm and 2.5 mm on the ZID). The position of the governor foot can be altered by means of the suction head height control. The automatic pile height control on the feeder is stopped under the following circumstances: actuation of an emergency stop switch actuation of the suction head limitation switch (11S31) actuation of the upper pile safety switch (11S32) actuation of the upper main pile limitation switch (11B33) actuation of the upper auxiliary pile limitation switch (11S36) (only in case of non-stop) actuation of the pile stop button (11S26) actuation of the main pile down button (11S25) Sheeter in operation (extra accessory) The sensor automatic pile transport (11B35) does not detect any paper (only during the first 30 sheets in the closed loop control)

Sequence of main pile height control

127

Feeder pile control

Function

Automatic pile height control of main pile (standard)


The automatic main pile height control on the feeder is activated as soon as one of the following conditions is met:
11S65 11S35

The sensor automatic pile transport (11S35) detects paper when raising the main pile (actuation of the button main pile up, 11S24) The press turns, the feeder is engaged and the switch automatic pile transport (11S35) detects paper

Switching points of the automatic main pile height control


Automatic pile height control
Governor foot is positioned vertically 11S65 detects too little paper Pile up (by preset value)

The pile is controlled by the automatic pile height control so that its upper edge is always at the level of the governor foot (11S65) - with vertically positioned governor foot. As soon as the sensor detects too little paper on the pile, the pile is raised by the adjustable height (the pile lift increment on the feeder can be set between 0.5 mm and 2.5 on the ZID). The position of the governor foot can be adjusted (manually) via the suction head height control. The automatic pile height control on the feeder is stopped under the following circumstances: actuation of an emergency stop switch actuation of the suction head limitation switch (11S31) actuation of the upper pile safety (11S32) actuation of the upper main pile limitation switch (11S33) actuation of the upper auxiliary pile limitation switch (11S36) (only in case of non-stop) actuation of the pile stop button (11S26) actuation of the main pile down switch (11S25) sheeter in operation (extra accessory) The sensor automatic pile transport (11S35) does not detect any paper (only during the first 30 sheets in the closed-loop control)

Sequence of the automatic pile height control for the main pile

128

Feeder pile control

Function

Automatic pile height control of auxiliary pile


The automatic pile height control of auxiliary pile on the feeder is activated as soon as the toggle switch is in position auxiliary pile on (11S27) and the sensor/switch automatic pile transport (Preset: 11B35, standard: 11S35) detects paper. The pile is controlled by the automatic pile height control so that the upper edge of the pile is always at the level of the governor foot (11S65) - with governor foot positioned vertically. As soon as the sensor detects too little paper on the pile, the pile is raised by an adjustable height (the pile lift increment on the feeder can be adjusted between 0.5 mm and 2.5 mm on the control console display ZID). The position of the governor foot can be altered via the suction head height control.

11S65 11B35

Switching points of the automatic pile height control of auxiliary pile


Automatic pile height control
Governor foot is positioned vertically 11S65 detects too little paper Pile up (by preset value)

The automatic pile height control at the feeder is stopped under the following circumstances: actuation of an emergency stop switch actuation of the suction head limitation button (11S31) actuation of the upper pile safety switch (11S32) actuation of the upper auxiliary pile limitation switch (11S36) actuation of the pile stop button (11S26) actuation of the auxiliary pile down button (11S29) unloading the auxiliary pile detection sensor (11B11) (only with Preset) sheeter in operation (extra accessory) The sensor automatic pile transport (11B35) does not detect any paper.

Sequence of the automatic pile height control for the auxiliary pile

129

Feeder pile control

Function

Transport of main pile


11S24

Main pile up The main pile can only be raised manually if the automatic pile height control of the main pile is not active. The upwards movement of the main pile is controlled via the button main pile up (11S24) on the feeder operation panel. If one of the following circumstances is met upon actuation of the button, the main pile moves upwards: The toggle switch (11S27) is in position auxiliary pile on The sensor auxiliary pile detector (11B11) is damped (only in case of non-stop with Preset) The toggle switch is in position auxiliary pile off (11S27) and the automatic pile transport (Preset: 11B35, standard: 11S35) detects no paper

11B33

fast

Switching points of main pile up


Main pile up
Permissible start condition 11S24 (keep pressed) Main pile up, fast Preset: 11B33 or 11B35 Standard: 11S33 or 11S35 Main pile stop

When the pile support plate reaches the upper main pile limitation (Preset: 11B33, standard: 11S33) or when the automatic pile transport (Preset: 11B35, standard: 11S35) detects paper, the transport of the main pile stops. The upwards movement of the main pile is interrupted under the following circumstances: actuation of an emergency stop switch actuation of the suction head limitation switch (11S31) actuation of the upper pile safety switch (11S32) actuation of the upper auxiliary pile limitation switch (11S36) (only in case of non-stop) actuation of the main pile down button (11S25) actuation of the pile stop button (11S26) sheeter in operation (extra accessory)

Sequence of main pile up

The pile transport can only be continued if the respective cause has been eliminated.

130

Feeder pile control

Function

Main pile down


11S25 11S26

The downward movement of the main pile is controlled via the button main pile down (11S25) on the feeder operation panel. The speed is changed (slow/fast) depending on the position of the main pile. The button main pile down (11S25) is furnished with a self-stopping mode. If the button is actuated, the main pile moves downwards at fast speed. When it reaches the pile support plate limitation (11S39), the main pile stops. In case of the preset version, the pile support plate is automatically centered in this position (maximum duration: 25 s). During this centering process, the control does not respond to the actuation of the main pile down button (11S25). If the main pile down button (11S25) is actuated again, the main pile (without self-stopping) moves further downwards at slow speed. When it reaches the bottom main pile limitation (11S34), the main pile stops. The downward movement of the main pile is interrupted if one of the following conditions is met: actuation of an emergency stop switch actuation of the lower end stop switch (11S34) actuation of the pile support plate limitation switch (11S39) actuation of the pile stop button (11S26) actuation of the main pile up button (11S24)

fast

11S39 slow 11S34

Switching points of main pile down


Main pile down
Permissible start condition 11S25 (self-stopping mode) Main pile down, fast 11S39 Preset: main pile stop and automatic centering of the pile support plate Standard: main pile stop 11S25 (no self-stopping mode) Main pile down, slow 11S34 Main pile stop

An interrupted pile transport can only be continued after elimination of the cause.

Sequence of main pile down and passing both speed ranges

131

Feeder pile control

Function

Transport of auxiliary pile


Preconditions The auxiliary pile can only be transported if the switch switching off the auxiliary pile (11S56) is clear. (Only with Preset) Auxiliary pile up
11S28

The auxiliary pile can only be moved up manually, if the automatic pile height control of the auxiliary pile is not active. The upwards movement of the auxiliary pile is controlled via the button auxiliary pile up (11S28) on the feeder operation panel. The auxiliary pile moves upwards at a constant speed. When it reaches the upper auxiliary pile limitation (11S36), the transport mechanism of the auxiliary pile stops. The upwards movement of the auxiliary pile is interrupted if one of the following conditions is met: actuation of an emergency stop switch actuation of the suction head limitation switch (11S31) actuation of the upper pile safety (11S32) actuation of the pile stop button (11S26) actuation of the auxiliary pile down button (11S29) sheeter is in operation (extra accessory)

11S36

fast

Switching points of auxiliary pile up


Auxiliary pile up
Permissible starting point 11S28 (keep pressed) Auxiliary pile up 11S36 Auxiliary pile stop

An interrupted pile transport can only be continued after the respective cause has been eliminated.

Sequence of auxiliary pile up

132

Feeder pile control

Function

Auxiliary pile down


11S29

The downwards movement of the auxiliary pile is controlled via the button auxiliary pile down (11S29) on the delivery operation panel. The auxiliary pile moves downwards at a constant speed. When it reaches the bottom auxiliary pile limitation (11S37), the transport mechanism of the auxiliary pile stops.
fast

The downward movement of the auxiliary pile is stopped if one of the following conditions is met:
11S37

actuation of an emergency stop switch actuation of the upper main pile limitation sensor (11B33) (only in case of Preset with non-stop) actuation of the pile stop button (11S26) actuation of the auxiliary pile up button (11S28) sheeter is in operation (extra accessory)

Switching points of auxiliary pile down


Auxiliary pile down
Permissible starting point 11S29 (keep pressed) Auxiliary pile down 11S37 Auxiliary pile stop

An interrupted pile transport can only be continued if the respective cause has been eliminated.

Sequence of auxiliary pile down

133

Feeder pile control

Function

Non-stop operation (Preset)


Preconditions The non-stop operation on the Preset feeder requires the following preconditions: The press is in production mode The toggle switch (11S27) is in position auxiliary pile off The non-stop bar is unhinged so that the switch switching off the auxiliary pile (11S56) is clear The non-stop bar is at the level of the pile board (starting position for inserting the support rods)

Basic function The non-stop operation on the Preset feeder consists of the following sub-steps: Transfer of pile: Inserting the support rods creates main and auxiliary pile. The auxiliary pile takes over the automatic pile height control Pile change: The (empty) main pile moves downwards. There it is loaded and moves back up to the auxiliary pile Pile merging: Main and auxiliary pile are merged by pulling out the support rods. The main pile takes over the automatic pile height control again.

134

Feeder pile control

Function

Main pile
Automatic pile height control of main pile on

Auxiliary pile
Automatic pile height control of auxiliary pile off

Inserting support rods

Inserting support rods 11S27 auxiliary pile on Auxiliary pile up, slow

Pile transfer

11B11 damped Automatic pile height control of main pile off Awaiting starting point Main pile down, fast 11S39 Main pile stop Centering main pile (automatically) 11S25 (no self-stopping mode) Main pile down, slow 11S34

11B11 damped Auxiliary pile stop Automatic pile height control of auxiliary pile on

Pile change

Main pile stop (loading) 11S24 Main pile up, fast

Main pile stop Aligning main pile (manually) 11S24 Main pile up, fast 11B11 not damped Automatic pile height control of main pile on 11S27 auxiliary pile off Automatic pile height control of auxiliary pile off Removing support rods Removing support rods 11S29 Auxiliary pile down 11S37 Auxiliary pile stop

Pile merging

Sequence of non-stop operation (Preset)


135

Feeder pile control

Function

Pile transfer The support rods are inserted (manually) and the toggle switch (11S27) is brought into the position auxiliary pile on. The auxiliary pile moves upwards until the sensor auxiliary pile detection (11B11) is damped. This activates the automatic pile height control on the auxiliary pile and deactivates it on the main pile. When reaching the starting point (dependent on the automatic pile height control of the auxiliary pile), the main pile moves automatically downwards. Pile change The main pile stops when reaching the pile support plate limitation (11S39). In this position, the pile support plate is automatically centered (max. duration: 25 s). When actuating the button main pile down (11S25), the main pile moves further downwards at slow speed. When reaching the bottom limit position (11S34), the main pile stops and can be loaded. When actuating the button main pile up (11S24), the pile moves back upwards. The main pile must be aligned manually just before it reaches the auxiliary pile. Pile merging When reaching the auxiliary pile, the sensor auxiliary pile detection (11B11) is no longer damped, whereupon the automatic pile height control of the main pile is activated again. The toggle switch is put into the position auxiliary pile off (11S27), this deactivates the automatic pile height control on the auxiliary pile. The support rods are pulled out (manually). Upon actuation of the button auxiliary pile down (11S29) the non-stop bars move downwards. When reaching the bottom auxiliary pile limitation (11S37), the non-stop bars stop (starting position).

136

Feeder pile control

Function

Non-stop operation (standard)


Preconditions The non-stop operation on the standard feeder requires the following preconditions: The press is in production mode. The toggle switch is in position auxiliary pile off (11S27) The non-stop bar is at the level of the pile support board (starting position for inserting the support rods)

Basic function The non-stop operation on the standard feeder consists of the following sub-steps: Pile transfer: Inserting support rods creates main and auxiliary pile. The auxiliary pile takes over the automatic pile height control Pile change: The (empty) main pile moves downwards. There it is loaded and moves back up to the auxiliary pile Pile merging: Main and auxiliary pile are merged by pulling out the support rods. The main pile takes over the automatic pile height control again.

137

Feeder pile control

Function

Main pile
Automatic pile height control of main pile on

Auxiliary pile
Automatic pile height control of auxiliary pile off

Inserting support rods

Inserting support rods 11S28 Auxiliary pile up, slow

Pile transfer

11S27 Auxiliary pile on Automatic pile height control of main pile off

11S27 auxiliary pile on Automatic pile height control of auxiliary pile on

11S25 (self-stopping mode) Main pile down, fast 11S39 Main pile stop 11S25 (no self-stopping mode)

Pile change

Main pile down, slow 11S34 Main pile stop (loading) 11S24 Main pile up, fast Height of auxiliary pile reached Main pile stop

11S27 auxiliary pile off Automatic pile height control of main pile on Removing support rods

11S27 auxiliary pile off Automatic pile height control of auxiliary pile off Removing support rods 11S29 Auxiliary pile down 11S37 Auxiliary pile stop

Pile merging

Sequence of nonstop operation (standard)

138

Feeder pile control

Function

Pile transfer The support rods are inserted (manually). Through actuation of the auxiliary pile up button (11S28), the non-stop bars are moved upwards (until the support rods are slightly lifted). The toggle switch (11S27) is brought into position auxiliary pile on, this activates the automatic pile height control on the auxiliary pile and deactivates it on the main pile. Pile change When actuating the button main pile down (11S25), the main pile moves in self-stopping mode downwards at fast speed. The main pile stops when reaching the pile support plate limitation (11S39). When actuating the button main pile down (11S25) once more, the main pile (without self-stopping mode) moves downwards at slow speed. When reaching the bottom limitation (11S34) the main pile stops and can be loaded. When actuating the button main pile up (11S24), the main pile moves upwards at fast speed. The main pile must be moved up to the auxiliary pile, so that the auxiliary pile is relieved. Pile merging The toggle switch is put into position auxiliary pile off (11S27), this reactivates the automatic pile height control on the main pile and deactivates it on the auxiliary pile. The support rods are pulled out (manually). When actuating the button auxiliary pile down (11S29), the non-stop bars move downwards. When reaching the bottom limitation of auxiliary pile (11S37), the non-stop bars stop (starting position).

139

Feeder pile control

11M1 Main pile motor (Preset)

11M1 Main pile motor (Preset) Place of installation


11M1

Place of installation of main pile motor (Preset)

Layout 1 2 3 4
Motor electronics Motor and brake Gear unit Male connector

Layout of main pile motor (Preset)

140

Feeder pile control

11M1 Main pile motor (Preset)

Task and function


The main pile motor moves the main pile upwards and downwards by means of pile chains. A brushless motor is used which can perform the following functions: Speed control Changeover between two different speed levels (fast and slow) Electric deceleration (controlled by the respective power part) Stopping or emergency braking by means of the brake installed

The motor is provided with the following internal functions for the purpose of controlling and monitoring: Commutation and speed detection by means of Hall signals Temperature detection through resistor

Technical specifications
Output: 0.18/0.36 kW Power supply: DC 120 V Speed (gear unit): 5.7/40 min1 Ratio: 100:1 Resistor code: 2 (560 W)

141

Feeder pile control

11M1 Main pile motor (Preset)

Pin assignment
Pin Function X1 motor line (slow) Y1 motor line (slow) Z1 motor line (slow) X2 motor line (fast) Y2 motor line (fast) Z2 motor line (fast) Brake (reference potential DC) Brake (DC +24 V) Hall 1 Hall 2 Hall 3 Resistor code PTC (temperature monitoring) Auxiliary supply of motor electronics UH Ground auxiliary supply PE conductor

1 2 3 4 5

A B C

A1

1 2 3 4 5

B1 C1 A2 B2 C2 C5 B5 B4 A5

Pin assignment on main pile motor (Preset)

B3 A4 A3 C4 C3

142

Feeder pile control

11M1 Main pile motor (standard)

11M1 Main pile motor (standard) Place of installation


11M1

Place of installation of main pile motor (standard)

Layout 1 2 3 4
Motor electronics Motor and brake Gear unit Male connector

Layout of main pile motor (standard)

143

Feeder pile control

11M1 Main pile motor (standard)

Task and function


The main pile motor moves the main pile upwards and downwards by means of the pile chains. A three-phase induction motor is used which carries out the following functions: Changeover between two different speed levels (fast and slow) Stopping and emergency braking by means of the brake installed

The motor is provided with the following internal functions for the purpose of controlling and monitoring: Speed detection via Hall signals Temperature detection via resistor

Technical specifications
Output: 0.13/0.42 kW Power supply: 220 V / 50 Hz 265 V / 60 Hz Speed (gear unit): 9.5/41.5 min1 (220V) 11.5/49.7 min1 (265V) Ratio: 66:1 Resistor code: 2 (560 W)

144

Feeder pile control

11M1 Main pile motor (standard)

Pin assignment
Pin A1 A B C 1 2 3 4 5 B1 C1 A2 B2 C2 A3 B5 C5 B4 Function Winding U1 (slow) Winding V1 (slow) Winding W1 (slow) Winding U2 (fast) Winding V2 (fast) Winding W2 (fast) N1, N2 Brake (reference potential DC) Brake (DC +24 V) Hall 1 Hall 2 Resistor code PTC (temperature monitoring) Auxiliary voltage of motor electronics UH Ground auxiliary voltage PE conductor

pin assignment of main pile motor (standard)

A5 C3 B3 C4 A4

145

Feeder pile control

11M2 Auxiliary pile motor

11M2 Auxiliary pile motor Place of installation

11M2

11M2

Preset feeder

Standard feeder

Place of installation of auxiliary pile motor

Layout 1 2 3 4
Motor electronics Motor and brake Gear unit Male connector

Layout auxiliary pile motor


146

Feeder pile control

11M2 Auxiliary pile motor

Task and function


The auxiliary pile motor moves the auxiliary pile upwards and downwards by means of the pile chains. A three-phase induction motor is used which can execute the following functions: Changeover between two different speed levels (fast and slow) Stopping and emergency braking by means of the brake installed

The motor is provided with the following internal functions for the purpose of controlling and monitoring: Speed detection via Hall signals Temperature detection via resistor

Technical specifications
Output: 0.09/0.4 kW Power supply: 220 V / 50 Hz 265 V / 60 Hz Speed (gear unit): 11.3/48.4 min1 (220V) 13.9/58.7 min1 (265V) Ration: 57:1 Resistor code: 8 (56 kW)

147

Feeder pile control

11M2 Auxiliary pile motor

Pin assignment
Pin A1 A B C 1 2 3 4 5 B1 C1 A2 B2 C2 A3 B5 C5 B4 Function Winding U1 (slow) Winding V1 (slow) Winding W1 (slow) Winding U2 (fast) Winding V2 (fast) Winding W2 (fast) N1, N2 Brake (reference potential DC) Brake (DC +24 V) Hall 1 Hall 2 Resistor code PTC (temperature monitoring) Auxiliary voltage motor electronics UH Ground auxiliary voltage PE conductor

Pin assignment main pile motor (standard)

A5 C3 B3 C4 A4

148

Feeder pile control

11B11 Auxiliary pile detection

11B11 Auxiliary pile detection Place of installation

11B11

Place of installation 11B11 (Preset feeder)

Layout 1 2
Sensor Cable

Sensor 11B11 with cable

149

Feeder pile control

11B11 Auxiliary pile detection

Task and function


The inductive sensor 11B11 monitors whether the non-stop bar is loaded. In case of a loaded non-stop bar, the auxiliary pile presses a trip bar downwards. The sensor detects the trip bar (metal). Switching output: normally open contact

Connection
Core colour 11B11 brown blue black Function + 24V DC 24V DC signal Terminal 12X2: +1 12X2: 1 FEM64: XE11

Cable end sensor 11B11

Removal and installation


The sensor is screwed down to a base plate which is located at the non-stop bar.

Removal and installation 11B11

150

Feeder pile control

11B11 Auxiliary pile detection

Setting

14 0.2 mm

In its basic setting the sensor protrudes the base plate by 14 mm (see figure).

Setting 11B11

Checking the circuit state


EAK_11 E11 11B11 The output signal of the sensor 11B11 reaches the EAK_11, input 11.

Signal flow

Position signal E11

The input signal E11 can be checked on the service display EAK: 0: 1: The sensor detects no metal (the trip bar is unloaded) The sensor detects metal (the trip bar is loaded)

Service display, signal E11

151

Feeder pile control

11B33 Upper main pile limitation

11B33 Upper main pile limitation Place of installation

11B33

Place of installation 11B33 (Preset feeder)

Layout 1 2
Sensor Cable

Sensor 11B33 with cable

152

Feeder pile control

11B33 Upper main pile limitation

Task and function


The inductive sensor 11B33 monitors whether the pile support plate has reached the uppermost position. The sensor detects the pile support plate (metal). Switching output: normally closed contact

Connection
Core colour 11B33 brown blue black Function + 24V DC 24V DC signal Terminal 12X2: +1 12X2: 1 FEM64: XE33

Cable end sensor 11B33

Removal and installation


The sensor is screwed down to the non-stop bar.

Removal and installation 11B33

153

Feeder pile control

11B33 Upper main pile limitation

Setting
In its normal position the sensor protrudes the non-stop bar by 24 mm (see figure).

24 mm

Setting 11B33

Checking the circuit state


EAK_11 E33 11B33 The output signal of the sensor 11B33 reaches EAK_11, input 33.

Signal flow

Position signal E33

The input signal E33 can be checked on the service display EAK: 0: 1: The sensor detects metal (the pile support plate is located at level of the sensor) The sensor detects no metal (the pile support plate is located below the sensor)

Service display, signal E33

154

Feeder pile control

11B35 Automatic pile transport

11B35 Automatic pile transport Place of installation

11B35

Place of installation 11B35 (Preset feeder)

Layout 1 2
Sensor Cable

Sensor 11B35 with cable

155

Feeder pile control

11B35 Automatic pile transport

Task and function


The capacitive sensor 11B35 detects whether the upper edge of the pile (paper) is at the respective height. Switching output: normally open contact

Connection
Core colour 11B35 brown blue black Function + 24V DC 24V DC signal Terminal 12X2: +1 12X2: 1 FEM64: XE35

Cable end sensor 11B35

Removal and installation


The sensor 11B35 is screwed down to the pile support frame in a special holder. When installing the cable make sure that no moveable parts are touched (risk of wearing through). The tape driving shaft is particularly critical.

Removal and installation 11B35

156

Feeder pile control

11B35 Automatic pile transport

Checking the circuit state


EAK_11 E35 11B35 The output signal of the sensor 11B35 reaches EAK_11, input 35.

Signal flow

Position signal E35

The input signal E35 can be checked on the service display: 0: 1: The sensor does not detect an object (the upper edge of pile is below the sensor) The sensor detects an object (the upper edge of pile is at the level of the sensor)

Service display, signal E35

157

Feeder pile control

11S34 Bottom main pile limitation

11S34 Bottom main pile limitation Place of installation


11S34 11S34

Preset feeder

Standard feeder

Components

Place of installation 11S34

Task and function


The position switch 11S34 deactivates the pile drive when the main pile has reached its lowest position. There is a trip cam at the pile change which actuates the position switch via a shifter mechanism.

158

Feeder pile control

11S34 Bottom main pile limitation

Setting
To set the bottom main pile limitation, the main pile chains must be shortened or lengthened accordingly. The position switch 11S34 must not be changed. Basically the following procedure for shortening or lengthening the main pile chains applies. Furthermore, the instructions and safety hints of the service manual for the mechanics are to be obeyed.

Lower the pile support plate of the feeder until the pile support plate rests on the floor or on an elevation (e.g. pallets) and the pile chains are relaxed Lengthen or shorten the main pile chains accordingly

Checking the circuit state


EAK_11 E34 11S34 The output signal of the switch 11S34 reaches EAK_11, input 34.

Signal flow

Position signal E34

The input signal E34 can be checked on the service display EAK: 0: 1: switch is actuated switch is not actuated

Note: The signal is also displayed on the service display SEK. Service display, signal E34

159

Feeder pile control

11S34 Bottom main pile limitation

Components

160

Delivery pile control

Block diagrams

Delivery pile control


Block diagrams Block diagram (Preset)

Pile height

Switches and sensors

Controls

Outputs

Safety circuit

SEK

EAK_12

Press control

REK2

ESK

Auxiliary drive control

A A A

HAK_01 B LTK500 BAK

C B B

HAK_02 B

LTK50

Main pile

M 12M1

M 12M2

Auxiliary pile

Preset delivery with auxiliary pile

161

Delivery pile control

Block diagrams

Block diagram (standard)

Pile height

Switches and sensors

Controls

Outputs

Safety circuit

SEK

EAK_12

Press control

REK2

ESK

Auxiliary drive control

HAK_01 B

HAK_02 B

STK1

LTK50

Main pile

M 12M1

M 12M2

Auxiliary pile

Standard delivery with auxiliary pile

162

Delivery pile control

Layout

Layout Overview
The pile control of the delivery is used to control main pile and auxiliary pile and other outputs (solenoid-operated valves). It consists of the following functional units: Press control: recording and evaluating input signals for controlling the pile drives and outputs Safety circuit: recording and evaluating safety-relevant signals for emergency shutdown of pile drives Auxiliary drive control: control of pile motors

The following components are part of the pile control: SEK Safety input board

EAK_12 Input/output board on board slot 12 (signal acquisition delivery) REK2 ESK Processor board on board slot 2 (press control) Input/output control board

HAK_01 Auxiliary drive board on board slot 1 HAK_02 Auxiliary drive board on board slot 2 STK1 BAK LTK500 LTK50 Pile control board on board slot 1 Brake control board Power part board 500W Power part board 50W

163

Delivery pile control

Layout

Press control
Inputs Outputs The press control records the signals of the switches and sensors on the delivery and the delivery controls via the inputs of EAK_12. REK2 evaluates these signals and generates control signals for the pile motors and solenoid-operated valves. The solenoid-operated valves are controlled via the outputs of EAK_12. The control signals for the pile motors are passed on to the auxiliary drive control via the ESK. The ESK has the following operation set for controlling the individual pile motors: ESK Auxiliary drive control Pile stop (pile height control off) Pile up (slow) Pile down (slow) Pile up, fast (only for main pile) Pile down, fast (only for main pile) Pile height control on Rack mode (parameter: rack height)

EAK_12

REK2

Press control

Safety circuit
The SEK detects the signals of the safety-relevant switches on the delivery. It evaluates these signals and if necessary it generates control signals for the emergency shutdown of pile drives. These control signals are passed on directly to the auxiliary drive control. The signals of the safety circuit take priority over the signals of the press control. Auxiliary drive control The ESK is provided with the following operation set for controlling the individual pile motors: Pile drive enabled Pile up blocked Pile down blocked

Inputs

SEK

Safety circuit

164

Delivery pile control

Layout

Auxiliary drive control


The auxiliary drive control prepares the control signals of SEK and ESK and controls the individual pile drives. Each drive is assigned with a control section (component of a HAK) and a power part (dependent on the motor used). Depending on the press version, the assignments listed below are possible - see also block diagrams. Control section HAK01 Part B HAK01 Part B HAK02 Part A

Safety circuit

Press control

HAK_01

HAK_02

LT

LT

LT

Drive Main pile (Preset) Main pile (standard) Auxiliary pile (with auxiliary pile at feeder) Auxiliary pile (no auxiliary pile at feeder)

Power part BAK+LTK500 Part B STK1 Part B LTK50 Part A

12M1 12M2 12M2

Auxiliary drive control

HAK01 Part C

LTK50 Part A

The signal of the capacitive sensor for the automatic pile height control is prepared in the power part of the main pile. The prepared signals is passed on to the power part of the auxiliary pile. Both power parts pass the signal on to the corresponding control section. See chapter control systems / auxiliary drive control for further details about the auxiliary drive control.

165

Delivery pile control

Overview of components

Overview of components Operator side

12S130 12S55 12S56 12S33 12S34 12S131 12S35 12Y11 12Y13 12Y14/15 12Y49

12B69 12S42 12S41 12B129a

12Y60/61 12S34b 12B129 12S42 12S117

12B65

Components on the operator side

166

Delivery pile control

Overview of components

Drive side

12M1 12M2 12S39 12S55a

12S130a 12Y62 12S34a 12S38 12S36

Components on the drive side

167

Delivery pile control

Overview of components

Motors
Equipment 12M1 12M1 12M2 Function with nonstop D D Preset without nonstop D Standard with without nonnonstop stop D D D Remarks

Main pile drive (Preset) Main pile drive (standard) Auxiliary pile drive

Brushless motor Three-phase a.c. motor

Switches and sensors


Equipment 12S33 12S34 12S34a 12S34b 12S35 12S36 12S38 12S39 12S41 12S42 Function with nonstop Upper main pile limitation Bottom main pile limitation Bottom main pile limitation Bottom main pile limitation Sheet jogger 1 Sheet jogger 2 Overshooting control Monitoring suction drum Pile rake stop Pile rake down D D D D D D D D D Preset without nonstop D D D D D D D Standard with without nonnonstop stop D D D D D D D D D D D D D D D D D D Remarks

only with raised delivery, same function as 12S34 only with raised delivery, same function as 12S34

12S55 12S55a 12S56 12B65 12B69 12S117

Upper auxiliary pile limitation Upper auxiliary pile limitation Bottom auxiliary pile limitation Changeover fast/slow Pile height control switching point 1: changeover fast/slow switching point 2: upper main pile limitation Upper edge of pile at delivery Upper edge of pile at delivery Angular stop O.S. Angular stop D.S. Pile down, slow

D D D D D D D D D

D D D D D

with board fitting on D.S. with rake fitting on O.S. same function as 12S55

12B129 12B129a 12S130 12S130a 12S131

D D D D D D D D

D D D D D D D D

Receiver (light barrier) Transmitter (light barrier) same function as 12S130

168

Delivery pile control

Overview of components

Solenoid-operated valves
Equipment 12Y11 12Y13 12Y14 12Y15 12Y49 12Y60 12Y61 12Y62 Function with nonstop D D D D D D D D Preset without nonstop D D D D Standard with without nonnonstop stop D D D D D D D D D D D D Remarks

Sheet stop Sheet catcher Supporting cross bar on Supporting cross bar off Locking of sheet stops Rack delivery on Rack delivery off Suction air sheet catcher

only with rake only with rake only with board only with board

169

Delivery pile control

Function

Function Automatic pile height control


The automatic pile height control on the delivery is automatically activated as soon as one of the following conditions is met:
12B69

The height control for the main pile at the feeder is on The automatic pile height control for the auxiliary pile control on the feeder is on The paper run is switched on The sheeter is in operation (extra accessory)

The automatic pile height control on the feeder is stopped under the following circumstances:

Switching points of the automatic pile height control


Automatic pile height control
Permissible start condition

Actuation of the pile stop button (12S124) Actuation of the main pile up (12S45) or main pile down (12S46) button (main pile only) Actuation of the auxiliary pile up (12S53) or auxiliary pile down (12S54) button (auxiliary pile only) Opening of the sheet stop (12Y11)

12B69 detects paper Pile down (by 2 mm)

Sequence of automatic pile height control

Under normal circumstances the automatic pile height control refers to the main pile. In addition, the automatic pile height control at the auxiliary pile is activated and deactivated in non-stop operation (see chapter non-stop operation). The automatic pile height control controls the pile in such a way that the upper edge is always at the level of the sensor automatic pile height control (12B69). As soon as the sensor detects the upper edge of the pile (paper), the pile is lowered by 2 mm. In case the sensor automatic pile height control (12B69) fails to work, an emergency control is automatically activated. With this emergency control, the delivery pile is moved downwards synchronously to the feeder pile.

170

Delivery pile control

Function

Transport of main pile (Preset)


On the Preset version, the main pile is driven by a brushless motor by means of which three speed levels are passed. Main pile up
12S45

12S117/2 12B69 12S117/1 12B65

slow

The upwards movement of the main pile is controlled by means of the button main pile up (12S45) on the delivery operation panel. Depending on the position of the main pile, the speed is changed (fast/slow). When reaching the upper main pile limitation (12S117/switching point 2) or the automatic pile transport (12B69), the transport mechanism of the main pile stops. The upwards movement of the main pile is interrupted under the following circumstances:

fast 12S131 slow

Actuation of an emergency stop switch Actuation of the overshooting control switch (12S38) Actuation of the sheet jogger switch (12S35 or 12S36) Actuation of the monitoring suction drum switch (12S39) Actuation of the angular stop switch (12S130) Opening of the sheet stop (12Y11) (only if no non-stop operation) Actuation of the main pile down button (12S46)

Switching points of main pile up (Preset)


Main pile up
Permissible start condition 12S45 (keep pressed) Main pile up, slow

12S131 Main pile up, fast 12B65 or 12S117/1 Main pile up, slow 12B69 or 12S117/2 Main pile stop

The continuation of an interrupted pile transport is only possible after elimination of the respective cause.

Sequence of main pile up and passes through all three speed levels (Preset)

171

Delivery pile control

Function

Main pile down


12S46 12S124

The downward movement of the main pile is controlled by means of the button main pile down (12S46) on the delivery operation panel. Depending on the position of the main pile, the speed is changed (fast/slow). The button main pile down (12S46) is equipped with a self-stopping mode. If the button was actuated for more than 1.5 s, the main pile moves down to the bottom main pile limitation (12S34). The self-stopping mode can be interrupted by means of the button pile stop (12S124). The downward movement of the main pile is interrupted under the following circumstances:

slow 12S117/1 12B65 fast 12S131 slow 12S34

Actuation of an emergency stop switch Actuation of the pile stop button (12S124) Actuation of the main pile up button (12S45)

Switching point of main pile down (Preset)


Main pile down
Permissible start condition 12S46 (self-stopping mode after 1.5 s) Main pile down, slow 12B65 or 12S117/1 Main pile down, fast 12S131 Main pile down, slow 12S34 Main pile stop

The interrupted pile transport can only be continued after elimination of the respective cause.

Sequence of main pile down and passing through all three speed levels (Preset)

172

Delivery pile control

Function

Transport of main pile (standard)


On the standard version the main pile is driven by a three-phase a.c. motor, by means of which two speed levels are passed. Main pile up
12S45

12S33 12B69

The upwards movement of the main pile is controlled by means of the button main pile up (12S45) on the delivery operation panel. The main pile moves upwards at a constant speed (fast). When reaching the upper main pile limitation (12S33) or the automatic pile transport (12B69), the transport mechanism of the main pile stops. The upwards movement of the main pile is interrupted under the following circumstances:
fast

Actuation of an emergency stop switch Actuation of the overshooting control switch (12S38) Actuation of the sheet jogger switch (12S35 or 12S36) Actuation of the monitoring suction drum switch (12S39) Actuation of the angular stop switch (12S130) Opening of the sheet stop (12Y11) (only if no non-stop operation) Actuation of the main pile down button (12S46)

Switching points of main pile up (standard)


Main pile up
Permissible start condition

12S45 (keep pressed) Main pile up, fast 12S33 or 12B69 Main pile stop

An interrupted pile transport can only be continued after elimination of the respective cause.

Sequence of main pile up (standard)

173

Delivery pile control

Function

Main pile down


12S46 12S124

The downward movement of the main pile is controlled by means of the button main pile down (12S46) on the delivery operation panel. Depending on the position of the main pile, the speed is changed (fast/slow). When reaching the bottom limit position (12S34), the transport mechanism of the main pile stops. The button main pile down (12S46) is provided with a self-stopping mode. If the button was actuated for more than 1.5 s, the main pile moves down to the bottom main pile limitation (12S34). The self-stopping mode can be interrupted by means of the button pile stop (12S124). The downward movement of the main pile can be interrupted under the following circumstances: Actuation of an emergency stop switch Actuation of the pile stop button (12S124) Actuation of the main pile up button (12S45)

fast

12S131 slow 12S34

Switching points of main pile down (standard)

Main pile down


Permissible start condition 12S46 (self-stopping mode after 1.5 s) Main pile down, fast 12S131 Main pile down, slow 12S34 Main pile stop

An interrupted pile transport can only be continued after elimination of the respective cause.

Sequence of main pile down and passing through both speed levels (standard)

174

Delivery pile control

Function

Transport of auxiliary pile


Auxiliary pile up
12S53

The upward movement of the auxiliary pile is controlled by means of the button auxiliary pile up (12S53) on the delivery operation panel. The auxiliary pile moves upwards at a constant speed. When reaching the upper auxiliary pile limitation (12S55), the transport of the auxiliary pile stops. The upward movement of the auxiliary pile is interrupted under the following circumstances: Actuation of an emergency stop switch Actuation of the overshooting control switch (12S38) Actuation of the sheet jogger switch (12S35 or 12S36) Actuation of the monitoring suction drum switch (12S39) Actuation of the angular stop switch (12S130) Triggering of the sensor automatic pile height control (12B69) Opening of the sheet stop (12Y11) (only if no non-stop operation) Actuation of the auxiliary pile down button (12S54)

12S55

Switching points of auxiliary pile up


Auxiliary pile up
Permissible start condition 12S53 (keep pressed) Auxiliary pile up 12S55 Auxiliary pile stop

An interrupted pile transport can only be continued after elimination of the respective cause.

Sequence of auxiliary pile up

175

Delivery pile control

Function

Auxiliary pile down


12S54

The downward movement of the auxiliary pile is controlled by means of the button auxiliary pile down (12S54) on the delivery operation panel. The auxiliary pile moves downwards at a constant speed. When reaching the bottom auxiliary pile limitation (12S56), the transport mechanism of the auxiliary pile stops. The downward movement of the auxiliary pile is interrupted under the following circumstances:

12S56

Actuation of an emergency stop switch Actuation of the angular stop switch (12S130) Actuation of the auxiliary pile up button (12S53)

Switching points of auxiliary pile down


Auxiliary pile down
Permissible start condition 12S54 (keep pressed) Auxiliary pile down 12S56 Auxiliary pile stop

An interrupted pile transport can only be continued after elimination of the respective cause.

Sequence of auxiliary pile down

176

Delivery pile control

Function

Non-stop operation
Basic function The separation of pile occurs in non-stop operation by means of rake or board in the main pile and auxiliary pile. The auxiliary pile takes over the automatic pile height control, the main pile executes a pile change or a rack formation. After that the two piles are remerged. The rack function is a special version of the non-stop operation which is selected and adjusted (if available) by means of the control console. Besides main and auxiliary pile further components are involved in the non-stop operation: Sheet catcher Sheet stop front edge (only with rake) Supporting cross bar (only with rake) Guide rails (only with board)

177

Delivery pile control

Function

Main pile
Permissible start condition 12S42

Auxiliary pile
Permissible start condition

Pile separation

Main pile down, fast Pile change: 12S41 or 12B129 Rack: adjusted rack height Main pile stop (insert rake/board) 45 mm paper on auxiliary pile Automatic pile height control of main pile on (insert rake/board) 45 mm paper on auxiliary pile Automatic pile height control of auxiliary pile on

12S46 (self-stopping) Main pile down, fast 12S131

Pile change (rack)

Main pile down, slow 12S34 Main pile stop (unloading) 12S45 Main pile up, slow 12S131 Main pile up, fast

Rake: 12B129 Board: 12S41 free

Rake: 12B129 Board: 12S41 free Automatic pile height control of auxiliary pile off (pull out rake/board) Rake: 12S42 free Board: 12S10 actuated

Pile merging

Automatic pile height control of main pile off (pull out rake/board) Time delay 10 s

Automatic pile height control of main pile on

Auxiliary pile up 12S55 (starting position) Auxiliary pile stop

Sequence of non-stop operation

178

Delivery pile control

Function

Note: The following must be observed with the sequence of the non-stop operation (see figure):
The steps for unloading are omitted with the rake function Not all speed alterations are executed in case of the standard version

Pile separation When putting on the rake/board (12S42), the main pile moves downwards at fast speed. The main pile stops under the following circumstances:
12S41 12B129

Pile change: Inserting the rake/board (12S41) or lowering the upper edge of pile until it is at the level of the light barrier (12B129) rake: When reaching the preset rake height (the rake height can be adjusted on the ZID between 20 mm and 300 mm in increments of 10 mm)

12S42 12S41

As soon as 45 mm of paper are placed on the auxiliary pile, main and auxiliary pile execute pile height regulations. Pile change The main pile moves downwards in self-stopping mode by pressing the button main pile down (12S46, for more than 1.5 s). After the main pile has been emptied it moves back to the level of the auxiliary pile when actuating the button main pile up (12S45). When moving upwards and downwards the main pile runs through the same speed levels as described in the paragraph Transport of main pile. Rack After positioning the rack, the main pile moves back to the level of the auxiliary pile by actuation of the button main pile up (12S45) .

Switching points for pile separation and pile merging

179

Delivery pile control

Function

Pile merging The main pile moves upwards until the corresponding condition is met. Rake: the upper edge of the pile has reached the height of the light barrier (12B129) Board: the main pile lifts the board from underneath (12S41 free)

The automatic pile height control for main and auxiliary pile is interrupted for 10 seconds. Within this period, the rake/ board can be pulled out. Then the main pile takes over the automatic pile height control again. The auxiliary pile frame moves upwards back into its basic position. In case of the version with board, the guide rails must be retracted in addition - see paragraph guide rails. Sheet catcher When separating the pile, the sheet catchers retain the paper coming from above, this activity is supported by suction air activated in addition. When putting on the rake/board (12S42), the main pile moves downwards (see pile separation). If the preset moment of application is reached, the sheet catchers extend (12Y13) and the suction air is switched on (12Y62). The moment of application can be adjusted on the ZID within a range of 1 to 9 press rotations.

Extending and retracting sheet catcher


Sheet catcher
Permissible start condition 12S42 Main pile down Moment of application reached Extending sheet catcher (12Y13) Suction air on (12Y62) 12S41 Suction air off (12Y62) Retracting sheet catcher (12Y13)

When inserting the rake/board (12S41), the suction air is switched off (12Y62) and the sheet catchers retract (12Y13).

Sequence of extending and retracting sheet catcher


180

Delivery pile control

Function

Front edge sheet stop (with rake) The front edge sheet stop is locked during the entire non-stop operation with rake. The locking facility can also be operated manually on the control console. After putting on the rake (12S42), the locking facility is switched on (12Y49). When pulling out the rake (12S42 free), the locking facility is switched off again (12Y49).

Front edge sheet stop


Front edge sheet stop
Permissible start condition 12S42 Sheet stop locked (12Y49) 12S42 free Sheet stop released (12Y49)

Sequence of front edge sheet stop

181

Delivery pile control

Function

Supporting cross bar (with rake) The supporting cross bar is needed for the non-stop operation with rake to put on the rods of the rake. Dependent on the press-specific version, there are two different options for controlling the supporting cross bar. Without time delay: When putting on the rake (12S42), the supporting cross bar extends (12Y14). When pulling out the rake (12S41 and 12S42 free) the supporting cross bar retracts again (12Y15). With time delay: When inserting the rake (12S41 and 12S42) the supporting cross bar extends after 3 seconds (12Y14). When pulling out the rake (12S41 and 12S42 free) the supporting cross bar retracts again (12Y15).

Extending and retracting supporting cross bar


Cross bar without delay time
Permissible start condition 12S42 Extending cross bar (12Y14) Pile change or forming a rack 12S41 and 12S42 free Retracting cross bar (12Y15)

Sequence of extending and retracting supporting cross bar (without delay time)
Cross bar with delay time
Permissible start condition 12S41 and 12S42 Await time (3 s) Extending cross bar (12Y14) Pile change or forming a rack 12S41 and 12S42 free Retracting cross bar (12Y15)

Sequence of extending and retracting supporting cross bar (with delay time)

182

Delivery pile control

Function

Guide rails (with board)


12S10

The guide rails are needed for the non-stop operation with board to act as a lateral support of the board. By pressing the button pile board on/off (12S10) the guide rails extend (12Y60). After that the board can be inserted in the guide rails. After completion of the unloading process or after insertion of spacer angles for a rack, the main pile moves back to the height of the auxiliary pile (12S41 becomes clear). By pressing the button pile board on/off (12S10) the guide rails retract (12Y61).

Extending and retracting guide rails


Guide rail
Permissible start condition 12S10 Extending guide rail (12Y60) Pile change or forming a rack 12S41 free and 12S10 Retracting guide rail (12Y61)

Sequence of extending and retracting guide rails

183

Delivery pile control

Function

Removal of sample sheet


12S11

The removal of sample sheet is controlled by means of the button sample sheet removal (12S11) on the delivery operation panel. When the button is actuated, the automatic pile height control is interrupted. The sheet catchers extend (12Y13), for reason of better adhesion it is possible to additionally activate suction air (optional) (12Y62). The stop shaft swings up (12Y11) and the sheet can be removed. Actuating the button sample sheet removal (12S11) again, cancels the removal of sample sheet, the pile executes the automatic pile height control. When removing a sample sheet the locking of the front edge sheet stop (12Y49) is deactivated if it was activated beforehand.

Removal of sample sheet

Removal of sample sheet


Permissible start condition 12S11 Extending sheet catcher (12Y13) Suction air on (12Y62) - optional Swinging up stop shaft (12Y11) 12S11 Suction air off (12Y62) - optional Retracting sheet catcher (12Y13) Swinging back stop shaft (12Y11)

Sequence of sample sheet removal

184

Delivery pile control

Function

Paper blockage
Paper blockage
Permissible start condition Stop condition Paper supply at feeder blocked

In case of a paper blockage, the paper supply is blocked at the feeder. To trigger a paper blockage, either main pile or auxiliary pile must meet one of the following stop conditions. Main pile: (Only if the delivery is not in non-stop operation) Switch pile down slow (12S131) overshot Switch bottom main pile limitation (12S34) reached

Sequence of paper blockage

Auxiliary pile: Switch bottom auxiliary pile limitation (12S56) reached Maximum paper height in non-stop operation reached (depending on paper thickness between 1500 and 4000 sheets)

The paper blockage is only cancelled after elimination of the respective cause.

185

Delivery pile control

12M1 Main pile motor (Preset)

12M1 Main pile motor (Preset) Place of installation

12M1

Place of installation of main pile motor (Preset)

Layout 1 2 3 4
Motor electronics Motor and brake Gear unit Male connector

Layout of main pile motor (Preset)

186

Delivery pile control

12M1 Main pile motor (Preset)

Task and function


The main pile motor moves the main pile upwards and downwards via the pile chains. A brushless motor is used which can execute the following functions: Speed control Changeover between two different speed levels (fast and slow) Electrical deceleration (controlled by the corresponding power part) Stopping or emergency braking by means of installed brakes

The motor is provided with the following internal functions for the purpose of control and monitoring: Commutation and speed recording via Hall signals Temperature recording via resistor

Technical specifications
Output: 0.18/0.36 kW Power supply: DC 120 V Speed (gear unit): 5.7/40 min1 Ratio: 100:1 Resistor code: 2 (560 W)

187

Delivery pile control

12M1 Main pile motor (Preset)

Pin assignment
Pin Function X1 motor line (slow) Y1 motor line (slow) Z1 motor line (slow) X2 motor line (fast) Y2 motor line (fast) Z2 motor line (fast) Brake (reference potential DC) Brake (DC +24 V) Hall 1 Hall 2 Hall 3 Resistor code PTC (temperature monitoring) Auxiliary voltage motor electronics UH Ground auxiliary voltage PE conductor

1 2 3 4 5

A B C

A1

1 2 3 4 5

B1 C1 A2 B2 C2 C5 B5 B4 A5

Pin assignment of main pile motor (Preset)

B3 A4 A3 C4 C3

188

Delivery pile control

12M1 Main pile motor (standard)

12M1 Main pile motor (standard) Place of installation

12M1

Place of installation of main pile motor (Standard)

Layout 1 2 3 4
Motor electronics Motor and brake Gear unit Male connector

Layout of main pile motor (standard)

189

Delivery pile control

12M1 Main pile motor (standard)

Task and function


The main pile motor moves the main pile upwards and downwards by means of the pile chains. A three-phase induction motor is used which can execute the following functions: Changeover between two different speed levels (fast and slow) Stopping and emergency braking by means of the installed brake

The motor is provided with the following internal functions for the purpose of controlling and monitoring: Speed recording via Hall signals Temperature recording via resistor

Technical specifications
Output: 0.13/0.42 kW Power supply: 220 V / 50 Hz 265 V / 60 Hz Speed (gear unit): 9.5/41.5 min1 (220V) 11.5/49.7 min1 (265V) Ratio: 66:1 Resistor code: 2 (560 W)

190

Delivery pile control

12M1 Main pile motor (standard)

Pin assignment
Pin A1 A B C 1 2 3 4 5 B1 C1 A2 B2 C2 A3 B5 C5 B4 Function Winding U1 (slow) Winding V1 (slow) Winding W1 (slow) Winding U2 (fast) Winding V2 (fast) Winding W2 (fast) N1, N2 Brake (reference potential DC) Brake (DC +24 V) Hall 1 Hall 2 Resistor code PTC (temperature monitoring) Auxiliary voltage of motor electronics UH Ground auxiliary voltage PE conductor

Pin assignment of main pile motor (standard)

A5 C3 B3 C4 A4

191

Delivery pile control

12M2 Auxiliary pile motor

12M2 Auxiliary pile motor Place of installation

12M2

Place of installation of auxiliary pile motor

Layout 1 2 3 4
Gear unit Motor Motor electronics Circular connector

Layout of auxiliary pile motor

192

Delivery pile control

12M2 Auxiliary pile motor

Task and function


The auxiliary pile motor moves the auxiliary pile upwards and downwards by means of the pile chains. A brushless motor is used which can execute the following functions: Speed control Electric deceleration (controlled by the corresponding power part) Deceleration through the self-locking gear unit

The motor is provided with the following internal functions for the purpose of controlling and monitoring: Commutation and speed recording via Hall signals

Technical specifications
Output: 30 Watt Power supply: DC 48 V Speed (gear unit): 1 min1 Ratio: 2564:1 Resistor code: 5 (5.6 kW)

193

Delivery pile control

12M2 Auxiliary pile motor

Pin assignment
Pin 1 2 3 4 6 7 8 9 11 12 Function X motor line Y motor line Z motor line Hall C Hall B Auxiliary voltage of motor electronics UH Hall A Ground auxiliary voltage Resistor code PE conductor

Pin assignment auxiliary pile motor

13 14

194

Delivery pile control

12B65 Changeover fast/slow

12B65 Changeover fast/slow Place of installation

12B65

Place of installation 12B65

Layout 1 2
Sensor Cable

Sensor 12B65 with cable

195

Delivery pile control

12B65 Changeover fast/slow

Task and function


The ultrasonic sensor 12B65 monitors whether the upper edge of the pile (paper, pallet or pile support plate) is at the corresponding height. The output signal is used to change the speed to fast/slow. Switching output: normally closed contact

Connection
Core colour 12B65 brown blue black Function + 24V DC 24V DC signal Terminal 12X2: +1 12X2: 1 12X2: 116

Cable end sensor 12B65

Removal and installation


The sensor 12B65 is fixed to the control lever by means of two screws. When installing the cable there must be enough room for the rotary movement of the lever.

Removal and installation 12B65

196

Delivery pile control

12B65 Changeover fast/slow

Checking the circuit state


EAK_12 E65 12B65 12S117/1 The output signal of the sensor 12B65 reaches EAK_12, input E65 via the switch 12S117/switching point 1 (at the control lever).

Signal flow

Position signal E65

The input signal E65 can be checked on the service display EAK: 0: The sensor 12B65 detects an object (the pile is at the level of the sensor) or 12S117/ switching point 1 is actuated (the pile support plate presses the control lever upwards) The sensor 12B65 does not detect any object (the pile is below the sensor) or 12S117/switching point 1 is not actuated (the control lever is not actuated)

1:

Service display, signal E65

197

Delivery pile control

12B69 Pile height control

12B69 Pile height control Place of installation

12B69

Place of installation 12B69

Layout 1 2
Sensor Cable

Sensor 12B69 with cable

198

Delivery pile control

12B69 Pile height control

Task and function


The capacitive sensor 12B69 monitors whether the upper edge of the pile (paper) is level with the sheet stop. Based on this sensor signal, the control systems regulates the position of the delivery pile. Switching output: normally open contact

Connection
Core colour 12B69 brown blue black Function + 24V DC 24V DC signal Terminal 12X2: +1 12X2: 1 12X2: 69

Cable end sensor 12B69

Removal and installation


The sensor 12B69 is fixed to the support on the sheet jogger shaft by means of a screw. When installing the cable there must be enough room for the rotary movement of the stop shaft and for the adjustment of the sensor at the support. The cable must not be fixed to movable parts (except for the sheet jogger shaft). These are in particular the following points: Sheet catcher hose Non-stop frame

Removal and installation 12B69

199

Delivery pile control

12B69 Pile height control

Setting
In the normal position the sensor is fixed in the bottom third of the oblong hole (see figure) and the rack height is adjusted to 70 mm. Depending on the condition of the pile or the printing material, this position can be altered.

approx. 50 mm

Note: A repositioning of the sensor needs to be considered in non-stop operation for the rack height (adjustable on the control console)

Normal setting

Checking the circuit state


EAK_12 E70 HAK_01 12B69 HAK_02 The output signal of the sensor 12B69 reaches EAK_12, input 70 and the HAK control sections of the main and auxiliary pile drive (exact assignment see block diagram).

Signal flow

Position of signal E70

The input signal E70 can be checked on the service display EAK: 0: 1: The sensor detects no object (the pile is below the sensor) The sensor detects an object (the pile is located at the level of the sensor)

Service display, signal E70

Note: The signal is also displayed as status signal on the service display of the two respective HAK control sections.

200

Delivery pile control

12B129 Delivery upper edge of pile

12B129 Delivery upper edge of pile Place of installation

12B129a

12B129

Place of installation 12B129 and 12B129a

Layout 1 2
12B129 Sensor Cable

12B129a

Sensor 12B129 and 12B129a with cable

201

Delivery pile control

12B129 Delivery upper edge of pile

Task and function


The light barrier 12B129 monitors whether the upper edge (paper, pallet or pile support plate) of the main pile is located at the respective level underneath the auxiliary pile. By means of this sensor signal, the separation and merging of the pile is controlled in non-stop operation with board. The light barrier consists of a transmitter (12B129a) and a receiver (12B129). Switching output: dark switching

Connection
12B129 12B129 Core colour brown blue Function + 24V DC 24V DC signal Terminal 12X2: +1 12X2: 1 FAM64:XA29

Cable end sensor 12B129

black 12B129a

12B129a

Core colour brown blue

Function + 24V DC 24V DC

Terminal 12X2: +1 12X2: 1

Cable end sensor 12B129a

202

Delivery pile control

12B129 Delivery upper edge of pile

Removal and installation


Transmitter and receiver of the light barrier are screwed down to the support (metal plate). Both supports can be relocated in height through the oblong holes. Both supports must be at the same level. When installing the cable there must be enough room for the upward and downward movement of the non-stop frame. O.S. In its normal position, the light barrier should be set as high as possible to prevent a lowering of the pile below the rear edge stop.

D.S.

12B129a

12B129

Removal and installation 12B129

Checking the circuit state


EAK_12 E77 12B129a 12B129 The output signal of the sensor 12B129 (receiver) reaches EAK_12, signal E77.

Signal flow

Position of signal E77

The input signal E77 can be checked on the service display EAK: 0: 1: The light barrier is not interrupted The light barrier is interrupted

Service display, signal E77

203

Delivery pile control

12S34 Bottom main pile limitation

12S34 Bottom main pile limitation Place of installation

12S34

Place of installation 12S34

Task and function


The position switch 12S34 switches the main pile drive off when the main pile has reached its lowest position. There is a pin on the pile chain which actuates the position switch via a shifter mechanism. Principle of operation: normally closed contact

204

Delivery pile control

12S34 Bottom main pile limitation

Setting 1 2 3
Lower the pile support plate of the delivery until the pile support plate rests on the floor and the pile chains are relaxed. Slacken the fixing bolt 2.

1 at the control plate

Adjust the control plates so that the position switch 12S34 is actuated in this position of the delivery pile support plate.

Position switch 12S34

Mounting plate with (actuated) position switch

205

Delivery pile control

12S34 Bottom main pile limitation

Checking the circuit state


EAK_12 E34 12S34 12S34a 12S34b The output signal of the switch 12S34 reaches EAK_12, input 34 via the switches 12S34a and 12S34b (if available).

Signal flow

Position of signal E34

The input signal E34 can be checked on the service display EAK: 0: 1: at least one switch is actuated no switch is actuated

Service display, signal E34

206

Sheet alignment

Block diagram

Sheet alignment
Block diagram
Double-sheet detector SM74 / 52 O.S. D.S. 1B66 1B65 Sheet alignment control D.S. 1B13 O.S. 1B49 Pull lay control D.S. 1B9 O.S. 1B10 1B11 Double-sheet detector SM102/CD102

RL12 1AUM1

RL12

SUM1 RL12

SUM1 RL12

DBE

Automatic misalignment control 11M7 Automatic sheet arrival control SM102/CD102 = 11M3 SM74 = 1M7

Sheet stop finger O.S . 1Y15 D.S . 1Y46

Gripper opening

1Y16

SSM1 M

SSM1

SSK

EAK 1

IDS Displays

SAK

ESK

SVM

MID11

MID12

REK1

REK2

DSK

DNK

ZID

Legend:

Data line

Control lines

Block diagram of sheet alignment


207

Sheet alignment

Block diagram

The sheet alignment system consists of: the sheet alignment control BAK, the pull lay control ZMK, the double-sheet detector DBE, the automatic sheet arrival control BAR (not on SM52), the automatic misalignment control (only on SM102 with Preset and CD102).

As a result of mechanically controlled sequences of motions, the sheet is aligned with the sheet alignment system before it enters the first printing unit. At the same time, the electronic control system: registers the point of time of sheet arrival, monitors sheet infeed, detects double-sheets.

From different sensors the electronic control system receives information from the area of the front lays at certain interrogation points. The sensor signals are processed on the processor board 2 (REK2). The REK2 shows the result of the evaluation on the control console display ZID and the press displays MID. Simultaneously, the electronic control system activates various actuators (drives, valves etc.) in the press.

208

Sheet alignment

Block diagram

Degree values relevant to sheet alignment


The illustration opposite shows the different interrogation points in the area of the front lays. The relation between the degree values and the processes in the press is explained in more detail on the next pages. To make the relation clear, the illustration shows the operation points Feeder ON and Feeder OFF. Table of degree values: Feeder ON Feeder OFF SM52 SM74 285_ 303_ 20_ 330_ 42,5_ 330_ 40_ 15_ 72_ SM102 CD 102 192,0_1 170,0_1 222,0_ 200,0_ 208,0_1 186,0_1 238,0_ 216,0_ 336,0_ 313,0_ 311,0_ 3,0_ 289,0_ 341,5_

BAK ZMK DBE

1 2 3 4 5

230_

Interrogation points

1 only for presses with Preset feeder

209

Sheet alignment

1B13/1B49 Sheet alignment control

1B13/1B49 Sheet alignment control Block diagram


For correct sheet transfer from the feeder into the first printing unit, the sheet must be placed against the front lays as follows:

BAK

FK Front lays ANK 1B13/1B49 Paper

Interrogation points

Sheet alignment control D.S. 1B13 O.S. 1B49

1 and 20_ 3, SM74 between 285_ 1 and 40_ 3, SM102 between 222_ 1 and 336_ 3, SM102 with Preset between 192_ 1 and 336_ 3, CD102 between 200_ 1 and 313_ 3, CD102 with Preset between 170_ 1 and 313_ 3. The optimum sheet arrival of the electric 2 is as
SM52 between 240_ follows: for SM74 at 303_, for SM102 at 238_, for SM102 with Preset at 208_, for CD102 at 216_. for CD102 with Preset at 186_.

RL12

RL12

1 LVT1 1EVM4
MID12

Displays MID11

The following applies to the degrees listed (see block diagram):


ZID

At 1 and paper run: the ANK must not detect paper. At 3 and paper run: the ANK must detect paper. At 5 and paper run: to analyze the information provided by the pull lay control (1B9/1B10) the ANK must detect paper.

EAK 1

DNK

ESK

SVM

DSK

The sensors (1B13 and 1B49) of the sheet alignment control register at which point of time the sheets arrive at the front lays. Each sensor housing contains an ANK and FK sensor. ANK = sensor for sheet alignment control FK = sensor for overshooting-sheet control

REK2

Legend:

Data line Control lines

Note: Speedmaster SM52 is only equipped with one sensor (1B49) of the sheet alignment control.

Block diagram of sheet alignment control


210

Sheet alignment

1B13/1B49 Sheet alignment control

The signals of the sensors are transmitted to the amplifiers (RL12) where they are amplified. The signals from the amplifiers reach the processor board REK2 via the distribution box 1LVT1, the input/output distributor module EVM (only SM52), the input/ output board EAK and the input/output control board ESK.

The REK2 analyzes the signals of the sheet alignment control. The evaluated signals are required for the following functions of the printing press: sheet alignment at the front lays, misaligned-sheet display (trend display), automatic sheet arrival control (servo-drive 11M3/1M7), automatic misalignment control (servo-drive 11M7).

The REK2 shows the result of the evaluation on the control console display ZID and the press displays MID. D.S. Circuit states of the ANK and FK sensors in the MID

1
O.S.

FK display (sensor for overshooting control) ANK display (sensor for sheet alignment control)

Circuit states displayed on the MID

With the help of the MID on the control panel of the feeder, the FK sensors 1 and ANK sensors 2 can be adjusted and monitored. The MID reflects the circuit state of the corresponding sensor on the drive side and on the operator side. Symbol lit Symbol not lit = = sensor detects paper sensor does not detect paper

The FK and ANK displays are visible when the switch Safe on the control panel of the feeder is set to Safe and the printing speed is x 3500 i.p.h.

Note: On Speedmaster SM52 the symbols of two sensors are displayed, even though only one sensor if fitted.

211

Sheet alignment

1B13/1B49 Sheet alignment control

Sheet alignment errors detected by the ANK sensors


The ANK sensors detect:
BAK SM52 240_ SM74 285_ SM102 222_ SM102 with Preset 192_ CD102 200_ CD102 with Preset 170_

early sheets (first sheet), late sheets (missing sheets), misaligned sheets.

Paper (first sheet)

An early sheet exists if the first sheet of the sheet stream already covers the ANK sensor at press angle 1. The feeder and press stop immediately. The sheets are held back on the feed table.

Early sheet
A late sheet exists if none of the ANK sensors detects paper at press angle 3. The feeder stops and the remaining sheets are held back on the feed table. The sheets inside the press are printed and transported to the delivery. The press speed is then reduced to 3 000 i.p.h.

BAK SM52 20_ SM74 330_ SM102 336_ SM102 with Preset 336_ CD102 313_ CD102 with Preset 313_

Late sheet
A misaligned sheet exists if only one of the ANK sensors either on the drive side or on the operator side detects paper at press angle 3. The feeder stops and the remaining sheets are held back on the feed table. The sheets inside the press are printed and transported to the delivery. The press speed is then reduced to 3 000 i.p.h.

BAK SM74 330_ SM102 336_ SM102 with Preset 336_ CD102 313_ CD102 with Preset 313_

O.S.

Paper

Paper

D.S.

Note: On SM52 misalignment control is not required.

Misaligned sheet
212

Sheet alignment

1B13/1B49 Sheet alignment control

Sheet alignment error detected by the FK sensors


The FK sensors detect:
BAK SM52 20_ SM74 330_ SM102 336_ SM102 with Preset 336_ CD102 313_

overshooting sheets.

Paper

Given a continuous sheet flow, an overshooting sheet exists if one of the FK sensors detects paper at press angle 3. The feeder and press stop immediately. The shingled sheets remain on the feed table.

Overshooting sheet

Note: The press can be started again from the feeder even if the FK sensor still detects the sheet of paper after the fault message Overshooting sheet. The press stops as soon as the pushbutton Production run or the illuminated pushbutton Feeder ON is pressed.

Extended functions
The extended functions are only active with the inductive double-sheet detector of SM52 and SM74. During paper transport: The control system monitors the paper transport on the feed table. For this purpose, the control system needs the signal from the FK sensor and the measuring result of the double-sheet detector. If during paper run the FK sensors do not detect a sheet being fed in although the double-sheet detector has registered a good sheet (no double-sheet), the control system switches the feeder off. There is probably a paper jam on the feed table. In the case of a double-sheet: The control system stops the press immediately (emergency stop) if the FK sensors detect paper in the case of a double-sheet. Thus no multiple sheets are fed into the press.

213

Sheet alignment

1B13/1B49 Sheet alignment control

Misaligned-sheet display (trend display)


During paper run or production run, the misalignedsheet display appears on the MID. This display changes permanently and is a trend indication for the operator. The misaligned-sheet display does not intervene in press control. The ANK sensors of the sheet alignment control detect the misaligned sheet at the front lays. This misalignment between the drive side (D.S.) and operator side (O.S.) is determined and converted into a degree value. The degree value is represented as a line symbol on the MID (see ill.). The display is only visible if no settings and adjustments, fault messages, malfunctions or other information

Display of misaligned sheet. Drive side advanced.

Good sheet Optimum sheet arrival Misaligned sheet, D.S. advanced Display of misalignment up to max. 18 Misaligned sheet, O.S. advanced Display of misalignment up to max. 18

are indicated on the MID.

Note: The fault message Misaligned sheet and the misaligned-sheet display are not identical.

214

Sheet alignment

1B13/1B49 Sheet alignment control

Place of installation
The sensors of the sheet alignment control are located at the front lays.

1B13 1B49

Place of installation of sheet alignment control

Layout and task


Running direction of paper FK ANK Reflex sensor Amplifier

The reflex sensors on the drive side and operator side of the sheet alignment system serve for paper detection. Each reflex sensor has two optical sensors ANK and FK monitoring the sheet alignment. The FK and ANK sensors are fitted in a housing. Viewed in the running direction of the paper, the paper first covers the ANK sensor. ANK = sensor for sheet alignment control FK = sensor for overshooting sheet control In the amplifier of the reflex sensor, the sensor signals are amplified and transmitted to the electronic control system. The amplifiers of the two reflex sensors are located at the side frame on the O.S., under the feed table.

X2

X1 To 1LVT1

Reflex sensor with amplifier

Pin assignment
ground free +24K FK+ ANK+ free ANK FK

Pin assignment 1B49:X1/1B13:X1

215

Sheet alignment

1B13/1B49 Sheet alignment control

Removal and installation

2
1/21

Position the press: SM102: 100 3 degrees CD102: 70 3 degrees

Loosen the fixing bolt on the brass block (1/21 rev.).

O.S. D.S.

Pull off the reflex sensor with the brass block towards the front.

Remove the amplifier.

216

Sheet alignment

1B13/1B49 Sheet alignment control

Disconnect the cable leading to 1LVT1.

Remove the reflex sensor.

7
2 1

Slide the new reflex sensor into the guide of the holder.

Note: To fix the reflex sensor in position, carefully tighten the fixing bolt (tightening torque approx. 1 Nm).
Tighten the fixing bolt.

Turn the handwheel anticlockwise until the end stop comes to rest on the cross bar.

217

Sheet alignment

1B13/1B49 Sheet alignment control

10

O.S.

D.S.

Connect the cable coming from 1LVT1 to the amplifier.

Fasten the amplifier.

11
1.5 2.0 mm

12

Push the reflex sensor and brass block on the guide pins through to the stop. Check the distance (1.5 2.0 mm).

Tighten the fixing bolt on the brass block.

218

Sheet alignment

1B13/1B49 Sheet alignment control

Adjustment

1
0

Bring the bending in the 0 position. Press the pushbutton Forward until the sheet stop fingers are raised.

Position the press: SM102: 333 1 degree CD102: 310 1 degree

Turn the handwheel anticlockwise until the end stop comes to rest on the cross bar.

219

Sheet alignment

1B13/1B49 Sheet alignment control

Turn the handwheel back by one revolution.

Place a sheet of paper of max. width (102cm) and approx. 20cm length against the front lays.

MID

MID

D.S. O.S.

D.S. O.S.

Turn the adjusting screw until the ANK symbol on the MID just lights up.

Turn the adjusting screw until the ANK symbol on the MID just lights up. Both ANK symbols on the MID must be lit.

220

Sheet alignment

1B13/1B49 Sheet alignment control

10

2 1/6

Turn the handwheel clockwise for 1.3 mm +/0.1 mm (2 1/6 revs), using the scale as a reference.

Both ANK symbols must be lit. The FK symbols must not be lit.

11

1.3 mm +/ 0.1 mm FK ANK Front lay

MID

10 mm Paper

D.S. O.S.

Check the distance between the front lays and ANK sensor.

221

Sheet alignment

1B13/1B49 Sheet alignment control

Checking the circuit state


1B13 in the service display of the EAK: Input 13 = ANK (O.S.) Input 15 = FK (O.S.) 1B49 in the service display of the EAK: Input 49 = ANK (D.S.) Input 51 = FK (D.S.) 1 0 = sensor detects paper = sensor does not detect paper

Service display Present input/output, input/output board EAK

222

Sheet alignment

1B9/1B10 Pull lay control

1B9/1B10 Pull lay control Block diagram


The pull lay control (ZMK) monitors the entire pull procedure, i. e. the correct sheet infeed and the pull end position. The following applies to the degrees listed (see block diagram): At 4 and paper run: the ZMK must not detect any paper. At 5 and paper run: the ZMK and ANK must detect paper. At 5 and no paper run: the ZMK signal is not analyzed because the sheet alignment control does not detect paper.

ZMK
SM52 330_ SM74 15_ SM102 311_ CD102 289_ SM52 42.5_ SM74 72_ SM102 3_ CD102 341.5_ Paper

1B9/1B10

Interrogation points

Pull lay control D.S. 1B9 O.S. 1B10 Audible signal device 12 H 55 SUM1 RL12 SUM1 RL12 Audible signal device 11 H 55

The reflex sensors on the drive and operator sides serve for paper detection. Depending on the pull direction only one of the two reflex sensors is necessary for monitoring. The pull direction is entered under the command Presetting. Only the reflex sensor of the active pull lay is interrogated. In the signal conversion modules SUM 1 the signals of the reflex sensors are amplified. The circuit state of each sensor is signalled by an LED on the corresponding SUM 1 (LED is lit = reflex sensor detects paper). SM52 only: On SM52 the signals are amplified by the amplifiers of the reflex sensors RL12.

1 LVT 1 1EVM4

12 LVT 1 12EVM4

11 LVT 1 11EVM4

EAK 1

EAK 12

EAK 11

Displays MID12 MID11 ZID

The electronic control system evaluates the signals of the signal conversion modules. The signals from the amplifiers reach the processor board REK2 via the distribution box 1LVT1, the input/output distributor module EVM (SM52 only), the input/ output board EAK, the input/ output control board ESK.

ESK

SVM

DNK DSK

REK2 Legend: Data line Control lines

Block diagram of pull lay control


223

Sheet alignment

1B9/1B10 Pull lay control

The REK2 analyzes the signals of the pull lay control. In the case of a pull or sheet infeed error, it passes the fault message to the control console display ZID, the press displays MID and the audible signal devices 11H55 and 12H55. For an acoustic fault message to be output, the function Audible signal device / pull lay control must be switched on in the central control console. D.S. Circuit states of the ZMK sensors on the MID

Display of pull lay control

O.S.

Circuit states displayed on the MID

With the help of the MID on the control panel of the feeder, the reflex sensors 1 B9 and 1 B10 can be monitored. The MID reflects the circuit state of the corresponding sensor. Symbol lit Symbol not lit = sensor detects paper = sensor does not detect paper

The circuit states of the reflex sensors are visible when the switch Safe on the control panel of the feeder is set to Safe and the printing speed is x 3500 i.p.h.

When does a sheet infeed error/pull error exist?


ZMK SM52 330_ SM74 15_ SM102 311_ CD102 289_ Paper

A sheet infeed error exists if the sheet is already below the reflex sensor at the interrogation point. The sensor detects paper.

Sheet infeed error

224

Sheet alignment

1B9/1B10 Pull lay control

ZMK SM52 42.5_ SM74 72_ SM102 3_ CD102 341.5_ 1B13/1B49 1B9/1B10 Paper

A pull error exists if, at the interrogation point: the ANK sensors (1B13/1B49) detect the print sheet and the ZMK sensor does not detect the print sheet.

Pull error

225

Sheet alignment

1B9/1B10 Pull lay control

Place of installation
The pull lays with the reflex sensors are fitted on two cross bars in front of the transfer gripper drum. One pull lay is fitted on the operator side (1B10) and one on the drive side (1B9).

1B9 1B10

Place of installation of pull lays

Signal conversion modules SUM1

Under the feed table, the two signal conversion modules SUM1 are fitted on a support bar. Each is allocated to one of the pull lays.

Place of installation of signal conversion modules

226

Sheet alignment

1B9/1B10 Pull lay control

Adjustment (Preset version)


The adjustment must be made: for the first start-up when changing the printing material (paper) in the case of frequent fault messages. Enter the required sheet width in the command mode Presetting. After command enabling, the control system positions the pull lay to the entered format. Set the selector switch Safe on the control panel at the feeder to Safe. Press the illuminated pushbutton Feeder, so that the button is lit. Press the pushbutton Forward until the sheet stop fingers are raised. Press the pushbutton Forward until the pull lay stop is below the upper edge of the sheet metal plate. The pull rail must not have grabbed the sheet yet. The sheet can still be moved. Pull the sheet against the pull lay stop; the paper must be under the reflex sensor 1. Turn the knurled head screw 2 clockwise, until the green LED at the corresponding signal conversion module goes off. Turn the knurled head screw 2 anticlockwise, until the green LED just lights up. Turn the knurled head screw 2 anticlockwise for another 10 notch positions (= 0.3 mm; corresponds to approx. 1/4 rev. of 2). Take out the sheet. The LED of the reflex sensor goes off.

2 3

5
Adjustment of pull lays
a) b) Pull direction of sheet of paper Running direction of paper

6 7 8

c) Edge for format adjustment

227

Sheet alignment

1B9/1B10 Pull lay control

Adjust the spring pressure with the knurled head screw 3. The pressure the pull roll exerts on the printing material must be so strong that each sheet is pulled reliably to the pull lay stop. The locking nut 4 prevents the pressure from changing once it has been set. Reflex sensor Knurled head screw Knurled head screw Locking nut

1 2 3 4

Adjustment of pull lays

228

Sheet alignment

1B9/1B10 Pull lay control

Adjustment (standard version)


1 mm The adjustment must be made: a b for the first start-up when changing the printing material (paper) in the case of frequent fault messages. Loosen the tommy bar screw 1 and position the pull lay so that it complies with the sheet size at the feeder. Move the magnet cover plate 2 with recess until it is approx. 1mm away from the pull lay stop 3.

1 2

Note: The pull lay stop must not lie on the magnet cover plate while the paper is being pulled.

3
+ -

Set the selector switch Safe on the control panel at the feeder to Safe. Press the illuminated pushbutton Feeder, so that the button is lit. Press the pushbutton Forward until the sheet stop fingers are raised. Press the pushbutton Forward until the pull lay stop is below the upper edge of the sheet metal plate. The pull rail must not have grabbed the sheet yet. The sheet can still be moved. Pull the sheet against the pull lay stop; the paper must be under the reflex sensor 4. Loosen the knurled head screw bit.

4
c

5
Adjustment of pull lays
a) b) Pull direction of sheet of paper Running direction of paper

6 7 8 9

c) Edge for format adjustment

5 a little

Turn the knurled head screw 6 clockwise, until the green LED at the corresponding signal conversion module goes off. Turn the knurled head screw 6 anticlockwise, until the green LED just lights up. Turn the knurled head screw 6 anticlockwise for another 14 notch positions (= 0.4 mm; corresponds to approx. 1/4 rev. of 6).

229

Sheet alignment

1B9/1B10 Pull lay control

q w e

Retighten the knurled head screw 5. The LED of the corresponding reflex sensor must still be lit. Take out the sheet. The LED of the reflex sensor goes off. Adjust the spring pressure with the knurled head screw 8. The pressure the pull roll exerts on the printing material must be so strong that each sheet is pulled reliably to the pull lay stop. The locking nut 9 prevents the pressure from changing once it has been set.

Pull lay

Checking the sensing distance of the reflex sensors


This check must be carried out: . for the first start-up in the case of frequent fault messages.

The distance between the lower edge of the reflex sensor and the surface of the magnet cover plate 2 must be 4.5 5 mm. When fitting the reflex sensor pay attention to this.

Sensing distance

1 2 3 4 5

Tommy bar screw Magnet cover plate Pull lay stop Reflex sensor Knurled head screw

6 7 8 9

Knurled head screw Paper Knurled head screw Locking nut Lower edge of reflex sensor

230

Sheet alignment

1B11 Double-sheet detector

1B11 Double-sheet detector Block diagram


Optical sensor system Transmitter 1B11S Receiver 1B11E The double-sheet detector monitors sheet infeed at the feeder. It detects multiple sheets and irregularities in the sheet flow and thus prevents malfunctions. An optical sensor system consisting of a transmitter (1 B11 S) and a separate receiver (1 B11 E) transmits light through the paper. The receiver supplies a signal. The amplitude of the signal depends on the thickness and nature of the printing material. The control device DBE supplies the optical sensor system with operating voltage. Apart from this, the control device helps to process the sensor signal and to adjust the double-sheet detector to the printing material used. Shortly before the sheet enters the first printing unit, the electronic control system checks the amplitude of the signal supplied by the receiver. Monitoring occurs at the following press angles: EAK 1
ZID

Control device DBE 1LVT1


Displays MID12 MID11

336 _ (SM102), 313_ (CD102).

DNK

If the light does not pass through the paper at this point, there are two or more sheets. The signal reaches the processor board REK2 via the distribution box 1 LVT1, the input / output board EAK, the input / output control board ESK.

ESK

SVM

DSK

REK2

Legend:

Data line Control lines

Block diagram of double-sheet detector

The REK 2 analyzes the signals from the doublesheet detector. If there is a double-sheet, REK 2 stops the feeder. The electronic control system reduces the press speed to 3 000 i.p.h. Simultaneously, REK 2 transmits a fault message to the control console display ZID and the press displays MID.

231

Sheet alignment

1B11 Double-sheet detector

Fault messages in the case of a double-sheet


Press display MID The fault symbol # appears under the pictogram for double-sheet.

MID after detection of a double-sheet


Selection Control console display ZID Selection of the display Entire press (production run display). Symbol Double-sheet detector The symbol Double-sheet detector appears if the sensor 1B65 or 1B66 detects a double-sheet.

Selection and symbol


Selection Selection of the display Feeder / warning

Symbol Electronic double-sheet detector

The symbol Electronic double-sheet detector appears if the sensor 1B65 or 1B66 detects a double-sheet.

Selection and symbol

232

Sheet alignment

1B11 Double-sheet detector

Place of installation
The control device of the double-sheet detector is fitted near the signal conversion modules at the sheet alignment system.

Control device

Control device of double-sheet detector


The sensor is fitted on the press centreline in the area of the front lays.

Sensor of double-sheet detector

Sensor of double-sheet detector

233

Sheet alignment

1B11 Double-sheet detector

Layout

Components of double-sheet detector

1 2 3 4

Control device of double-sheet detector DBE with operators controls 1 B11 S Transmitter with connecting cable and fixing bracket 1 B11 E Receiver with connecting cable and fastening element Cable to distribution box 1LVT1 at PU 1. It comprises: the power supply for the control device DBE (+ 24 V) the signal line from the control device DBE to the electronics. Potentiometer for adjustment of sensitivity

6 7

The LED lights up as soon as there are two or more sheets. Selector switch for adjustment of paper thickness

Paper thick

Control device off

Paper thin

234

Sheet alignment

1B11 Double-sheet detector

Connection and pin assignment

X1

1LVT1 at PU1 1B11 Transmitter

Control device

X2

X3 1B11 Receiver

Connection principle
Pin assignment of connector X1: Contact no. on X 1 1 2 3 4 5 Function Ground 24 V +24 V Signal Core identification 1 +1 XE 11 Terminal in LVT X2: 1 X2: + 1 FEM 64 XE 11

235

Sheet alignment

1B11 Double-sheet detector

Removal and installation


The transmitter and receiver are each screwed to the fastening elements with one screw. Each fastening element is held in place by two screws. The distance between transmitter and receiver must be between 8 mm 12 mm.

Note: The upper edge of the receiver 1 B11 E must be flush with the table edge.
The transmitter and receiver must be in perfect alignment, i.e. arranged on the same centreline. The control device is screwed to the fixing bracket with 3 screws. The fixing bracket is screwed to the press with two screws.

Components of double-sheet detector

1 2 3 4 5 6 7

Receiver 1 B11 E Transmitter 1 B11 S Fastening element for receiver Fastening element for transmitter Screws for fastening element Fixing bracket for control device Screws for fixing bracket

236

Sheet alignment

1B11 Double-sheet detector

Adjustment Attention:
The adjustment must be carried out: each time the printing material changes, if printed sheets are printed on again.

Prerequisite for adjustment: press ready to run, paper run possible.

1 2

Check the distance between the transmitter and receiver: required distance 8 12 mm. The receiver does not jut out from the table edge. Position the press to a press angle of 281 1 degrees (CD102) or 304 1 degrees (SM102) and place a sheet of maximum width against the front lays and pull lay stop. Set the selector switch for paper thickness 0 to and turn the potentiometer anticlockwise to the stop. The LED is lit. Turn the potentiometer slowly clockwise and watch the LED :

if..

.. LED

goes off:

.. LED

does not go off:

Continue turning the potentiometer clockwise for another 10 scale marks. Continue with

5 6 7

8.

Set the selector switch 0 to and turn the potentiometer anticlockwise to the stop. Turn the potentiometer clockwise until the LED goes off. Continue turning the potentiometer clockwise for another 10 scale marks.

Check the functioning of the double-sheet detector with a simulated double-sheet.

237

Sheet alignment

11M3 Automatic sheet arrival control

11M3 Automatic sheet arrival control


possible sheet arrival BAK optimum sheet arrival 285_ 222_ 192_ 200_ 170_ 303_ 238_ 208_ 216_ 186_ 330_ SM74 336_ SM102 336_ SM102 with Preset 313_ CD102 313_ CD102 with Preset

The automatic sheet arrival control influences the transport of the sheets to the front lays. It regulates the shingle stream in such a way that the individual sheets are positioned against the front lays at a certain press angle (see illustration). By means of a servo-drive (11M3) the drive chain of the feeder is adjusted. Thus the point of time of sheet arrival is controlled.

Point of time of sheet arrival


Sheet alignment control D.S. 1B13 O.S. MID11 1B49 MID12 RL12 RL12 DNK DSK ZID Displays

1LVT1

The ANK sensors (1B13/1B49) register when the sheets arrive at the front lays. On the basis of the ANK signals the computer on the processor board REK2 determines the point of time of sheet arrival. If there is a deviation from the optimum sheet arrival, the shingle stream at the feeder must be regulated. REK2 passes the new reference values for sheet arrival to the servo-drive control board SSK. The SSK controls the servo-drive 11M3. If the automatic sheet arrival control reaches the end of its control range in the process, the symbol End of positioning range appears on the press displays MID and on the control console display ZID (production run display). The press control is not affected by this.

EAK

ESK

SVM

SSK

SAK
1SSM1

REK2

11M3

M Automatic sheet arrival control

Legend:

Data lines Control lines

Block diagram of automatic sheet arrival control

238

Sheet alignment

11M3 Automatic sheet arrival control

The symbol End of positioning range will, however, only disappear when the operator repositions the servo-drive manually. This can be done at the control console by means of the Sheet arrival control function.

End of positioning range displayed on the press display MID

Activating and inactivating the automatic sheet arrival control

Selecting the automatic sheet arrival control

Symbol Automatic sheet arrival control on / off

Inactivating and activating the automatic sheet arrival control: in the preselection display, by means of the function button.

If the symbol is lit, the automatic sheet arrival control is active.

Preselection/coarse display

Sheet arrival control


The sheet arrival control is automatically activated when the operator switches off the automatic sheet arrival control. Symbol of the sheet arrival control in the ... actual value / coarse display For the sheet arrival control the operator enters a fixed value. The setting is made at the control console by means of the right-hand +/buttons. Press model actual value / fine display SM102 CD102 SM74 Setting range Standard Preset version version 2 to +18 10 to +10 10 to +10 4 to +16

239

Sheet alignment

11M3 Automatic sheet arrival control

Graphical representation of sheet arrival


The graphical representation of sheet arrival is only visible during paper run.

Selecting the fine display


Deviation from optimum sheet arrival D.S. Mean value of the two deviations Deviation from optimum sheet arrival O.S.

Note: The display is updated with a delay. Actual value/fine display


The misaligned-sheet display on the MID gives the operator information about sheet arrival. Optimum sheet arrival Sheet arrives at the front lays before the optimum sheet arrival

Misaligned-sheet display

Sheet arrives at the front lays after the optimum sheet arrival

240

Sheet alignment

11M3 Automatic sheet arrival control (standard version)

11M3 Automatic sheet arrival control (standard version) Place of installation

Printing unit 1 and feeder

Technical data
Motor data U P = = DC 24 V 5 W

Potentiometer data U R = = DC 10 V 10 KW

241

Sheet alignment

11M3 Automatic sheet arrival control (standard version)

Interconnection diagram
X10 X5

SSR

SSR X10
X11 X12 X3 X13 X14 X4

SSR X11

11 11

Backplane of servo-drive plug-in unit SSR

1SSM2: X1

11LVT1

1SSM2: X2
X1 X3 X2

1SSM2

Servo-drive distributor module 1SSM2

11M3: X1

3 2

4 5 1

11M3

Servo-drive 11M3
11M3:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 1SSM 1 X5: A1 X5: A2 X5: A3 X5: A4 X5: A5 SSR X10: B2 X10: D2 X11: 3 X11: 4 X11: 5 SIGNAL Motor + Motor 10V Tap

+ 10V 0V

X1: X1: X3: X3:

1 2 3 4

X3: 5

242

Sheet alignment

11M3 Automatic sheet arrival control (standard version)

Removal and installation

1
1
0 1

2 2 1

4
1

3 1 2

243

Sheet alignment

11M3 Automatic sheet arrival control (standard version)

5
2

1 2 mm

7
1

8
3 2 1

22 5 4
0 1

244

Sheet alignment

11M3 Automatic sheet arrival control (standard version)

10

11

12

2 1 1

245

Sheet alignment

11M3 Automatic sheet arrival control (standard version)

13

Checking the operating range 1


Servo-drive Automatic sheet arrival control 11M3 Input + 18 2 Incremental value 3134 " 4 inc 963 " 4 inc

Service display Values, incremental values servo-drives

246

Sheet alignment

11M3 Automatic sheet arrival control (Preset version)

11M3 Automatic sheet arrival control (Preset version) Place of installation

11M3

Operator side

Technical data
Motor data U P = = DC 24 V 5 W

Potentiometer data U R = = DC 10 V 10 KW

247

Sheet alignment

11M3 Automatic sheet arrival control (Preset version)

Interconnection diagram
X10 X5

SSR

SSR X10
X11 X12 X3 X13 X14 X4

SSR X11

11 11LVT1 1SSM1: X1
X3 X4

Backplane of servodrive plug-in unit SSR

X2 X1 X5

1SSM1: X3

1SSM1

Servo-drive distributor module 1SSM1

11M3: X1

3 2

4 5 1

11M3

Servo-drive 11M3
11M3:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 1SSM 1 X5: A1 X5: A2 X5: A3 X5: A4 X5: A5 SSR X10: B2 X10: D2 X11: 3 X11: 4 X11: 5

+ 10V 0V

X1: X1: X3: X3:

1 2 3 4

X3: 5

248

Sheet alignment

11M3 Automatic sheet arrival control (Preset version)

Removal and installation

2
1 2
2.0 mm (approx. 1 rev.)

Remove the servo-drive Automatic sheet arrival control 11M3.

Turn the mechanism against the upper stop. Set the distance ( 2.0 mm ).

01

3891 2 11M3: X1

Fasten the servo-drive to the mounting plate. Insert plug 11M3: X1. Set to 3891"2 inc. 249

Sheet alignment

11M3 Automatic sheet arrival control (Preset version)

Install the servo-drive.

Checking the operating range 1


Servo-drive Automatic sheet arrival control 11M3 Input + 10 10 Incremental value 205 " 4 inc 3891 " 4 inc

Service display Values, incremental values servo-drives

250

Sheet alignment

11M7 Automatic misalignment control

11M7 Automatic misalignment control


Sheet alignment control D.S. 1B13 O.S. MID11 1B49 MID12 RL12 RL12 ZID DNK DSK Displays

The automatic misalignment control influences the position of the sheets in such a way that they arrive parallel to the front lays. Automatic control is effected through: the servo-drive 11M7, the guide rail (D.S.) of the forwarding suckers at the suction head. by the ANK sensors on the D.S. and O.S.

The misalignment is registered:


1LVT1

The deviation between the registered values is an indication of the misalignment of the sheets in relation to the front lays (not to the feed table). EAK ESK
SVM

If the misalignment exceeds three degrees, the automatic control compensates for the deviation. The automatic misalignment control does not intervene in press control.

SSK

SAK
1SSM1

REK2

11M7

M Automatic misalignment control

Legend:

Data lines Control lines

Block diagram of automatic misalignment control


Position of guide rail D.S. at suction head Position of sheet Front lays O.S. D.S.

The graphical representation on the left shows the mechanical principle of the misalignment correction.

Principle of the misalignment correction


251

Sheet alignment

11M7 Automatic misalignment control

Activating and inactivating the automatic misalignment control

Selecting the automatic misalignment control

Symbol Automatic misalignment control on / off

Inactivating and activating the automatic misalign ment control: in the preselection display, by means of the function button.

If the symbol is lit, the automatic misalignment control is active.

Preselection/coarse display

Misalignment control
The misalignment control is automatically activated when the operator switches off the automatic misalignment control. Symbol of the misalignment control in the ... actual value/coarse display actual value/fine display For the misalignment control the operator enters a fixed value. The setting is made at the control console by means of the right-hand +/ buttons. Setting range Press model SM102 CD102 10 to +10 10 to +10

252

Sheet alignment

11M7 Automatic misalignment control

Graphical representation of sheet arrival

Selecting the fine display


The graphical representation of sheet arrival also gives the operator information about the misalignment of the sheets during paper run. Deviation from optimum sheet arrival D.S. Mean value of the two deviations Deviation from optimum sheet arrival O.S.

Actual value/fine display Note: The display is updated with a delay.

During paper run or production run, the misalignedsheet display appears in the MID. This display changes permanently and is a trend indication for the operator. Good sheet optimum sheet arrival Misaligned sheet, D.S. advanced Display of misalignment up to max. 18 Misalignedsheet display Misaligned sheet, O.S. advanced Display of misalignment up to max. 18

253

Sheet alignment

11M7 Automatic misalignment control

Place of installation

11M7

Preset feeder

Technical data
Motor data U P = = DC 24 V 5 W

Potentiometer data U R = = DC 10 V 10 KW

254

Sheet alignment

11M7 Automatic misalignment control

Interconnection diagram
X10 X5

SSR

SSR X10
X11 X12 X3 X13 X14 X4

SSR X13

11 11LVT1 2SSM1: X1
X3 X4

Backplane of servodrive plug-in unit SSR

X2 X1 X5

2SSM1: X3

2SSM1

Servo-drive distributor module 2SSM1

11M7: X1

3 2

4 5 1

11M7

Servo-drive 11M7
11M7:X1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 2SSM 1 X5: A1 X5: A2 X5: A3 X5: A4 X5: A5 SSR X10: X10: X13: X13:

+ 10V 0V

X1: X1: X3: X3:

1 2 3 4

B10 D10 3 4

X3: 5

X13: 5

255

Sheet alignment

11M7 Automatic misalignment control

Removal and installation

O.S. D.S. O.S. D.S.

Guide rails Remove the servo-drive Automatic misalignment control 11M7. Position the guide rails of the forwarding suckers parallel to each other.

3
4)

05

2048 2

11M7: X1 256 Insert plug 11M7: X1. Set to 2048 2 inc.

Sheet alignment

11M7 Automatic misalignment control

Install the servo-drive.

Checking the operating range 1


Servo-drive Automatic misalignment control 11M7 Input 10 +10 Incremental value 1434 " 2 inc 2662 " 2 inc

Service display Values, incremental values servo-drives

257

Sheet alignment

11M7 Automatic misalignment control

258

Sheet monitoring

1...nB48/1...nB48a Sheet travel monitor

Sheet monitoring
1...nB48/1...nB48a Sheet travel monitor
The sheet travel monitor Paper run Reflex sensor 1...9B48 Paper Control switch 1...9B48a Segment disk Impression cylinder monitors the paper run, is fitted in each printing unit, consists of: the reflex sensor 1...9B48, the control switch 1...9B48a, the segment disk for the control switch.

The reflex sensor detects the front edge of the paper at the impression cylinder. The control switch and the segment disk determine the point of time of the interrogation. The signals from the reflex sensor and control switch are combined in the reflex sensor and transmitted to the control system. Signals during paper run (see illustration): The segment disk is within the operating range of control switch 1...9B48a. At the same time, the reflex sensor 1...9B48 detects the front edge of the paper. The LED on the reflex sensor 1...9B48 is lit. No signal to the control system.

LED

Irregularity in paper run No paper

LED 1 LVT1
Displays MID12 MID11 ZID

Signals in the case of irregularities in the paper run (see illustration): The segment disk is within the operating range of control switch 1...9B48a. At the same time, the reflex sensor 1...9B48 does not detect paper. The LED on the reflex sensor 1...9B48 is not lit. Signal to control system. REK2 intervenes in press control.

EAK 1
DNK

ESK

SVM

DSK

REK2

Legend:

Data line Control lines

Block diagram of sheet travel monitor


259

Sheet monitoring

1...nB48/1...nB48a Sheet travel monitor

The electronic control system analyzes the signals from the reflex sensor as long as there is paper in the press. Via the input/output board EAK of the corresponding printing unit and the input/output control board ESK the signals are transmitted to the processor board REK2. In the case of a fault, REK2 intervenes in press control and triggers various processes: press and feeder stop, dampening systems and inking units are thrown off, impression throw-off, display of fault at printing unit, in press displays MID and control console display ZID.

In the MID, the position code of the corresponding printing unit appears under the fault symbol.

Fault display in MID


Fault display in production run display (ZID) Symbol Blanket control detects paper (fault display in ZID) In the ZID (production run display), the fault symbol appears with the corresponding position code. Simultaneously, the symbol Blanket control detects paper appears in the fault display. The fault can be acknowledged and deleted by pressing the button allocated to the symbol. The fault is eliminated: after removing the sheet from the base or after removing the piece of sheet from the blanket and after lifting the guard Plate cylinder.

The electronic control system allows the press to continue running.

260

Sheet monitoring

1...nB48/1...nB48a Sheet travel monitor

Service display
To check the input 48, select the service display Present input/output (e.g. EAK2_02) of the corresponding printing unit. Buttons to be pressed for this selection:

1)

2)

3)

4)

Service display EAK2_02 of PU2

Circuit state of input 48: 1 = reflex sensor detects paper, no signal to the control system. 0 = reflex sensor does not detect paper, signal to control system.

Input 48 (sheet travel monitor 1...9B48)

261

Sheet monitoring

1...nB48/1...nB48a Sheet travel monitor

Place of installation
1...nB48 (middle of press) 1...nB48a (operator side)

Impression cylinder in printing unit

Speedmaster CD operator side

262

Sheet monitoring

1...nB48/1...nB48a Sheet travel monitor

Components
Reflex sensor 1...nB48

Reflex sensor 1...nB48 detects does not paper detect paper 24V LED (LED lit) 0V (LED not lit) 3 4 2 1

ca. 24V

0V

Reflex sensor
Control switch 1...nB48a

Control switch

Adjustment
Adjustment of reflex sensor 1...nB48

Adjustment of control switch 1...nB48a

263

Sheet monitoring

1...nB48/1...nB48a Sheet travel monitor

1...nB48

70 1 mm Remove reflex sensor 1...nB48. Fit the reflex sensor and insert the plug. Set the distance (70 1 mm) between the reflex sensor and impression cylinder.

4
1.0_

LED LED LED

Turn the impression cylinder in the direction of printing (see arrow) so that the LED just lights up (reflex sensor detects cylinder surface).

Turn the impression cylinder back by 1.0 (see arrow). The LED is not lit.

1...nB48a 1...nLVT1 Remove control switch 1...nB48a. Withdraw the plug from 1...nB48. Fit the control switch and connect it with the reflex sensor (see circuit diagram).

264

Sheet monitoring

1...nB48/1...nB48a Sheet travel monitor

7
1...nB48a Segment disk 0.8 1.0 mm

The segment disk must run in the middle of the recess and must not contact the control switch. Pay attention to both segments.

Select the service display Present input/ output of the corresponding printing unit.

Direction of printing

2) 1

1) Loosen the segment disk. Turn the segment disk in the direction of printing until input 48 changes from 1 to 0. Fasten the segment disk. Check the adjustment.

265

Sheet monitoring

1...nB48/1...nB48a Sheet travel monitor

266

Plate clamping device

Autoplate

Plate clamping device


Autoplate Method of functioning
The main components of Autoplate are: a modified plate cylinder with air supply and two pneumatic bars to open the front and rear clamping bars, a pressing bar which is brought into contact with the plate cylinder by two cylinders, two position switches which monitor the position of the pressing bar, four pneumatic valves which actuate the pneumatic bars, the two cylinders of the pressing bar and the control air for the air supply.

For actuation of the cylinders an operating pressure of approx. 6 bars is required. This pressure is generated by the pneumatic system compressor E4 and is kept at a constant level by the maintenance unit. The compressor is switched on after Main switch on.

Air supply, connections: S Control air, air supply 1 Opening the rear clamping bar 2 Opening the front clamping bar Control panel Pressing bar Position switch Finger guard 2: n S 25 a Monitoring the pressing bar D.S. n S 25 b Monitoring the pressing bar O.S. Pneumatic n Y7 n Y 61 n Y 62 n Y 63 valves from top to bottom: Pressing bar on / off Control air, air supply Opening the front clamping bar Opening the rear clamping bar

2 3 4 5

Operator side of printing unit

Note: Before the rear or front clamping bar is opened, control air must be admitted to the air supply facility in the plate cylinder. For this purpose, the plate cylinder must be at standstill; otherwise the gaskets could become subject to abrasion. This, in turn, could cause unintentional venting of the control line. Then the rear and front clamping bars cannot be opened anymore.
267

Plate clamping device

Autoplate

Fault display

Button sequence

The pressing bar and / or the upper finger protecting bar was actuated. The following position switches can be actuated: Monitoring the pressing bar n S 25 a (drive side) n S 25 b (operator side), Monitoring finger guard 2 n S 25 (operator side).

Malfunctions in 2nd printing unit

268

Plate clamping device

Autoplate

Block diagram
E4 n Y7 n Y 61 n Y 62 n Y 63

n S4

n S17

n S59 n H59

n S 25a / n S 25b

EAK15

EAKn

SEK

REK1 DSK DNK ZID REK2

ESK

Legend: Parallel data line Serial data line

SAK

Control line Pneumatic line

Electronic control system

Block diagram Autoplate


E4 n Y7 n Y61 n Y62 n Y63 n S4 n S17 Pneumatic system compressor Pneumatic valve Pressing bar on / off Pneumatic valve Control air, air supply Pneumatic valve Opening the front clamping bar Pneumatic valve Opening the rear clamping bar Selector switch Safe Pushbutton Position

n S59 / n H59 Illuminated pushbutton Plate clamping n S25 a / b Position switch Monitoring the pressing bar D.S./O.S. 269

Plate clamping device

Autoplate

Sequence of functions
The indicated press angles are valid for printing unit 1. From unit to unit these values differ as follows: Speedmaster SM 102 74.57 _ , Speedmaster CD 102 197.28 _.

Condition: The plate cylinder will only turn to the correct position for plate clamping/unclamping, if the coarse register is set to zero or if the coarse register sensor n B53 has acquired the current press angle (see also chapter Coarse register monitoring).

Positioning the plate cylinder

Unclamping the rear edge of the plate

Plate removal

Unclamping / clamping the front edge of the plate

Plate insertion

Clamping the rear edge of the plate

Actuation of operators controls:

Opening the rear clamping bar n Y63 actuated

0.3 s

0.3 s

2.0 s
Opening the front clamping bar n Y62 actuated

0.3 s 1.0 s

2.0 s
Air supply control air n Y61 actuated

0.5 s
Enabling main motor

2.0 s

0.5 s
Enabling main motor

Enabling main motor

0.5 s 1.8 s
Pressing bar on / off n Y7 actuated Press angle

0.5 s

264.8 _

322.6 _

297.5 _

270

Plate clamping device

1...nB53 Coarse register monitoring

1...nB53 Coarse register monitoring Place of installation


The sensor Coarse register monitoring B53 is fitted in each printing unit. It is located behind the servo-drive of the circumferential register where it is screwed to a fixing angle.

B53

Place of installation of sensor Coarse register monitoring

Layout/connection 1 2 3
Sensor Locking nut Connecting cable Function DC 24V ground 24V output signal

Core brown blue black

Layout of sensor Coarse register monitoring 1...nB53

271

Plate clamping device

1...nB53 Coarse register monitoring

Task/function 1 2
Positioning bolt Sensor B53

Sensor and positioning bolt

The inductive sensor 1...nB53 registers the manual coarse adjustment of the circumferential register. After each coarse adjustment of the circumferential register, the operator must turn the press at crawl speed for at least one full revolution. Only then can the sensor register the adjustment and pass the corresponding adjustment value on to the press control system. While the press turns at crawl speed, the sensor sees the positioning bolt rotating past it. The zero position of the plate cylinder serves as a reference point for the sensor. If the sensor detects a deviation from the reference point with the help of the positioning pin, the value is passed on to the press control system. The deviation corresponds to the coarse adjustment of the register. The press control system determines the press angle on the basis of the adjustment value. Thus exact positioning of the plate cylinder is possible again (e.g. important for the function Autoplate).

Note: To ensure that the sensor recognizes the manual coarse adjustment of the register, the press must turn at crawl speed for min. 1 revolution after every adjustment.

Removal and installation 1 2


Positioning bolt Sensor B53

1.0 mm 0.5 mm

The sensor must be installed in such a way that there is a distance of 1 mm 0.5 mm between the positioning bolt and the sensor. Tighten the sensor with the locking nut and carry out the Adjustment (see next page).

Fitting the sensor "Coarse register monitoring

272

Plate clamping device

1...nB53 Coarse register monitoring

Adjustment
Note: The adjustment is necessary after every:
installation and removal of the sensor, exchange of the software, exchange of the processor boards REK 1 / 2 and of the display control board DSK, basic initialization of REK 1 / 2 and DSK, first start-up. Set the circumferential register on all printing units manually to 0. Insert the positioning bolt at 52 mm 1. Also refer to the operating manual, chapter C Printing unit, circumferential register Setting to zero .

Set the circumferential register to zero on CPC 1-04 (precision setting). Also refer to the operating manual for CPC 1-04. Set perfector presses to straight printing. Turn the press at crawl speed. Select the function Coarse register adjustment value 2 for each printing unit at the control console (Service display, Printing unit). The corresponding symbol lights up. The symbol cannot be deactivated anymore. The operator guidance disappears. The reference-point run starts. After the zero position of the coarse register has been detected by the sensor, the function 2 becomes inactive. The sensor has determined the zero position and has passed it on to the press control system.

3 4 5

273

Plate clamping device

1...nB53 Coarse register monitoring

274

Washup devices

Control by command Washup

Washup devices
Control by command Washup Selection of functions
Command Washup

Actual value display Printing unit selection

Service display

Printing unit selection

The command Washup can be aborted any time with the button Delete.

Input

Only with start-up warning

Control by command Washup


275

Washup devices

Messages

Messages Faults at print start and during printing

Messages

Press not ready to run

Fault in the press. Washing cannot be carried out.

Note: Terminate the command Washup with the button Delete. To locate the fault select Entire press and the fault display.

Paper in the press

On command initiation there is still paper in the press. Washing can only be carried out when the paper has been transported out of the printing units into the delivery. Only applies to presses with UV dryer The blanket and inking rollers may only be washed 180 s after the last drying. If the command is enabled earlier, the symbol will light up and the remaining waiting time will be indicated. The washup programme only starts after the waiting time.

Dryer waiting time

276

Washup devices

Messages

Not enough water

Not enough water in the washup solution container E9: Sensor B1 "Monitoring water" (blanket / inking roller washup device).

Not enough washup solution

Not enough washup solution in the washup solution container E9: Sensor B54 "Monitoring washup solution, blanket washup device". Sensor B55 "Monitoring washup solution, inking roller washup device.

Inking roller washup device monitoring of ink blade

In the displayed printing unit the ink blade is not fitted. The sensor nB43 is not damped.

277

Washup devices

Service display Washup

Service display Washup Functions of the blanket washup device GTW


Button sequence

With the help of the Service display, spray procedures with water and washup solution can be initiated. Apart from this, the washup blades can be thrown on/off. All functions can be activated during standstill of the press or during Run. The functions can be activated either printing unit by printing unit or for all units simultaneously. The corresponding solenoid valves are then actuated in the printing units.

Functions of the washup devices


Spraying with water Solenoid valve 1...nY54 actuated.

Spraying with washup solution

Solenoid valves 1...nY52 and 1...nY55 actuated.

Washup blade on/off

Solenoid valve 1...nY53 actuated.

Functions of the impression cylinder washup device DZW


Spraying with water Solenoid valve 1...nY43 actuated. The washup brush motors M43, M50...M56 start up. Solenoid valve 1...nY42 actuated. The washup brush motors M43, M50...M56 start up.

Spraying with washup solution

278

Washup devices

Service display Washup

Functions of the inking roller washup device FWW


Button sequence

With the help of the Service display, spray procedures with water and washup solution can be initiated. Apart from this, the ink blades can be thrown on/off. All functions can be activated during standstill of the press or during Run. The functions can be activated either printing unit by printing unit or for all units simultaneously. The corresponding solenoid valves are then actuated in the printing units.

Functions of the washup devices


Spraying with water Solenoid valve 1...nY44 actuated.

Spraying with washup solution

Solenoid valve 1...nY50 actuated.

Ink blade on/off

Solenoid valve 1...nY51 actuated.

279

Washup devices

Service display Washup

Selecting the washup solution


Button sequence

If you press the button Entire press in the Service display, you can choose between washing with mineral oil-based and vegetable oil-based washup solution. After a change, the parameters will be reset to default values.

Choosing between mineral oil-based and vegetable oil-based washup solution

Selectable functions Washing the blanket Washing the inking rollers Washing the impression cylinder

Mineral oil-based solution

Vegetable oil-based solution

280

Washup devices

Blanket washup device (GTW)

Blanket washup device (GTW) Block diagram

1...nY54

1...nY52

1...nY55

1...nY53

1...nY56

E4

E9

EAK Parallel data line Serial data line DSK REK2 ESK Control line Washup solution or water conduit DNK2 Pneumatic line ZID

Block diagram Washing the blanket


E4 E9 Y52 Y53 Y54 Pneumatic system compressor Washup solution container Blanket, washup solution Blanket, washup blade Blanket, water Y55 Y56 Blanket, washup brush Blanket, driving clutch

281

Washup devices

Blanket washup device (GTW)

Layout 1 2 3 4 5 6 7 8 9
Blanket cylinder Rubber roller Rider roller Drop tubes for water and washup solution Wiper roller Washup blade Ink trough Spray tube for washup solution, washup brush Washup brush

Blanket washup device

Function
When the command has been enabled and the washup speed reached (5 000 i.p.h.), the drive of the washup brush is engaged by the solenoid valve nY56. The washup brush then turns at washup speed. The wiper roller and washup brush are driven. When the washup brush has been engaged and the 1st spray procedure has occurred, the washup device is brought in the position for washup (nY53), i.e. thrown on the blanket cylinder. First spraying with washup solution occurs. The solution is sprayed onto the blanket cylinder in two different ways: via the drop tube (nY52), rider roller and rubber roller and via the washup solution spray tube for the washup brush and the washup brush (nY55).

282

Washup devices

Blanket washup device (GTW)

After the spray procedures with washup solution spraying with water occurs (nY54). The blade is in permanent contact with the wiper roller. The ink removed by the blade is collected in the ink trough and passed to a reservoir from there. Such a reservoir is provided on the drive side of each printing unit. After washing of the blanket, the press stays in operation (3000 i.p.h.).

283

Washup devices

Blanket washup device (GTW)

Setting the number of cylinder revolutions and spray procedures for water and washup solution
Button sequence

The first actuation of the function button allocates the corresponding device to the right-hand and left-hand +/ buttons. After the allocation, the parameters can be changed with the +/ buttons. Pressing the function button again inactivates the device again.

Blanket washup device selected


Changeover between settings for water (top) and for washup solution (bottom) with the 1st function button (above the left-hand +/ buttons). Enter the number of cylinder revolutions with the left-hand + / buttons. water from 0 to 50 washup solution from 0 to 150. Enter the number of spray procedures with the right-hand +/ buttons. The setting range for the spray procedures goes from 10% to 100%. 10% = 1 spray procedure. 100% = 10 spray procedures.

284

Washup devices

Blanket washup device (GTW)

Example
Setting for water: 10 30% 10 cylinder revolutions 3 spray procedures

Setting for washup solution: 40 30% 40 cylinder revolutions 3 spray procedures

Flow chart: Washing with washup solution and water


1.2 s

Water (nY54)
0.7 s (0.3 s if vegetablebased)

Washup solution (nY52) Blanket washup brush (nY55) Blanket driving clutch (nY6) Blanket washup blade (nY53) Revolutions 0 4 40 99 104 102
0.3 s

Flow chart: Washing with washup solution and water

285

Washup devices

Inking roller washup device (FWW)

Inking roller washup device (FWW) Block diagram

1...nY44

1...nY50

1...nY9

1...nY10

1...nY11

1...nY51

E4

E9

EAK Parallel data line Serial data line DSK REK2 ESK Control line Washup solution or water conduit DNK2 Pneumatic line

ZID

Block diagram Washing the inking rollers


E4 E9 Y9 Y10 Y11 Pneumatic system compressor Washup solution container Inking form rollers Ink ductor Dampening rollers Y44 Y50 Y51 Inking rollers, water Inking rollers, washup solution Ink blade

286

Washup devices

Inking roller washup device (FWW)

Layout 1 2 3 4 5 6 7 8
Ink fountain roller Ink ductor Drop tubes for water and washup solution Dampening roller Plate cylinder Inking form roller Distributor cylinder Ink blade with rubber strip and ink fountain


Inking roller washup device

Function
When the command has been enabled and the washup speed reached (5 000 i.p.h.), washup solution is sprayed onto the inking rollers. For this purpose, the valve nY50 Inking rollers washup solution is actuated. Then the ink ductor is thrown on (nY10). After 40 cylinder revolutions and two spray procedures, the ink blade is thrown on ( nY51). The preselected spray procedures / cylinder revolutions are carried out. After the last spray procedure, the ink ductor is thrown off. Simultaneously, the inking form rollers (nY9) are brought into contact with the plate cylinder. When the inking form rollers are thrown off again, the plate cylinder is predampened during 20 revolutions, nY11 actuated. The press stops when washing is completed.

287

Washup devices

Inking roller washup device (FWW)

Setting the number of cylinder revolutions and spray procedures for water and washup solution
Button sequence

The first actuation of the function button allocates the corresponding device to the right-hand and left-hand +/ buttons. After the allocation the parameters can be changed with the +/ buttons. Pressing the function button again inactivates the device again.

Inking roller washup device selected Changeover between settings for water (top) and for washup solution (bottom) with the 1st function button (above the left-hand +/ buttons). Enter the number of cylinder revolutions with the left-hand + / buttons. Water: 0 ... 500 Washup solution: 150 ... 1000; if the ink fountain roller is washed in addition: 225 ... 1500. Enter the number of spray procedures with the right-hand + / buttons. Setting possible from 0% ... 100%.

Setting 100% 90% 80% 70% 60% 50% L 0%

1 spray procedure every ... 16 20 24 28 32 36 L 56

revolutions

The first spray procedure lasts 0.8 s, the others 0.4 s.

288

Washup devices

Inking roller washup device (FWW)

Additional washing of printing plate and ink fountain roller


Additional washing of printing plate Additional washing of ink fountain roller Condition: Before selecting the function Additional washing of ink fountain roller, remove the ink from the ink fountain and carry out an ink shut-off at CPC 1-04. The printing plate and ink fountain roller can be washed in addition via the inking roller washup device. The inputs are valid for the selected printing units.

Example
Setting for water: 50 70% 50 cylinder revolutions one spray procedure every 28 revolutions

Setting for washup solution: 225 70% 225 cylinder revolutions one spray procedure every 28 revolutions

289

Washup devices

Inking roller washup device (FWW)

Flow chart: Washing with mineral oil-based washup solution without water
If printing plate is washed as well

Dampening rollers (n Y11) Inking form rollers (n Y9) Ink ductor (n Y10) Ink blade (n Y51) Water (nY44) Washup solution (n Y50) Revolutions
0.4 s 0.2 s 0.2 s
66% of preselected cylinder revolutions if printing plate is washed as well 80% of preselected cylinder revolutions if printing plate is washed as well

20

20

40

30 20

Preset spray procedures washup solution

Preselected cylinder revolutions washup solution

Flow chart: Washing with mineral oil-based washup solution without water

Flow chart: Washing with mineral oil-based washup solution and water
Dampening rollers (n Y11) Inking form rollers (n Y9) Ink ductor (n Y10) Ink blade (n Y51) Water (nY44) Washup solution (n Y50) Revolutions
0.2 s 0.4 s 0.4 s

as 1st section above (without water)

x1
Preset spray procedures washup solution

x2

x2

Preset spray procedures water

40

30

20

Preselected cylinder revolutions washup solution

Preselected cylinder revolutions water

Flow chart: Washing with mineral oil-based washup solution and water
290

Washup devices

Inking roller washup device (FWW)

Flow chart: Washing with vegetable oil-based washup solution and water
If printing plate is washed as well

Dampening rollers (nY11) Inking form rollers (nY9) Ink ductor (nY10) Ink blade (nY51) Water (nY44) Washup solution (nY50) Revolutions
0.4 s 0.2 s 80% of preselected cylinder revolutions if printing plate is washed as well

66% of preselected cylinder revolutions if printing plate is washed as well

8
0.2 s

0.4 s

0.4 s

x1

x1

x1

x1

x2

x2

80

30 20

Preset spray procedures washup solution

Preset spray procedures water

Preselected cylinder revolutions washup solution

Preselected cylinder revolutions water

Flow chart: Washing with vegetable oil-based washup solution and water

291

Washup devices

Impression cylinder washup device (DZW)

Impression cylinder washup device (DZW) Block diagram

1...nY43

1...nY42

1...nY41

M50 ... M56, M43

E4

E9

EAK Parallel data line Serial data line DSK REK2 ESK Control line Washup solution or water conduit DNK2 Pneumatic line

ZID

Block diagram Washing the impression cylinder


E4 E9 Pneumatic system compressor Washup solution container 1...nY41 1...nY42 1...nY43 Impression cylinder, washup brush Impression cylinder, washup solution Impression cylinder, water

M50 ... M56, M43 Washup brush motors

292

Washup devices

Impression cylinder washup device (DZW)

Layout 1 2 3 4 5 6 7
Impression cylinder washup device
Impression cylinder Spray tube for water Washup brush motor Washing trough Spray tube for washup solution Blade Washup brush

Function
Each printing unit has a washup brush which is connected with the washup brush motor via gears. The motor is located in the middle of the printing unit, under the impression cylinder. When the command has been enabled and the washup speed of 5000 i.p.h. has been reached, the following functions are initiated: starting up the washup brush motors M50 ... M56, M43 throwing on the washup brushes (1...nY41) opening the spray tubes for washup solution (1...nY42) opening the spray tubes for water (1...nY43).

The washup solution and water for the impression cylinder washup device come from the washup solution container E9 which also supplies the blanket washup device. After washing, the press stays in operation (3000 i.p.h.).

293

Washup devices

Impression cylinder washup device (DZW)

Setting the number of cylinder revolutions and the spray duration for water and washup solution
Button sequence

The first actuation of the function button allocates the corresponding device to the right-hand and left-hand +/ buttons. After the allocation the parameters can be changed with the +/ buttons. Pressing the function button again inactivates the device again.

Impression cylinder washup device selected

Changeover between settings for water (top) and for washup solution (bottom) with the 1st function button (above the left-hand +/ buttons). Enter the number of cylinder revolutions for water and washup solution with the left-hand +/ buttons: Water: Washup solution: 0 and 30 0, 50 and 100

Enter the spray duration for water and washup solution with the right-hand +/ buttons: Setting range from 0 to 100%. Dependent on the setting, the basic pulse duration for washup solution and water is shortened or lengthened.

Setting 0% 10% L 50% L 90% 100%

Change in basic pulse duration 0.5 s 0.4 s L 0 L + 0.4 s + 0.5 s

294

Washup devices

Impression cylinder washup device (DZW)

Example
Setting for water: 0 50% 0 cylinder revolutions basic spray duration +/ 0 s

Setting for washup solution: 50 50% 50 cylinder revolutions spray duration 0 s

Flow chart: Washing with washup solution and water

Washup brush motor (M43, M50...M56) Impression cylinder washup brush (n Y41) Water (nY43)
2.0 s+/x 0.7s+/x 0.7 s+/x 0.5 s+/x 0.5 s 1,0 s

Spray duration

3.0 s+/x

2.0 s+/x

1.0 s+/x

Washup solution (n Y42) 25 Revolutions


Preselected cylinder revolutions washup solution

25

25

25

15

15

30

Preselected cylinder revolutions water

Flow chart: Washing with washup solution and water

295

Washup devices

M43, M50...M56 Washup brush motors

M43, M50 ... M56 Washup brush motors Place of installation


The washup brush motors are located in the middle of each printing unit, below the impression cylinder. They are accessible through the lower opening in the side frame on the O.S. These washup brush motors are only available for CD102.

Washup brush motor in printing unit

Pin assignment
Pin A2
A B C 1 2 3 4 5

Function AC 400 / 480 V phase U AC 400 / 480 V phase V AC 400 / 480 V phase W PE conductor

B3 C2

Plugs M43-X1, M50-X1 ... M56-X1

296

Washup devices

E9 Washup solution container

E9 Washup solution container Block diagram 1 2


15K4M M4 B1 M4 B54 B55 E9 F70 B1 B54 B55 F70 Pressure reducer with check valve Safety valve Contactor, pneumatic system compressor Pneumatic system compressor Sensor Monitoring water. Sensor Monitoring washup solution, blanket washup device Sensor Monitoring washup solution, inking roller washup device Washup solution container Pressure switch

15K4M

E9

EAK

ESK

REK Pneumatic line Control line Parallel data line

Block diagram: washup solution container E9

297

Washup devices

E9 Washup solution container

Warnings
Symbols appear in the following displays if there are malfunctions in connection with the washup solution container: Not enough washup solution production run display, display which appears after initiating the command Washup, fault display Entire press/warning.

Not enough washup solution in the washup solution container E9. Sensor B54 Monitoring washup solution, blanket washup device. Sensor B55 Monitoring washup solution, inking roller washup device. Not enough water in the washup solution container E9. Sensor B1 Monitoring water. At an air pressure x 0.48 bars, pressure switch F 70 responds. In the control console display ZID both symbols appear: Not enough washup solution and Not enough water.

Not enough water

Insufficient pressure in the container

298

Washup devices

E9 Washup solution container

Place of installation

Place of installation of washup solution container E9

Washup solution container E9

The washup solution container is located under the footboard on the O.S. (on presses with up to 5 units at the 2nd unit, with 6 units at the 3rd unit; with 7 or more units one container at the 2nd unit and one at the 6th unit).

Layout Attention:
Only refill the washup solution container with the press switched off or the air supply shut off (stop-cock closed).

1 2 3 4 5 6 7 8 9 q
Washup solution container E9

Refill opening with cover and sieve Pressure regulator with manometer Three-way stop-cock Solenoid valve Check valve Pressure switch F70 Safety valve Sensor B55 Monitoring washup solution, inking roller washup device Sensor B1 Monitoring water Sensor B54 Monitoring washup solution, blanket washup device Terminal box with terminal strip E9-X1

299

Washup devices

E9 Washup solution container

Task
The washup solution container E9 supplies: the blanket washup device with water and washup solution, the inking roller washup device with water and washup solution.

In order to deliver water and washup solution, the pressure in the container must be between 0.48 bars and 1.0 bar. The pressure reducer reduces the air pressure from the pneumatic system compressor M4 to 0.5 bars. If the pressure drops below 0.48 bars, the pressure switch F70 responds. A warning appears in the control console display ZID. If the air pressure rises above 1.0 bar, the safety valve opens. The sensors B1, B54 and B55 monitor the liquid levels. If the levels drop below the min. permissible values, a warning appears in the control console display ZID. The initiated washup procedure is completed, but a new washup procedure cannot be started anymore.

Pin assignment E9-X1


Pin 3 4 5 2 1 1 2 3 4 5 Function DC 24 V 24 V Monitoring water Monitoring washup solution, blanket washup device Monitoring washup solution, inking roller washup device

Plug E9-X1

300

Washup devices

B1, B54, B55 Sensors at the washup solution container

B1, B54, B55 Sensors at the washup solution container Place of installation 1 2 3
B1 Monitoring water B54 Monitoring washup solution, blanket washup device B55 Monitoring washup solution, inking roller washup device

Sensors at washup solution container

Connection
Input at EAK : 0 level too low 1 level OK

Pin assignment
Marking X1 +1 Colour white brown Function signal DC +24 V

301

Washup devices

B1, B54, B55 Sensors at the washup solution container

Removal and installation 1 2 3


Float Sensor Width across flats 27 with marking

All three sensors are of identical design. For removal loosen the thread and unscrew the sensor. For installation introduce the sensor into the threaded hole, position the thread carefully and screw it in. The sensor is sealed up by the tapered thread and the Teflon sealing tape around it. Tighten the sensor with 5 Nm.

Sensor at the washup solution container

Adjustment
The mounting position of the sensor determines its switching function. Pay attention to the arrow on the flat face of the screw. Direction of arrow upward downward Function NC contact NO contact Symbol

Mounting position of sensor

302

Washup devices

1...nB43 Monitoring the ink blade

1...nB43 Monitoring the ink blade Place of installation


The inductive sensor is located on the inside of the side frame on the O.S. It is fitted in each printing unit at the paper outlet.

Sensor Monitoring the ink blade

Layout 1 2 3
Sensor Nut and locking nut Connecting cable

Sensor Monitoring the ink blade with nut and locking nut

303

Washup devices

1...nB43 Monitoring the ink blade

Task
The inductive sensor Monitoring the ink blade" 1...nB43 monitors the correct installation of the ink blade. When the ink blade is not fitted, automatic washing of the inking rollers is not possible.

Connection
Core brown blue black Function DC 24 V 24 V signal

Pin assignment
Input 43 of EAKn: (n = corresponding printing unit) 0 1 ink blade not fitted ink blade fitted

Removal and installation 1 2 3 4


Blade Sensor Nut/locking nut Side frame

4.0 mm

When fitting the sensor, screw it so far in the holder that the distance between ink blade and sensor is 4.0 mm. Tighten the nut and locking nut.

Installation of sensor "Monitoring the ink blade

304

Inking unit

Servo-drive ink fountain roller

Inking unit
Servo-drive ink fountain roller Place of installation
The servo-drives for the ink fountain rollers 1 are located on the operator side of the printing units.

D.S.

O.S.

Place of installation of servo-drive for ink fountain roller O.S.

Layout and task


The servo-drive for the ink fountain roller is a dc motor with brushes and potentiometer for position feedback. It is used for adjustment of the ink fountain roller stroke. Thus the ink stripe width can be influenced.

Servo-drive ink fountain roller

305

Inking unit

Servo-drive ink fountain roller

Technical data
Motor data U = DC 12 V Potentiometer data U = DC 10 V R = 10 kW

Terminal assignment
Terminal
black yellow beige yellow/green brown blue

Function DC 12 V (motor) DC 10 V (potentiometer) potentiometer Potentiometer tap

6 5 4 3 2 1

6 5 4 3 2 1

black yellow beige yellow/green brown blue

6 5 4 3 2 1

6 5 4 3 2 1

black blue red black red

1 2 4 5 6

Terminal strip of servo-drive for ink fountain roller

306

Inking unit

Servo-drive ink fountain roller

Removal and installation Attention:


Small parts can fall into the press during disassembly!

1
O.S.

Nut on servomotor Gear wheel Locking screw Anti-rotation element Retaining nut

2 3 4 5 1 2 3 4 5

Zero position of ink fountain roller Turn the threaded rod 2 against the left stop with the nut 1 . Disconnect the potentiometer from the terminal strip. Loosen the locking screw potentiometer.

3 and take out the 4 to the new

Attach the anti-rotation element potentiometer.

Ink fountain roller O.S.

Connect the new potentiometer and turn until the display on the central control console indicates 0,00. Install in reverse sequence. If you want to make a precision correction, loosen the retaining nut 5. Correct the value by slightly turning the potentiometer. Check the value displayed on the central control console.

6 7

307

Inking unit

Servo-drive diagonal register 1...nM6

Servo-drive diagonal register 1...nM6 Place of installation


The servo-drives for the diagonal register 1 are located on the operator side of the printing units.

D.S.

O.S.

Place of installation of servo-drive for diagonal register O.S.

Layout and task


The servo-drive for the diagonal register is a dc motor with brushes and potentiometer for position feedback. It is used for cocking the plate cylinder.

Speedmaster SM 102

Speedmaster CD 102

Servo-drive diagonal register on SM 102 and CD 102


308

Inking unit

Servo-drive diagonal register 1...nM6

Technical data
Motor data U = DC 24 V

Potentiometer data U = DC 10 V R= 10 kW

Pin assignment
Pin
1 2 3 4 5 2 1 3 4 5

Function DC 24 V (motor) DC 10 V (potentiometer) Potentiometer tap potentiometer

1 2 3 4 5

Plug of servo-drive of diagonal register

309

Inking unit

Servo-drive diagonal register 1...nM6

Removal and installation Attention:


Small parts can fall into the press during disassembly!

1 2 3 4 5 6 7 1 2 3

Plug 1...nM6-X1 Fixing bolts Hexagon nut Block Upper stop of eccentric sleeve Eccentric bolt Servo-drive

Withdraw the plug

1 from the servo-drive 7.

Remove the servo-drive by loosening the four fixing bolts 2. Positioning the diagonal register to zero: Turn the hexagon 3 below the block 4 until the distance between the upper stop 5 of the eccentric sleeve O.S. and the eccentric bolt 6 is 5 mm. Setting the central position for the new servo-drive: Connect the plug 1 to the servo-drive 7. Set the diagonal register display to 0,00 on the central control console. Alternatively, it is possible to set the variable voltage of the potentiometer to 5V at the servo-drive conversion module SSM in the distribution box of the printing unit. Installing the servo-drive: When installing the servo-drive, the backlash (flank clearance) is of no importance and can be neglected. When tightening the fixing bolts, pull the servo-drive outwards (away from the PU). Thus the backlash of the two pinions is adjusted.

Eccentric sleeve behind block

5mm

Servo-drive diagonal register, e.g. SM 102

Note: Do not loosen the eccentric bolt 6. After loosening the eccentric bolt, the plate cylinder and the dampening distributor must be adjusted parallel to each other again.

310

Inking unit

Servo-drive lateral register

Servo-drive lateral register Place of installation


The servo-drives for the lateral register 1 are located on the operator side of the printing units.

D.S.

O.S.

Place of installation of servo-drive for lateral register O.S.

Layout and task


The servo-drive for the lateral register is a dc motor with brushes and potentiometer for position feedback. It is used for adjustment of the plate cylinder in lateral direction.

Servo-drive lateral register

311

Inking unit

Servo-drive lateral register

Technical data
Motor data U = DC 12 V

Potentiometer data U = DC 10 V R = 10 kW

Terminal assignment
Terminal black yellow beige yellow/green brown blue black red blue brown blue 1 2 4 5 6 Function DC 12 V (motor) DC 10 V (potentiometer) potentiometer Potentiometer tap

6 5 4 3 2 1

6 5 4 3 2 1

Terminal strip of servo-drive for lateral register

312

Inking unit

Servo-drive lateral register

Removal and installation Attention:


Small parts can fall into the press during disassembly!

1 2
2.2...2.27 mm

Nut Gear wheel Nut Nut Anti-rotation element Sleeve

3 4 5 6

2.2...2.27 mm

Positioning the lateral register to zero: Turn the gear wheel 2 with the help of the nut 1 until the distance of 2.2...2.27 mm is obtained.

Lateral register O.S.

Note: Use a feeler gauge!

2 3 4 5 6 7 8

3. Loosen the nut 4.


Unscrew the nut Take out the potentiometer and disconnect the cable from the terminal strip. Attach the anti-rotation element potentiometer.

5 to the new

Connect and install the new potentiometer and turn until the display on the central control console indicates 0,00. Install in reverse sequence. If you want to make a precision correction, loosen the nut 4. To correct the value insert a screw driver in the sleeve 6 and turn the potentiometer axis slightly. Check the value displayed on the central control console.

313

Inking unit

Servo-drive circumferential register

Servo-drive circumferential register Place of installation


The servo-drives for the circumferential register 1 are located on the drive side of the printing units.

O.S.

D.S.

Place of installation of servo-drive for circumferential register D.S.

Layout and task


The servo-drive for the circumferential register is a dc motor with brushes and potentiometer for position feedback. It is used for adjustment of the plate cylinder in circumferential direction.

Servo-drive for circumferential register D.S.

314

Inking unit

Servo-drive circumferential register

Technical data
Motor data U = DC 12 V

Potentiometer data U = DC 10 V R = 10 kW

Terminal assignment
Terminal black yellow beige yellow/green brown blue black red blue brown blue 1 2 4 5 6 Function DC 12 V (motor) DC 10 V (potentiometer) potentiometer Potentiometer tap

6 5 4 3 2 1

6 5 4 3 2 1

Terminal strip of servo-drive for circumferential register

315

Inking unit

Servo-drive circumferential register

Removal and installation Attention:


Small parts can fall into the press during disassembly!

6.2...6.3 mm 6.2...6.3 mm

1 2 3 4 5 1

Nut Gear wheel Locking screw Anti-rotation element Nut

Positioning the circumferential register to zero: Turn the gear wheel 2 with the help of the nut 1 until the distance of 6.2...6.3 mm is obtained.

Note: Use a feeler gauge!

2
Circumferential register D.S.

Disconnect the potentiometer from the terminal strip. Loosen the locking screw potentiometer.

3 4 5 6 7

3 and take out the 4 to the new

Attach the anti-rotation element potentiometer.

Connect and install the new potentiometer and turn until the display on the central control console indicates 0,00. Install in reverse sequence. If you want to make a precision correction, loosen the nut 5. Correct the value by slightly turning the potentiometer. Check the value displayed on the central control console.

316

Inking unit

Inking unit temperature control

Inking unit temperature control Activation and inactivation

Selecting the display


The inking unit temperature control can be activated and inactivated at the central control console. Power supply is effected via plug E39-X1. On 7- and 8-colour presses, the required second inking unit temperature control is switched on and off via plug E39a-X1.

Actual value/fine display of control console display (ZID) Inking unit temperature control on/off

317

Inking unit

E39 Inking unit temperature control

E39 Inking unit temperature control Connection


Different models are available which differ in power. 7- and 8-colour presses require two inking unit temperature controls (E39 and E39a). The power supply for the unit(s) comes from the printing press. The illustration opposite is an example. The units differ in cabinet height and width.

E39-X1

Connection of inking unit temperature control E39

Pin assignment E39-X1 (only model 3/8)


Pin 3 7 1 2 3 4 5 6 7 8 9 10 Remaining pins PE conductor 9 Function Phase U Phase V Phase W

Plug E39X1 ( power supply )

318

Inking unit

E39 Inking unit temperature control

Pin assignment E39-X1 (models 6/12; 6/16; 9/20 and 9/25)


Pin
1 3 5 7 9

Function Phase U Phase V Phase W PE conductor

1
2 4 6 8 10

2 3

Remaining pins

4pole cable Plug E39X1 ( power supply )

319

Inking unit

E39 Inking unit temperature control

320

Dampening

1...nM1 Pan roller motors

Dampening
1...nM1 Pan roller motors Place of installation / plug connections 1
Connector 1...nM1-X3 ( power supply )

1...nM1-X3

1M1

2M1

3M1

Pan roller motors 1...nM1 at PU/CU on D.S.

Pin assignment
7 1 9 10 11 12 13 2 14 8 6 Pin 5 4 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 X motor line Y motor line Z motor line Hall-effect sensor, signal C Hall-effect sensor, tacho signal Hall-effect sensor, signal B DC 15 V Hall-effect sensor, signal A Ground of DC 15 V Motor code PE 321 Function

Connector 1...nM1-X3, pins in plug insert

Dampening

1...nM45 Blower motor for dampening system

1...nM45 Blower motor for dampening system Place of installation and task
The blower combination with the motor 1...nM45 is located under the guard of the inking and dampening rollers. The motor is a dc motor with brushes. It is integrated in the middle of the blower bar and drives a cross-flow fan.

nM45

Place of installation of blower motor for dampening system

Pin assignment
Pin 1 2 3
1 2 3

Function Enable message Ground 24 V DC 24 V

Plug of blower motor for dampening system

322

Dampening

1...nB32 Sensor Dampening solution control

1...nB32 Sensor Dampening solution control Place of installation


The capacitive sensor is located on the paper infeed side, D.S., in the dampening solution fountain.

nB32

Place of installation of sensor Dampening solution control

Layout/connection
Core brown blue black Function DC 24 V ground 24 V message

Sensor Dampening solution control

323

Dampening

1...nB32 Sensor Dampening solution control

Task/function
The capacitive sensor 1...nB32 monitors the level of the dampening solution in the fountain. The sensor works correctly when its sensing area is immersed in the dampening solution. With its sensing area immersed, the sensor is actuated. If the level of the dampening solution drops, the sensor will only change its circuit state if its sensing area is no longer in contact with the water film. The sensor is supplied with a stabilized direct voltage of DC 24 V.

324

Dampening

E40 Central dampening solution supply/ cooling and circulating unit

E40 Central dampening solution supply/cooling and circulating unit Layout of central dampening solution supply
The central dampening solution supply is in a separate cabinet. Generally, this cabinet is in the proximity of the central control cabinet. It is connected to the CP Tronic control system via a serial interface. The power supply and circuitbreakers are in the control cabinet of the printing press. For details please refer to the manufacturers manual. E40-X1: power supply E40-X2: serial interface

X1

X2

Central dampening solution supply Technotrans

X2

X1

Central dampening solution supply Baldwin, rear view

325

Dampening

E40 Central dampening solution supply/ cooling and circulating unit

Pin assignment X1, central dampening solution supply


Pin 3 7 9 Function Phase U Phase V Phase W PE conductor

1 2 3 4 5

6 7 8 9 10

*)

Remaining pins

Connector E40-X1, coming from the press

380...415 V " 15V * ) AC AC 460...500 V " 15V

at 50Hz at 60Hz

326

Dampening

E40 Central dampening solution supply/ cooling and circulating unit

Layout of cooling and circulating unit


The cooling and circulating units have no serial interfaces. The power supply and circuit-breakers are in the control cabinet of the printing press. A manufacturers manual is available. E40-X1: power supply

E40-X1

Cooling and circulating unit

Pin assignment X1, cooling and circulating unit


Pin 2 4 1 2 3 4 5 6 7 8 9 10 Remaining pins PE conductor Function AC 230 V Zero 230 V

Connector E40-X1, coming from the press

327

Dampening

E41 Dampening solution mixing unit

E41 Dampening solution mixing unit


The dampening solution mixing unit is an additional unit for cooling and circulating devices without integral additive-mixing units. It admixes additives to the dampening solution. Power supply comes directly from the mains and not from the press. For details please refer to the manufacturers documentation.

Dampening solution mixing unit

328

Central lubrication

Basic concept

Central lubrication
Basic concept Distinction
Two lubrication systems supply the press with lubricant: grease lubrication system (for the delivery), oil lubrication system (for the printing units, feeder and bearings on the D.S. and O.S. of the delivery chain sprocket shaft).

The grease lubrication system is divided into: lubrication circuit 1 (chain lubrication), lubrication circuit 2 (bearing lubrication).

The oil lubrication system is divided into: the circular lubrication system (drive side), the distributing lubrication system (operator side and some lubricating points on the drive side).

329

Central lubrication

Service display

Service display
Button sequence

Oil lubrication 1 2 3 4 5
Service display Oil lubrication
Pressure monitoring 1bar, 1F33 (flashes if the pressure switch was not actuated). Pressure monitoring 12bars, 1F34 (flashes if the pressure switch was not actuated). Oil pump M44 (flashes if motor circuit-breaker 15Q44 has responded). Number of cylinder revolutions since the last distributing lubrication. After completion of lubrication the counter is automatically zeroed. Distributing lubrication initiated manually (only when press is on Run). Number of cylinder revolutions at which automatic oil lubrication is initiated.

330

Central lubrication

Service display

Grease lubrication 7 8 9 q w e r t
Sensor Lubrication monitoring 2 12 B77 (bearing lubrication) (flashes if sensor is not actuated). Sensor Lubrication monitoring 1 12 B47 (chain lubrication) (flashes if sensor is not actuated). Motor grease lubrication 12M47. Number of cylinder revolutions since the last chain lubrication. After completion of lubrication the counter is automatically zeroed. Number of cylinder revolutions since the last bearing lubrication. After completion of lubrication the counter is automatically zeroed. Chain lubrication initiated manually (lubrication circuit 1); (only when press is on Run). Bearing lubrication initiated manually (lubrication circuit 2); (only when press is on Run). Number of cylinder revolutions at which bearing lubrication is initiated automatically. Number of cylinder revolutions at which chain lubrication is initiated automatically.

Service display Grease lubrication

331

Central lubrication

Fault messages

Fault messages Display Entire press/warning


Button sequence

Dependent on the press model, the fault display Entire press / Warning shows the fault symbols of the grease lubrication or oil lubrication system:

Oil lubrication not possible

Oil lubrication has not occurred. After main switch On and changeover between circular and distributing lubrication, the oil pressure has not been built up within 3 minutes. Pressure switch 1F33 (1 bar) or pressure switch 1F34 (12 bars) not actuated. Filter unit clogged.

Grease lubrication not possible

Chain or bearing lubrication has not occurred. The sensor Lubrication monitoring 1 12 B47 or the sensor Lubrication monitoring 2 12 B77 has not responded within 10 minutes. Solenoid valve 12 Y78 defective. Changeover between chain and bearing lubrication is not possible. Motor for grease lubrication 12 M 47 defective.

Motor circuit-breaker Q 44 has tripped The audible signal devices 11H55 and 12H55 give out a warning

The motor circuit-breaker has tripped. Oil pump M 44 not ready to run. While lubrication is in progress, a warning signal sounds if the printing speed is u 3 000 i.p.h.

332

Central lubrication

Grease lubrication

Grease lubrication Block diagram

15 Q 66 15 Q 47 12B47 15 K47 M 12M47 12Y78 12B77

11H55

12H55

Electronic control system Control line Power supply Grease line

Block diagram of grease lubrication

1 2
15Q66 15Q47

Pressure limiting valve (38 bars) Metering elements Main switch Motor circuit-breaker

12M47 12Y78 12B47 12B77 11H55 12H55

Motor Grease lubrication Changeover grease lubrication Lubrication monitoring 1 (chains) Lubrication monitoring 2 (bearings) Audible signal device (audio alert feeder) Audible signal device (audio alert delivery)

15K47M Contactor

333

Central lubrication

Grease lubrication

Place of installation
The motor for grease lubrication is located on the D.S. of the last printing unit. The sensors Lubrication monitoring are fitted at the first progressive distributor behind the motor.

Layout 1 2 3 4 5 6 7
Motor Grease lubrication 12 M 47 Grease reservoir Pressure relief valve Lubrication monitoring 212 B77 (bearing lubrication) Lubrication monitoring 112 B47 (chain lubrication) Progressive distributor Changeover grease lubrication 12 Y78 (between bearing and chain lubrication)

Components of the grease lubrication system

Function
When the press is switched on, the grease lubrication system is ready for operation. The motor for grease lubrication 12M47 delivers the lubricant to the progressive distributors via solenoid valve 12 Y78. Depending on the position of the solenoid valve, either the chains in the delivery (lubrication circuit 1) or the bearings (lubrication circuit 2) are supplied with lubricant. The progressive distributors pass the lubricant to the lubricating points via pistons. The progressive distributors are sequence-controlled and thus all pistons move uniformly. For this reason, only the movement of one piston is monitored per lubrication circuit.

334

Central lubrication

Grease lubrication

Monitoring the lubrication system


Inductive sensors monitor the two lubrication circuits. Each is equipped with an LED and can assume two circuit states. Pin of progressive distributor extended, sensor damped: LED is lit. Pin of progressive distributor retracted, sensor not damped: LED is not lit.

LED

Sensor with LED monitoring the lubrication circuit

On presses with standard delivery, the sensor 12 B47 (chain lubrication) is actuated twice while lubrication is in progress and three times on presses with extended delivery. The sensor 12 B77 (bearing lubrication) is actuated once while lubrication is in progress. If the sensors do not switch within 10 minutes after a lubrication process was triggered, the electronic control system shuts the motor for grease lubrication down. The warning Grease lubrication not possible appears.

335

Central lubrication

Grease lubrication

Triggering a lubrication process


When the press is switched on, the grease lubrication system is ready for operation. Lubrication is triggered either automatically:

1 2

chain lubrication every 2 500 to 30 000 cylinder revolutions; (after a basic initialization, the cycle is preset to 20 000 cylinder revolutions), bearing lubrication every 200 000 cylinder revolutions,

or manually by actuating the function button Manual chain or bearing lubrication.

Central lubrication selected, press on Run

Setting the lubrication cycle for lubrication circuit 1 (chain lubrication)


Button sequence

Number of cylinder revolutions for automatic chain lubrication (lubrication circuit 1). The cylinder revolutions can be set in the range from 2 500 to 30 000 in steps of 2 500.

Note: To set the lubrication cycle an additional button must be fitted on the EAM (input/output module). Before fitting or removing this button, turn off the main switch 15 Q 66 on the central control cabinet ZSG! Number of cylinder revolutions set to 20000

336

Central lubrication

Grease lubrication

Attention:

Even if the main switch is turned off, the press is not voltage-free and there are currentconducting components in the central control cabinet! The input/output module EAM is on the underside of the central control console. Plug the additional button into slot 7 of the EAM - X12.

EAM

EAM-X12
Group

1 2 3

Turn off the main switch 15Q66. Fit the button. Turn on the main switch 15Q66.

Now press the button you just fitted plus group button 2 on the central control console. Set the cylinder revolutions with the left-hand + / buttons.
Lubrication cycle for delivery 30000

2 500 5 000 L 25 000 30 000

Remove the button from slot 7 of the EAM - X12. Then check the cylinder revolutions for chain lubrication (lubrication circuit 1) in the service display Central lubrication on the central control console.

Changing the lubrication cycle Note: The value for bearing lubrication (lubrication circuit 2) is set to 200 000 cylinder revolutions and is non-adjustable.

Pressure relief valve of the motor


The motor for grease lubrication is protected by a pressure relief valve. In the case of malfunctions, this valve prevents the building up of impermissible high pressures in the lubrication system and opens at a pressure of 150 bars.

337

Central lubrication

Oil lubrication

Oil lubrication Block diagram

15 Q 66 15 Q 44 1F33 15X3 M44 Y67 1F34

11H55

12H55

Electronic control system Control line Power supply Oil line

Block diagram of oil lubrication

1 2
15Q66 15Q44 15X3 M44

Pressure relief valve (18 bars) Metering elements Main switch Motor circuit-breaker Plug Oil pump

Y67 1F33 1F34 11H55 12H55

Changeover oil lubrication Pressure monitoring (1 bar) Pressure monitoring (12 bars) Audible signal device (audio alert feeder) Audible signal device (audio alert delivery)

338

Central lubrication

Oil lubrication

Place of installation
The oil reservoir with oil pump M44, filter unit, solenoid valve Y67 and pressure relief valve is located on the D.S. under the footboard (on presses with up to 5 units at the last unit, with 6 or more units in the middle). On presses with coating unit the guard serves as oil reservoir and contains the oil pump, filter unit and valves. The two pressure switches, 1 F 33 and 1 F 34, are fitted at the first printing unit under the feeder.

Layout 1 2 3 4 5 6 7
Oil pump M 44 Filter unit Oil lubrication press Y 67 (changeover between circular lubrication and distributing lubrication) Pressure relief valve (18 bars) Pressure switch 1F34 (12 bars) Pressure switch 1 F 33 (1 bar) Oil reservoir

Components of the oil lubrication system

339

Central lubrication

Oil lubrication

Function
Switching on the press activates oil lubrication, i.e. the circular lubrication system is active and continuously lubricates the gears on the D.S. For the changeover to distributing lubrication the solenoid valve Y67 must be actuated. This is effected either automatically or with the function button Manual distributing lubrication. The distributing lubrication system supplies the bearings on the D.S. and O.S. with oil. After every changeover between distributing and circular lubrication, the oil pressure must build up within 3 minutes; otherwise the electronic control system outputs a fault message. Circular lubrication The oil is continuously fed to the lubricating points via the oil riser and drip pan. The circular lubrication system works at an oil pressure y 1 bar. The oil pressure is monitored by pressure switch 1 F 33 (1 bar). The oil flowing back down the side frames on the D.S. is returned to the lubrication circuit. Through a return line the oil flows either into the oil reservoir or into the coating unit guard. The return line is fitted above the cable duct on the D.S. Distributing lubrication The distributing lubrication system supplies the lubricating points through piston distributors. The oil pressure in the system is y 12 bars and monitored by pressure switch 1 F 34 (12 bars). On SM102-presses the residual oil is collected in the bases and can be drained off through a drain cock on the O.S. On CD102-presses the residual oil is collected in a reservoir on the D.S. which can be emptied.

340

Central lubrication

Oil lubrication

Triggering a lubrication process


Distributing lubrication is triggered:

1 2

automatically every 45 000 cylinder revolutions or by actuating the function button Manual distributing lubrication.

For activation the printing press must be on Run (3 000 i.p.h.).

Central lubrication selected, press on Run

Filter unit 1 2
Optical differential pressure indicator Filter housing with cartridge

The filter unit is fitted between the pump and the solenoid valve. The optical differential pressure indicator shows the degree of soiling of the filter cartridge: Green: filter cartridge okay Red: change filter cartridge

Filter unit

If the filter cartridge is soiled, the oil pressure between the oil pump and filter unit rises. The relief valve in the filter unit opens the bypass and the oil flows to the lubricating points without having been filtered. Change the filter at least every 6 months.

341

Central lubrication

Oil lubrication

Changing the filter

Changing the filter

Optical differential pressure indicator

The tightening torque for the filter housing must be 120 Nm +/ 15 Nm.

Pressure relief valve of the oil pump


A pressure relief valve is installed to protect the oil pump. In the case of malfunctions, this valve prevents the building up of impermissible high pressures in the lubrication system. It opens at a pressure of 18 bars and the oil flows back into the coating unit guard or the oil reservoir.

342

Central lubrication

M44 Oil pump

M44 Oil pump Place of installation


On presses with coating unit, the oil pump is located on the D.S. of the coating unit, below the footboard.

Location of oil pump on presses with coating unit, D.S.

On presses without coating unit, the oil pump is installed at the oil reservoir. The oil reservoir is located on the D.S. under the footboard (on presses with up to 5 printing units at the last printing unit).

Location of oil pump on presses with up to 5 PUs

343

Central lubrication

M44 Oil pump

On presses with 6 or more units, the oil reservoir is bigger and located in the middle of the press, under the footboard on the D.S.

Location of oil pump on presses with 6 or more PUs

Pin assignment
Pin A2
A B C 1 2 3 4 5

Function AC 400 / 480 V phase U AC 400 / 480 V phase V AC 400 / 480 V phase W PE conductor

B3 C2

Plug M44-X1

344

Central lubrication

12M47 Motor for grease lubrication

12M47 Motor for grease lubrication Place of installation


The motor for grease lubrication 12M47 is located on the D.S. of the delivery.

Motor for grease lubrication with grease reservoir

Pin assignment
Plug 12M47-X1 Pin 3 1 2 PE 1 2 3 PE Function DC 24 V Grease lubrication delivery chains

Plug 12M47-X1

345

Central lubrication

1F33 Pressure monitoring oil lubrication 1bar

1F33 Pressure monitoring oil lubrication 1bar Place of installation


The pressure switch Pressure monitoring oil lubrication 1 bar 1F33 is located on the drive side of the first printing unit, under the sheet alignment system. It is accessible through the door between the feeder and first printing unit on the O.S.

Place of installation Pressure monitoring oil lubrication 1 bar, 1F33

346

Central lubrication

1F34 Pressure monitoring oil lubrication 12bars

1F34 Pressure monitoring oil lubrication 12bars Place of installation


The pressure switch Pressure monitoring oil lubrication 12 bars 1F34 is located on the O.S. of the first printing unit, under the feeder. It is accessible through the door between the feeder and first printing unit on the O.S.

Place of installation Pressure monitoring oil lubrication 12 bars, 1F34

347

Central lubrication

12B47 Lubrication monitoring 1 12B77 Lubrication monitoring 2

12B47 Lubrication monitoring 1 and 12B77 Lubrication monitoring 2 Layout


The sensor 12 B47 for chain lubrication monitoring and the sensor 12 B77 for bearing lubrication monitoring are of identical design.

1 2 3 4 5 6 7 8

LED Sensor Locking nut Receptacle Plug Stop pin Sleeve Distributor

12B47 Lubrication monitoring 1 and 12B77 lubrication monitoring 2

Connection
Input 47 or 77 at EAK 12: 0 sensor not damped (LED off) 1 sensor damped (LED lit)

348

Central lubrication

12B47 Lubrication monitoring 1 12B77 Lubrication monitoring 2

Pin assignment
Marking 47 or 77 +1 1 Colour black brown blue Function signal DC 24 V

Sensor Lubrication monitoring

Removal and installation


To fit the sensor screw the receptacle into the sleeve using a copper disk and tighten it up. In doing so, align the receptacle in such a way that the sensor can be screwed in parallel to the longitudinal axis of the distributor. Screw the sensor manually into the receptacle until it contacts the stop pin and secure it with the locking nut. Then close the threaded hole of the receptacle from the bottom using the plug.

349

Central lubrication

12B47 Lubrication monitoring 1 12B77 Lubrication monitoring 2

350

Pneumatic system

15Y11 Admission of pressure, pneumatic system

Pneumatic system
15Y11 Admission of pressure, pneumatic system Place of installation
The solenoid valve Admission of pressure, pneumatic system 15Y11 is fastened to the side frame on the O.S. of the feeder and accessible through the protecting door.

15Y11

Admission of pressure, pneumatic system 15Y11 with plug

Task
When the pressure has been built up ( u5 bars ), the solenoid valve switches the pneumatic energy through the piping.

351

Pneumatic system

15Y11 Admission of pressure, pneumatic system

Pin assignment
Plug 15Y11-X1 Pin 1 1 3 PE 2 2 3 PE Function DC 24 V Signal 4 mA ... 20 mA

Plug 15Y11-X1

352

Pneumatic system

15B14 Pressure sensor Pneumatic system

15B14 Pressure sensor Pneumatic system Place of installation

The pressure sensor Pneumatic system 15B14 is located at the side frame on the O.S. of the feeder where it measures the air pressure in the pneumatic piping.

15B14

Place of installation of pressure sensor Pneumatic system 15B14

353

Pneumatic system

15B14 Pressure sensor Pneumatic system

Pin assignment
Plug 15B14-X1 Pin 1 2 PE 2 3 PE Function DC 24 V Sensor signal 4 mA ... 20 mA

3 1

Pressure sensor and connector

354

Pneumatic system

E4 Pneumatic system compressor

E4 Pneumatic system compressor Technical data


Technical data, see operating instructions 71.102.9100

Pin assignment
Pin A2
A B C 1 2 3 4 5

Function AC 400 / 480 V phase U AC 400 / 480 V phase V AC 400 / 480 V phase W DC 24 V Pressure switch F45 Blow-off valve Y68 PE conductor

B3 C2 C4 A5 B5

Plug E4-X1

355

Pneumatic system

E4 Pneumatic system compressor

356

Suction and blast air

1M9 Blast air regulation at the feeder

Suction and blast air


1M9 Blast air regulation at the feeder Block diagram
Displays MID11 MID12 ZID DNK DSK IDS

The blast air regulation at the feeder adapts the blast air pressure at the suction head to the press speed and ensures that the printing material is fanned. The blast air pressure is regulated by servo-drive 1M9 which controls a relief valve. The blast air pressure depends on two factors: the thickness of the stock (e.g. paper calliper); the production speed (preset speed). In the operator program of CPTronic the blast air regulation can be switched on and off. Automatic blast air regulation switched on means: characteristic-curve-dependent blast air regulation. The blast air pressure is automatically adapted by the CPTronic operator program on the basis of the entered paper thickness and the preset press speed. By pressing the right-hand +/ buttons on the control console the characteristic curve stored in the CPTronic control system can be modified manually. Automatic blast air regulation switched off means: manual blast air setting. The blast air pressure is set independently of the paper thickness and preset speed. It can be modified with the right-hand +/ buttons on the control console. The blast air regulation at the feeder does not intervene in the press control.

EAK

ESK

SVM

SSK

SAK
1SSM1

REK2

1M9

M Blast air regulation

Legend:

Data lines Control lines

Block diagram: blast air regulation at the feeder

357

Suction and blast air

1M9 Blast air regulation at the feeder

Characteristic-curve-dependent blast air regulation

Selection of the characteristic-curve-dependent blast air regulation


Function button Blast air regulation at the feeder on / off 1 If the background of the symbol is light, the characteristiccurvedependent blast air regulation is switched on. The characteristic curves are stored in the CPTronic operator program. The operator program automatically selects a suitable characteristic curve dependent on the thickness of the stock and the press speed. Preselection/coarse display

358

Suction and blast air

1M9 Blast air regulation at the feeder

Selection: manual change of characteristic-curvedependent blast air regulation


Function button Changing the slope

When you switch over to the actual value display and the background of the symbol is light, you can set the slope of the characteristic curves manually (and thus deviate from the CPTronic-values). The setting is made at the control console with the right-hand +/ buttons.

Manual change of the characteristiccurvedepen dent blast air regulation p [bar] 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0 3000 6000 9000 12000 15000 n [sheets / h] For a 0.05 mm thick paper the setting range for the slope is as follows for SM 102 and CD 102: Minimum: 0% (corresponds to the 0%-characteristic curve) Maximum:100% (corresponds to the 100%-characteristic curve)

Field of characteristic curves for a printing paper with a thickness of 0.05 mm (corresponds to a paper weight of approx. 50 g/m2)

359

Suction and blast air

1M9 Blast air regulation at the feeder

Manual blast air setting

Selection: changing the manual blast air setting


Function button Manual setting of blast air at feeder actuated (ON) 3 The manual blast air setting is activated automatically when the characteristic-curve-dependent blast air regulation is switched off. It does not depend on the paper thickness or preset speed. In this mode you can enter a percent value which is displayed on the control console display ZID. The setting is made at the control console with the right-hand +/ buttons. Changing the manual blast air setting The setting range for SM 102 and CD 102 is as follows: Minimum: 20% (corresponds to 0.2 bar above atmospheric pressure) Maximum:100% (corresponds to 1.0 bar above atmospheric pressure)

p [bar] 1.0

0.8

0.6

0.4

0.2 20 40 60 80 100 ZID display [%]

Characteristic curve of the manual blast air setting

360

Suction and blast air

1M9 Blast air regulation at the feeder

Place of installation
The blast air regulation is located on the bottom crossbar of the feeder in direction of the drive side (D.S.).

O.S.

D.S.

Blast air regulation at the feeder

361

Suction and blast air

1M9 Blast air regulation at the feeder

Layout and task


Dependent on the thickness of the printing material and the production speed, the blast air regulation at the feeder adapts the blast air pressure at the suction head and thus ensures that the printing material is fanned. The blast air regulation at the feeder consists of the following components:

1 2 3 4

Servo-drive 1M9 with dc motor with brushes, flange-mounted gear unit and potentiometer for position feedback. Motor bracket with protecting cover and threaded spindle inside Adjustable relief valve Manometer measuring the pressure above atmospheric (at feeder frame)

The servo-drive and relief valve are connected with each other by means of a mechanical coupling.

Servo-drive with adjustable relief valve

Manometers at feeder frame for pressure above atmospheric and low pressure

362

Suction and blast air

1M9 Blast air regulation at the feeder

Technical data
Motor data U = DC 24 V P=5W Potentiometer data U = DC 10 V R = 10 kW

Pin assignment
Contact
+ 1 2 3 4 5 3 4 2 1 5

Assignment Motor, + (DC 24 V) Motor, (DC 24 V) Potentiometer, + (DC 10 V) Potentiometer wiper Potentiometer, (DC 10 V)

1 2 3 4 5

Pin assignment: blast air regulation at the feeder

363

Suction and blast air

1M9 Blast air regulation at the feeder

Removal and installation

Attention:

Small parts can fall into the press during disassembly!

1 2 3

Inch the press until all blast air ducts at the rotary valve in the suction head are closed. Turn off the main switch. Loosen the four fixing bolts the protecting cover 2.

1 and remove

(4)

4
(4)

Unscrew the connector 1M9X1 3 and withdraw it from the servo-drive 4. Loosen the four fixing bolts 5 and remove the servo-drive together with the sleeve 6. Turn on the main switch (blast air is present).

364

Suction and blast air

1M9 Blast air regulation at the feeder

Turn the threaded spindle 7 manually until the manometer measuring the pressure above atmospheric at the feeder 8 indicates 0.6 bar. Check whether all blast air ducts at the rotary valve in the suction head are closed. Turn off the main switch. Connect the connector 3 with the new servo-drive 9 and tighten up the bolts. Turn on the main switch.

7 8 9

Switch off the automatic blast air regulation (this activates the manual blast air setting).

Note: Also refer to the section Manual blast air setting.

Operate the servo-drive 9 with the right-hand +/ buttons at no-load until the value 60% is indicated on the control console display ZID.

Note: While doing this, do not place the servodrive 9 on the threaded spindle 7.

365

Suction and blast air

1M9 Blast air regulation at the feeder

Push the servo-drive 9 onto the threaded spindle 7 so that the pin engages with two slots of the sleeve 6.

Note: Take care that the pin of the threaded spindle is not turned more than "90 while doing this.
(4)

Fasten the servo-drive fixing bolts 5.

9 with the four

Let the servo-drive 9 run over the entire operating range with the right-hand +/ buttons (i.e. from 20% to 100%).

Note: See also the next section Checking the operating range.

t
(4)

Put the protecting cover 2 back in place and fasten it with the four fixing bolts 1.

366

Suction and blast air

1M9 Blast air regulation at the feeder

Checking the operating range

Selecting the service display


Incremental values for the servo-drive 1M9 Blast air regulation at the feeder

Operating range for SM 102 and CD 102: Incremental value [n] 768 (min.) 2048 3328 (max.) ZID display Air pressure [%] [bar] 20 0.2 60 0.6 100 1.0

Service display

Note: The incremental values may differ from the displayed percent values / air pressure by up to "4 increments.
When you have finished checking, switch on the characteristic-curve-dependent blast air regulation.

367

Suction and blast air

1M9 Blast air regulation at the feeder

368

Other components

E4a Varnish supply unit

Other components
E4a Varnish supply unit Connections
The varnish supply unit receives 3AC 380 V and AC 230 V from the printing press. Both voltages pass through plug E4a-X1. The varnish sensor is located at the coating pan on the O.S. of the coating unit. It is connected to the distribution box at the coating unit. From there a cable leads to the varnish supply unit, plug E4a-X21. The varnish supply unit is remotely controlled with a cable. This cable is connected to plug E4a-X22. The varnish supply unit is located under the footboard on the D.S. of the coating unit. A manufacturers manual is available.

E4a-X21

E4a-X22 E4a-X1

Varnish supply unit

Pin assignment
E4a-X1 Pin A B C 1 2 3 4 5 A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 C1 C2 C3 C4 C5 Function Phase L1 AC 230 V Phase L2 Phase L3 Zero 230 V PE conductor

Plug E4a-X1, coming from the control cabinet

369

Other components

E4a Varnish supply unit

E4a-X21 Pin 2 6 1 5 3 4 1 2 3 4 Function DC 24 V (+1) for fault message Fault message Analog sensor signal: 0 ... 5 V Conductive level sensor DC 24 V Ground voltage for sensor

Plug E4a-X21, control lines

5 6

Fault messages
If the sensor Level in coating pan B32 detects that the level is too low and if the operating mode Varnish circulation has been selected for the coating unit, a fault message is transmitted to the CPTronic control system and the audible signal devices 11H55 and 12H55 output a warning. It is possible that the fault message is caused by the height adjustment of the level controller ( coating pan insert ).

Sensor Level in coating pan and level controller

370

Other components

L-B32 Level in coating pan

L-B32 Level in coating pan Place of installation


The sensor Level in coating pan is located at the coating pan on the O.S. of the coating unit.

Sensor Level in coating pan

Connection, pin assignment


Plug E4a-X2: 3 2 1 6 4 E4a-X2 5 2 3 183 170 171 L-LVT1-X2 4 blk br bl Sensor 5 6 green white grey yellow Pin 1 Colour brown Function DC 24 V (+1) for fault message Fault message Analog sensor signal: 0 ...5 V Conductive level sensor DC 24 V Ground voltage for sensor

L-B32

Connection of sensor Level in coating pan

371

Other components

L-B32 Level in coating pan

Layout, adjustment 1 2 3 4 5 6
108 mm Coating pan Pan roller Sensor Sensor holder Level controller Adjusting screws

Adjust the sensor so that the distance between the upper edge of the sensor and the upper edge of the sensor holder is 108 mm. The height of the level controller can be regulated by means of the adjusting screws. This influences the level in the coating pan. The immersion depth of the pan roller in the varnish should be approx. 10 mm.

approx. 10 mm

Mounting dimensions of sensor Level in coating pan

372

Other components

12E2 Powder spray unit

12E2 Powder spray unit Place of installation, layout 1 2 3


Powder spray device Powder tube Blower motor with suction filter

The powder spray device is located on the O.S. of the delivery. The motor is fitted on the O.S. of the delivery, on the inside of the press. Different types of powder spray devices can be connected to the printing press. We distinguish between: powder spray devices without serial interface, powder spray devices with serial interface.

Powder spray device, powder tube and motor at delivery

In the case of powder spray devices with serial interface, the motor is connected directly to the control box of the powder spray device.

Powder spray device with serial interface


Pin assignment 12E2-X1 Pin A2 B3 C B A 1 2 3 4 5 C2 A4 C5 Function L2 L1 L3 AC 230 V Zero 230 V PE

Plug 12E2-X1, coming from the press

373

Other components

12E2 Powder spray unit

Powder spray device without serial interface


Pin assignment 12E2-X2 The plug 12E2-X2 is at the distribution box of the delivery. Instead of the mechanical switch 12S68 a proximity switch can be fitted in the feeder (e.g. Betatronic powder sprayers). This switch is then connected directly to the powder spray device and is not led via the distribution box or plug 12E2-X2. Pin A1 Function Switch Powder on 12S68, switch contact 2 (not with proximity switch) DC 24 V for test button AC 230 V Switch Powder on 12S68, switch contact 1 (not with proximity switch) Impression on ( AC 230 V) Test ( DC 24 V) Zero 230 V PE conductor Press turns ( AC 230 V) PE

C B A 1 2 3 4 5

A2 A3

Plug 12E2X2, coming from the press, distribution box at delivery

A4

A5 B1 B2 B3 B4 B5 C1 C5

Pin assignment of proximity switch 12S68 Pin 3 4 5 2 1 1 2 3 4 5 Function Ground DC 24 V Signal Ground

Plug of proximity switch

374

Other components

12E2 Powder spray unit

Correcting the beginning of powdering


Settings The following settings are only required for powder spray devices with serial interface. Control panel at last printing unit / coating unit Selector switch Safe

Set the selector switch Safe to Safe.

Pushbutton Forward/ Backward

Inch the press until the front edge of the sheet is below the spray nozzles of the powder tube.

Sheet of paper

Required position of front edge of sheet

Positioning the sheet of paper


Control panel at delivery Press display MID

Read off the degree value indicated on the press display MID.

1
Indication on the MID while press is in inching mode

Display of degree value

375

Other components

12E2 Powder spray unit

Service display Delivery

4 1

Variable degree can be changed by entering another degree value.

Standard degree cannot be changed depends on the press model.

Service display Delivery


Entering the degree value

With the right-hand " buttons the degree value read off at the press display MID under 3 can be entered. When the function button is pressed, the variable degree 2 jumps back to the standard degree value 3.

Standard beginning of powdering

SM102 ( CD102) 2 PUs 4 PUs 5 PUs 6 PUs 7 PUs 8 PUs

+ extended + coating unit + coating unit High-pile delivery high-pile delivery + high-pile delivery + extended high-pile delivery 132 ( 101 ) 166 ( 250 ) 3 ( 325 ) 201 ( 39 ) 38 ( 114 ) 235 ( 189 ) 225 ( 102 ) 259 ( 251 ) 97 ( 326 ) 294 ( 40 ) 131 ( 115 ) 328 ( 189 ) 83 ( 176 ) 118 ( 326 ) 315 ( 39 ) 152 ( 114 ) 349 ( 189 ) 188 ( 263 ) + 74.6 ( 74.6 ) for every further coating unit 84 ( 177 ) 119 ( 326 ) 316 ( 40 ) 153 ( 115 ) 350 ( 189 ) 188 ( 264 ) + 74.6 ( 74.6 ) for every further coating unit

Degree values for the beginning of powdering SM102 (CD102)

376

Other components

12M35 Blower motor for powder spray device

12M35 Blower motor for powder spray device Place of installation, filter change
The motor is located at the delivery. It is mounted on the baseplate on the inside of the side frame, on the O.S. To change the suction filter, open the hinged cover above the footboard.

12E2-X1

Blower motor for powder spray device at delivery

Layout 1 2 3 4 5 6 7 8
Suction filter Air hose leading to powder spray device Plug connection M35-X1 Baseplate Casing cover with rotor vanes underneath Compressed-air cooler Hood for motor fan Pressure relief valve

Compressor motor M35

377

Other components

12M35 Blower motor for powder spray device

Changing the rotor vanes


Remove the casing cover of the compressor motor M35.

Note: When you loosen the lower fixing bolts of the casing cover, the compressed-air cooler becomes loose as well. Hold it tight.
The rotor vanes are accessible. If they are shorter than 27 mm (min. permissible length), they must be replaced.

27mm min.

Rotor vanes in motor 12M35

378

Other components

12S68 Switch Powdering cycle

12S68 Switch Powdering cycle Place of installation


The switch Powdering cycle 12S68 is located on the D.S. of the delivery. In the case of Betatronic from Grafix, Weko T 77Cs and Weko Ionomat Cs, the switch is connected directly to the powder spray device. With all other powder spray devices the switch is connected to the distribution box at the delivery.

Place of installation of switch Powdering cycle, 12S68

379

Other components

12S9, -a, -b, -c Monitoring the IR slide-in dryer

12S9, -a, -b, -c Monitoring the IR slide-in dryer Place of installation


Each IR slide-in dryer is equipped with a safety switch with NC and NO contacts. When the IR dryer is inserted, the switching element provided on the slide-in dryer actuates the safety switch on the drive side. Printing presses with several IR slide-in dryers (extended delivery) have 4 switches (12S9, 12S9a, 12S9b, 12S9c). The NC contacts of the safety switches are connected in series and the NO contacts in parallel.


Place of installation of safety switch Monitoring the IR slide-in dryer

Layout and connection 1 2 3


Sensor Openings for switching element Switching element (fitted on slide-in dryer) Marking 21-22 13-14 Function NC contact NO contact

NC contact ( s ) at input 9 of EAK12: 0 1 IR dryer(s) inserted IR dryer(s) removed

NO contact ( s ) at input 9 of SEK:

Sensor Monitoring the IR slide-in dryer

1 0

IR dryer(s) inserted IR dryer(s) removed

380

Other components

E8 Air supply cabinet

E8 Air supply cabinet Connections


The air supply cabinet receives 2 AC 380 V and the control signal Compressor on from the printing press. A thermostat in the control cabinet signals excessive temperatures to the CP Tronic control system. All cables are connected directly to terminal strips and are not led via plugs. For the exact terminal connections please refer to the circuit diagram and technical instructions of the manufacturer. Cable entries

Air supply cabinet, rear view

381

Other components

E39 Inking unit temperature control

E39 Inking unit temperature control Layout


The supply voltage for the inking unit temperature control comes from the control cabinet and is connected via plug E39-X1. A manufacturers manual is available. E39-X1: power supply

Inking unit temperature control

Pin assignment E39-X1


Pin 6 7 8 9 10 1 2 3 4 5 3 7 9 Function AC 230 V, phase U AC 230 V, phase V AC 230 V, phase W PE

Connector E39-X1, coming from the press

382

Other components

12E3 Static electricity eliminator

12E3 Static electricity eliminator

Attention:

Observe the circuit diagram! Cut off the power supply before working on the device!

Place of installation

Place of installation of static electricity eliminator

1 2 3 4

Power supply for static electricity eliminator (D.S.) Neutralizer bar Ion blowers Air-supported neutralizer bar

The static electricity eliminator consists of a power supply unit with high-voltage transformer, a neutralizer bar at the feeder and an air-supported neutralizer bar at the delivery. Two ion blowers can be additionally attached to the suction head (optional).

Note: The static electricity eliminator is optional and therefore not fitted on all presses.
For subsequent installation, threads are provided in the side frame as standard.

383

Other components

12E3 Static electricity eliminator

Layout 1 2 3 4 5 6
Mains switch Pilot lamp Power supply unit Power cable AC 230 V Ion blowers at feeder Neutralizer bar at delivery

Note: 2 different versions are available. Differences in the housing design do not affect the functions.

Static electricity eliminator 12E3 (ELTEX)

Static electricity eliminator, version 2 (SIMCO) 384

Other components

12E3 Static electricity eliminator

Task
The unit consisting of the power supply with high-voltage transformer plus connected neutralizer bars and ion blowers eliminates static charges on the sheets of paper.

385

Other components

WSA Intercom

WSA Intercom Layout 1 2 3 4


Loudspeaker Microphone Volume controller Illuminated pushbutton

The WSA consists of one intercom at the control panel at the feeder and one at the control panel at the delivery. Each intercom has a microphone, loudspeaker, illuminated pushbutton, volume controller and two electronic boards (main and secondary boards). The electronic boards are directly in the intercom.

Intercom at feeder

Intercom at delivery

386

Other components

WSA Intercom

Function 1 2 3 4 5 6 7
Secondary board with terminal strip 11WSA-X2/ 12WSA-X2 Main board Connection for volume controller Connection for microphone Connection for secondary board 11WSAX1/ 12WSA-X1 Connection for illuminated pushbutton Changeover switch main/secondary intercom

The intercom is set in such a way that the main intercom (H) is at the delivery and the secondary intercom (N) at the feeder. When the illuminated pushbutton is pressed at the delivery, speaking at the feeder is interrupted. The priority between the two intercoms can be reversed any time by means of the changeover switch on the main board. The setting of the switch must then be changed at both intercoms.

Electronic boards of intercom

387

Other components

IDS Encoder

IDS Encoder Place of installation

Encoder IDS

Place of installation of encoder in 1st PU

Task
The encoder is the basis for all speed- and degree-dependent functions. Examples of speed- and degree-dependent functions: motor regulation, interrogation points of sensors, positioning for plate change.

388

Other components

IDS Encoder

Function
Track A 5V 0V 5V 0V 5V 0V The encoder generates three pulse signals: track A, track B, track 0.

Track B

Track B is staggered by 90 in relation to track A. Per revolution track 0 generates one zero pulse. The inverted signals are also available from all 3 tracks. Tracks A and B each generate 1024 pulses per revolution.

Track 0

Pulse signals from the encoder

Pin assignment
Pin
G F M J A K B L E

Function DC+5V 5V Track A/ Track A Track B/ Track B Track 0/ Track 0

M, G, H A, L, D
D

C B
C

F E K J

Encoder plug

389

Other components

IDS Encoder

Installation variants
For presses with more than five printing units and sheet turning device a second encoder IDS is used. This IDS is used for closed-loop control of the main drive. The mechanical installation and removal of both IDS is identical (steps 1, 2, 3 and 6, 7, 8).

For the installation of the 2nd IDS (main drive regulation) the zero point adjustment is not required.
CD 102 Straight-printing presses On CD102 presses the IDS is always fitted in the 1st printing unit. SM102 Straight-printing presses IDS 1 SM1022 SM1022+L SM1023 SM1023+L SM1024 SM1024+L SM1025 SM1025+L SM1026 SM1026+L SM1027 SM1027+L SM1028 SM1028+L Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing unit unit unit unit unit unit unit unit unit unit unit unit unit unit 1 1 1 1 1 1 1 4 4 4 4 4 4 4 IDS 2 SM1022 SM1022+L SM1023 SM1023+L SM1024 SM1025 SM1025+L SM1026 SM1026+L SM1027 SM1027+L SM1028 SM1028 P5 SM1028+L SM1028+L P5 SM1028+L SM102 Perfector presses IDS 1 Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing unit unit unit unit unit unit unit unit unit unit unit unit unit unit unit unit 1 1 1 1 1 1 1 1 1 1 1 1 4 1 4 5 IDS 2 Printing Printing Printing Printing Printing Printing Printing

unit unit unit unit unit unit

4/5 4/5 4/5 4/5 4/5 4/5/6

unit 4/5

Removal and installation 2 1 2 3


Remove the plug. Loosen the stud. Remove the encoder.

Encoder IDS
390

3 1

Other components

IDS Encoder

Insert the gauge in printing unit 1.

Inserting the gauge

Line mark D

Positioning to zero

5 6 7 8

Use the crank handle to turn the impression cylinder to the zero position (line mark D). Fit the new encoder. Connect the encoder. Turn on the main switch 15Q66.

8 6

15Q66

Fitting the new encoder IDS

391

Other components

IDS Encoder

Turn the shaft of the encoder until 000.0 is displayed in the MID. Tighten the stud.


Adjustment of the encoder IDS

Note: If the value 000.0 is not displayed in the MID, continue with step q. If the setting is correct, continue with r.

e q

q w e

Loosen the locking nut. Turn the adjusting screw until 000.0 is displayed in the MID. Tighten the locking nut.

Precision adjustment of the encoder IDS

Remove the gauge from PU 1.

Removing the gauge

392

Location diagrams

ZSG Central control cabinet

Location diagrams
ZSG Central control cabinet Location and layout

Equipment zone E Swing frame Equipment zone A Power supply Equipment zone B Partition wall Equipment zone D Flat cable mounting plate Equipment zone C Mounting rack / control devices

Layout of central control cabinet


393

Location diagrams

ZSG Central control cabinet

Equipment zone A Power supply


This equipment zone contains the components necessary for connection to the power supply. The chapter Control systems describes how the press is connected to the power mains.

1 2 3 4 5 6 7 8 9 q w

15M1 15L1 15R120 15R48

Fan Power components Power choke - power converter Load resistor (only for presses with Preset) Load resistor (only for presses with auxiliary pile at the delivery) Semiconductor fuses Armature circuit M1 Main switch EMC filter Semiconductor fuses Mains Terminal strip PE conductor EMC filter Control transformer

15F2 15Q66 15Z2 15F1 15X1 PE 15Z1 15T1

Equipment zone Power supply

394

Location diagrams

ZSG Central control cabinet

Equipment zone B Partition wall


SLT GRM5 GRM24 GRM48 GRM120-2
SLT

Converter power part Rectifier module Rectifier module Rectifier module Rectifier module Flat switch Transformer protection, secondary Flat switch Transformer protection, secondary Circuit-breaker Feeder / delivery main pile (not for Preset version) Circuit-breaker Feeder auxiliary pile Contactor Pile control STK1 (without Preset) / LSR (with Preset) Contactor Pile control STK1 (with Preset) / STK2 (without Preset) Contactor Power supply connecting part of power converter Motor circuit-breaker Air supply cabinet E 8 Motor circuit-breaker Transformer protection, primary

15Q61 15Q62 15Q37

15Q38
GRM5 GRM24 GRM48 GRM120-2

15K37M

15K38M

15K48A
15Q61 15Q37 15K37M 15K48A 15Q65

15Q2 15Q65
15Q62 15Q38 15K38M 15Q2

Equipment zone Partition wall

SLT Converter power part The converter power part SLT contains the power electronics for driving the main drive. The chapter Control systems, subchapter Direct-current main drive lists the components of the converter power part.
SLT

Converter power part


395

Location diagrams

ZSG Central control cabinet

GRM Rectifier modules The equipment zone B Partition wall contains four rectifier modules.

F6 F8 F7 F5 F4 F3

1 2 3 4

GRM5 GRM24 GRM48

Rectifier module Rectifier module Rectifier module

GRM120-2 Rectifier module

The rectifier modules GRM24 and GRM48 are of identical design and interchangeable. Fuses:

Rectifier modules GRM

F6, F7, F8 (GRM5)

15 A, quick-acting, 6.3 x 32 mm

F5, F4 (GRM24 / GRM48) 20 A, quick-acting, 6.3 x 32 mm ca. AC 24 V 3 x ca. AC 35 V 3 x ca. AC 100 V F3 (GRM120) 32 A, slow-blowing

3 x ca. AC 26 V

ca. DC 36 V ca. DC 33 V

ca. DC 120 V

ca. DC 50 V

Voltages at the rectifier modules GRM

396

Location diagrams

ZSG Central control cabinet

Equipment zone C Mounting rack / control devices

Q.... Motor circuit-breakers


Q2a Q4 Q4a Q22 Q24 Q28 Q33 Q33a Q35 Q39

K....M Main contactors


22M K22M K33M K33aM K35M K39M

Q39

Q39a

Q40

Q44

Q22a

Q80 IWM

Earth-leakage monitor module

K39M

K40M

K22aM

K39M K39aM K46A K61A K50M K51M K52M K53M K54M K55M K56M K43M

Terminal amplifier module Flat-cable output module 64 outputs


KVM FAM 64 FEM 64

Flat-cable input module 64 inputs

BAM

BKM

SPM

VSM

SVM

SVM

ESM FEM10 AUM

Optocoupler 15U2
15X4

Terminal strips
15X3

Analog conversion module Flat-cable input module 10 inputs Interference suppressor module Interface distributor module Amplifier module Memory analog board module Brake coupling module Brake control module

Equipment zone Mounting rack / control devices


397

Location diagrams

ZSG Central control cabinet

Equipment zone D Flat cable mounting plate 1


15V1 The rectifier reduces the voltage from the power supply board NTK 24 (in the REE) to the supply voltage (22 V) for the signal lamps. Leading to the swing frame: backplane of input/output plug-in unit EAR / input/output auxiliary drive plug-in unit EHR From each press unit, input and output cables lead to the swing frame. The input/output cables are fastened on the flat cable mounting plate. Cable routing as shown in the sketch opposite. Fixing clips

2
I/O 1 I/O 2 I/O 3 I/O 4

13,15 5, 6 3, 4 1, 2 11,12 Flat cables from the press units

Equipment zone Flat cable mounting plate

398

Location diagrams

ZSG Central control cabinet

Equipment zone E "Swing frame


Equipment of swing frame for presses with:


REE2 EHE2 LTE

2 - 5 PUs, without Preset REE2 EHE2 LTE Computer plug-in unit 2 Input/output auxiliary drive plug-in unit 2 Power part plug-in unit SSE2 Servo-drive plug-in unit 2

1
REE2 EHE2 LTE

2 - 5 PUs, with Preset Computer plug-in unit 2 Input/output auxiliary drive plug-in unit 2 Power part plug-in unit SSE2/LSE Servo-drive plug-in unit 2/ power part plug-in unit for brushless pile motors

Swing frame for presses with 2- 5 PUs

Note: The electronic boards must be in their respective board slots. They must be correctly connected to the connectors of the backplane. In front of each plug-in unit the safety crossbar must be fitted.

399

Location diagrams

ZSG Central control cabinet

Swing frame for presses with 6- 8 PUs


REE2 EAE HAE2 LTE

Equipment of swing frame for presses with: 6 - 7 PUs, without Preset REE2 EAE HAE2 LTE Computer plug-in unit 2 Input/output plug-in unit Auxiliary drive plug-in unit 2 Power part plug-in unit SSE2 Servo-drive plug-in unit 2

6 - 7 PUs, with Preset, 8 PUs, with Preset, without non-stop delivery REE2 EAE HAE2 LTE Computer plug-in unit 2 Input/output plug-in unit Auxiliary drive plug-in unit 2 Power part plug-in unit SSE2/LSE Servo-drive plug-in unit 2 / power part plug-in unit for brushless pile motors

8 PUs, with Preset, with auxiliary pile at the delivery REE2 EAE HAE2 LTE Computer plug-in unit 2 Input/output plug-in unit Auxiliary drive plug-in unit 2 Power part plug-in unit SSE2/LSE2 Servo-drive plug-in unit 2 / power part plug-in unit for brushless pile motors 2

Note: The electronic boards must be in their respective board slots. They must be correctly connected to the connectors of the backplane. In front of each plug-in unit the safety crossbar must be fitted.

400

Location diagrams

ZSG Central control cabinet

Swing frame for presses with 9 PUs


REE2 EAE EHE2 LTE

Equipment of swing frame for presses with: 9 PUs, with Preset, without non-stop delivery REE2 EAE EHE2 LTE Computer plug-in unit 2 Input/output plug-in unit Input/output auxiliary drive plug-in unit 2 Power part plug-in unit SSE2/LSE Servo-drive plug-in unit 2/ power part plug-in unit for brushless pile motors

9 PUs, with Preset, with auxiliary pile at the delivery REE2 EAE EHE2 LTE Computer plug-in unit 2 Input/output plug-in unit Input/output auxiliary drive plug-in unit 2 Power part plug-in unit SSE2/LSE2 Servo-drive plug-in unit 2/ power part plug-in unit for brushless pile motors 2 SSE2/LSE2 Servo-drive plug-in unit 2 / power part plug-in unit for brushless pile motors 2

1 1

Note: The electronic boards must be in their respective board slots. They must be correctly connected to the connectors of the backplane. In front of each plug-in unit the safety crossbar must be fitted.

401

Location diagrams

ZSG Central control cabinet

Computer plug-in unit REE 2

Computer plug-in unit REE

1 2 3 4 5 6 7 8

NTK24 Power supply board NTK5 Power supply board REK386 Processor board 386 ESK_2 Input/ output control board SAK2 Memory analog board ESK_1 Input/ output control board REK1 Processor board SRK Power converter board

Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , input / output control boards ESK 2). Boards of the same type are interchangeable.

ESK_2 Input/ output control board The input/ output control board ESK_2 is required for presses with 9 printing units.

REK386 Processor board 386 EPROM module Computer motherboard The processor board 386 REK 386 consists of the computer motherboard RGP 3, the EPROM module EPM and the RGPcomputer module RRM.

RGPcomputer module

Layout of computer unit RGP3+RRM


REK1 Processor board EPROM module Computer motherboard The processor board REK 1 consists of the computer motherboard RGP 2 and the EPROM module EPM.

Layout of processor board REK1

402

Location diagrams

ZSG Central control cabinet

Input/output auxiliary drive plug-in unit EHE 2 The input/output auxiliary drive plug-in unit EHE 2 is required for presses with: 2 - 5 printing units, 9 printing units.

Input/output auxiliary drive plug-in unit for presses with 2- 5 printing units

1 2 3 4

NTK5 Power supply board HAK2 Auxiliary drive board SEK Safety input board

EAK2 Input/output board from right to left for: feeder, delivery, central control cabinet, printing units 1 to 5. EAK2 Input/output board for printing unit 9

Input/output auxiliary drive plug-in unit for presses with 9 printing units

Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , auxiliary drive boards HAK 2, input/ output boards EAK 2). Boards of the same type are interchangeable.

Input/output plug-in unit EAE The input/output plug-in unit EAE is required for presses with: 6 printing units.

1 2 3

NTK5 Power supply board SEK Safety input board

Input/output plug-in unit for presses with 6 printing units

EAK2 Input/output board from right to left for: feeder, delivery, central control cabinet, printing units 1 to 8.

Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , input / output boards EAK 2). Boards of the same type are interchangeable.

403

Location diagrams

ZSG Central control cabinet

Auxiliary drive plug-in unit HAE 2 The auxiliary drive plug-in unit HAE 2 is required for presses with: 6 - 8 printing units.

1 2
Auxiliary drive plug-in unit for presses with 6- 8 printing units

NTK5 Power supply board HAK2 Auxiliary drive board

Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , auxiliary drive boards HAK 2). Boards of the same type are interchangeable.

404

Location diagrams

ZSG Central control cabinet

Power part plug-in unit LTE

The power part plug-in unit LTE is required for all presses.

1 2 3 4

LTK500 LTK50 STK_2 STK_1

Power part board Power part board Pile control board Pile control board

Power part plug-in unit for presses with 7 printing units, without Preset, with auxiliary pile at feeder and delivery

Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power part boards LTK50, power part boards LTK500). Boards of the same type are interchangeable.

LTK50 Power part board The power part board LTK50 is only used for presses with: 2 - 7 printing units, with Preset, with auxiliary pile at the delivery, 7 printing units, without Preset, with auxiliary pile at the delivery

Power part plug-in unit for presses with 8- 9 printing units, with Preset, with auxiliary pile at the feeder

STK_1 Pile control board The pile control board STK_1 is used for all presses except for those with: 8 - 9 printing units, with Preset, without auxiliary pile at the feeder.

STK_2 Pile control board The pile control board STK_2 is only used for presses: without Preset, with auxiliary pile at the feeder.

Power part plug-in unit for presses with 8- 9 printing units, with Preset, without auxiliary pile at the feeder

405

Location diagrams

ZSG Central control cabinet

Servo-drive plug-in unit SSE2 The servo-drive plug-in unit SSE2 is required for presses with: 1 2 - 4 PUs, without Preset (only one SSK 2), 2 PUs, without Preset, without CPC, 5 - 7 PUs, without Preset,

Servo-drive plug-in unit for a press with 2- 7 PUs, without Preset

NTK24 SSK2

Power supply board Servo-drive control board

Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , servo-drive control boards SSK 2). Boards of the same type are interchangeable.

Servo-drive plug-in unit 2 / power part plug-in unit for brushless pile motors SSE 2/ LSE


Servo-drive plug-in unit/power part plug-in unit for brushless pile motors for presses with 6- 7 PUs, with Preset

The servo-drive plug-in unit / power part plug-in unit for brushless pile motors SSE 2/ LSE is required for presses with: 2 - 5 PUs, with Preset (only one NTK 24 and two SSK 2s), 2 PUs, with Preset, without CPC, 6 - 7 PUs, with Preset, 8 - 9 PUs, with Preset, without non-stop delivery

1 2 3 4

NTK24 Power supply board SSK2 Servo-drive control board LTK500 Power part board BAK Brake control board

Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , servo-drive control boards SSK 2). Boards of the same type are interchangeable.

406

Location diagrams

ZSG Central control cabinet

Servo-drive plug-in unit 2 / power part plug-in unit for brushless pile motors SSE 2/ LSE


Servo-drive plug-in unit/power part plug-in unit for brushless pile motors 2 for presses with 8 - 9 PUs, with Preset, with auxiliary pile at the delivery

The servo-drive plug-in unit / power part plug-in unit for brushless pile motors SSE 2 / LSE2 is required for presses with: 8 - 9 PUs, with Preset, with auxiliary pile at the delivery

1 2 3 4 5

NTK24 Power supply board SSK2 Servo-drive control board LTK50 Power part board LTK500 Power part board BAK Brake control board

Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , servo-drive control boards SSK 2). Boards of the same type are interchangeable.

407

Location diagrams

ZSP Central control console

ZSP Central control console Layout

Fixing bolts for console plate

Console plate

Display control board DSK

Input / output module EAM Display unit consisting of: display power supply board DNK display support plate control console display ZID

Support plate for: A transformer 13T1 B connector 13X1 C terminal strip 13X2

Hinged cover with opening for cables Casing of central control console

Door

Overall view

408

Location diagrams

Position switches

Position switches
2S29 2S28 1S28 1S29 11S37 11S34 11S31 11S65 11S56 2S25 2S25a 2S25b 2S24 2S26 1S25 1S25a 1S25b 1S24 2S20 2S31 2S37 1S26 11S40 11S38 11S38a 1S40 11S38b 11S36 11S32 11S4

1S40a

11S39

Preset feeder, printing units 1 and 2

12S55

12S55a 12S40 3...9S28 12S39 12S33 12S130 12S41 12S117 12S34b 12S34a 12S43 12S37 3...9S24 12S9 3...9S20 3...9S37

12S44 12S38 12S56 3...9S29 12S35 12S36 12S422) 12S130a 12S421) 12B129a 12B129

12S34 12S65a

1 2

Version with rake Version with board

Delivery with coating unit


Legend: Equipment O.S. Equipment D.S. Equipment which can be allocated neither to the D.S. nor to the O.S.

409

Location diagrams

Position switches

12S44

12S68


12S55 12S55a 12S40 3...9S28 12S35 12S42 12S56 12S36 12S39 12S37 3...9S29 12S34 12S9 12S37a 3...9S24 12S65a 12S34b 12S34a 3...9S20 12S411) 12S412) 12S65 12S43 12S9c 12S9b 12S9a Version with rake Version with board

3...9S37

1 2

Extended delivery with coating unit


Legend: Equipment O.S. Equipment D.S. Equipment which can be allocated neither to the D.S. nor to the O.S.

410

Location diagrams

Solenoid valves

Solenoid valves

2Y56

1Y56

11Y74 1Y45 1Y15 15Y11

11Y66 11Y16

11Y15 2Y12 2Y48 1Y12 1Y16 1Y48

2Y2 2Y9 2Y10 2Y11 2Y13 2Y53

2Y63 2Y62 2Y61 2Y7 2Y51 2Y39/2Y40

1Y2 1Y9 1Y10 1Y11 1Y13 1Y53 1Y47

back 1Y63 1Y62 1Y61 1Y7 1Y51 1Y39/1Y40 1Y50 1Y52 1Y55 1Y42 front or back 1Y52 1Y55 1Y42 1Y54 1Y43 1Y44 1Y54 1Y43

front

Preset feeder, printing units 1 and 2


Legend: Equipment O.S. Equipment D.S. Equipment which can be allocated neither to the D.S. nor to the O.S.

411

Location diagrams

Solenoid valves

12Y14/ 12Y15 12Y60/ 12Y61 12Y11 12Y49 12Y13 12Y4 12Y78 12Y62 4...9Y67 3...9Y48 3...9Y12

Delivery with coating unit

12Y60/ 12Y61


12Y14/ 12Y15 12Y11 12Y49 12Y13 12Y4 3...9Y12 4...9Y67 3...9Y48 12Y78 12Y62

Extended delivery with coating unit


Legend: Equipment O.S. Equipment D.S. Equipment which can be allocated neither to the D.S. nor to the O.S.

412

Location diagrams

Motors

Motors
2MD 1MD 11M11 2M45 Lateral register 2M1 Lateral register 11M6 2M6 2M5 Circumferential register M52 1M6 1M1 1M4 1M8 1M5 Circumferen1M7 tial register 11M3 M51 1M4 1M2 1M3 11M9 11M8 1M9 11M7 11M5 1M45 11M2 11M12 11M1

Preset feeder, printing units 1 and 2

12M2 12M5 12M7 12M6 12M3 12M47 M44 12M1 3...9M2

Delivery with coating unit


Legend: Equipment O.S. Equipment D.S. Equipment which can be allocated neither to the D.S. nor to the O.S.

413

Location diagrams

Motors


12M2 12M5 12M1 3...9M2 12M7 12M6 12M3 12M47 M44

Extended delivery with coating unit


Legend: Equipment O.S. Equipment D.S. Equipment which can be allocated neither to the D.S. nor to the O.S.

414

Location diagrams

Sensors

Sensors

2B43

2B32

1B43

1B32

15B14 11B35 1B11 1B13 2B48 2B48a 1B48 1B48a 1B9

11B10 11B55

1B10 HWI 1B49

11B33 11B11

Preset feeder, printing units 1 and 2

3...9B32 12B129 12B69 12B129a 12B65 12B77 12B47

Delivery with coating unit


Legend: Equipment O.S. Equipment D.S. Equipment which can be allocated neither to the D.S. nor to the O.S.

415

Location diagrams

Sensors


3...9B32 12B129 12B69 12B129a 12B65 12B77 12B47

Extended delivery with coating unit


Legend: Equipment O.S. Equipment D.S. Equipment which can be allocated neither to the D.S. nor to the O.S.

416

Location diagrams

Control panels

Control panels

F C D C D

Preset feeder, printing units 1 and 2

H C G F

Delivery with coating unit

417

Location diagrams

Control panels


H C F G

Extended delivery with coating unit

418

Location diagrams

Control panels

Feeder
Press control

Pile control

Preset feeder

419

Location diagrams

Control panels

Printing unit/coating unit


C

Printing unit control O.S.

Printing unit/ coating unit control D.S.

Dampening system control

Coating unit control D.S.

Printing unit/coating unit

420

Location diagrams

Control panels

Delivery
H

Press control

Pile control

Press display MID

Preset version

421

Location diagrams

Control panels

Dampening system control

Fan and dryer control

Preset version

422

Location diagrams

Operators controls

Operators controls

Description

Feeder

Printing/coating unit

Delivery

Remark

Pushbutton Run

11S2

12S2

Pushbutton Stop

11S30

12S8

Pushbutton Production run

11S19

12S60

Emergency stop button

11S1

1...nS1 (O.S.) 1...nS2 (D.S.)

12S1

Illuminated pushbutton Compressor on/off Illuminated pushbutton Feeder on/off Illuminated pushbutton Paper run on/off Pushbutton Fast

11S3 11H3 11S7 11H7 11S5 11H5 11S20

11S58 11H58 12S59 12H59 12S57 12H57 12S6

Pushbutton Slow

11S21

12S7

Pushbutton Forward

11S17

1...nS3 (O.S.) 1...nS6 (D.S.) 1...nS4 (O.S.) 1...nS7 (D.S.) 1...nS5 (O.S.) 1...nS8 (D.S.)

12S3

Selector switch Safe

11S18

12S4

Pushbutton Backward

12S5

Signal lamp Malfunction press Signal lamp Malfunction feeder Malfunction delivery Malfunction printing/coating unit Malfunction dryer

11H51

12H9

11H1

1...nH1

12H1

423

Location diagrams

Operators controls

Description

Feeder

Printing/coating unit

Delivery

Remark

Illuminated pushbutton Job counter on/off Pushbutton Crawl speed Pushbutton Position 1...nS23

12S63 12H63

1...nS17

Illuminated pushbutton Plate mounting

1...nS59 1...nH59

Pushbutton Auxiliary pile down

11S29

12S54

Pushbutton Auxiliary pile up

11S28

12S53

Toggle switch Auxiliary pile on/off Pushbutton Main pile down

11S27

11S25

12S46

Pushbutton Main pile up

11S24

12S45

Pushbutton Pile stop

11S26

12S124

Pushbutton Pile board on/off Pushbutton Removal of inspection sheet Press display MID Illuminated pushbutton Inking form rollers on/off 1...nS57 1...nS57

12S10 12H10 12S11 12S11a

424

Location diagrams

Operators controls

Description

Feeder

Printing/coating unit

Delivery

Remark

Illuminated pushbutton Ink ductor on/off Pushbutton + dampening Washing dampening/varnishing rollers Illuminated pushbutton dampening Selector switch Adjusting dampening rollers Pushbuttons Blast air regulation Pushbuttons Suction head height 11S117 11S118 11S44 11S44a 11S45 11S45a 11S46 11S47 11S58 11S58a 11S59 11S59a 11S59 11S60 11S63 11S62 11S9 11S10 11S48 11S57

1...nS58 1...nH58 1...nS22 12S17... 12S24

12S25... 12S32 1...nS21

Pushbuttons Suction head format Pushbuttons Main pile centering

Pushbuttons Auxiliary pile centering Pushbutton Pile stops larger format Pushbutton Pile stops smaller format Pushbutton Pile stops D.S. Pushbutton Pile stops O.S. Pushbuttons Format wheels Pushbuttons Sheet slowdown format

12S68 12S69

425

Location diagrams

Operators controls

Description

Feeder

Printing/coating unit

Delivery

Remark

Pushbuttons Sheet slowdown speed Pushbuttons Sheet jogger D.S. Pushbuttons Sheet jogger O.S. Potentiometer to regulate the displayed fans Potentiometer to regulate the displayed fans Potentiometer to regulate the displayed fans Potentiometer to regulate the displayed fans Potentiometer to regulate the displayed fans Potentiometer to regulate the displayed fans Pushbutton Dryer on/off

12S61 12S62 12S73 12S74 12S75 12S76 DSM5

DSM3

DSM6

DSM2

DSM1

DSM4

Selector switch for dryer

Potentiometer to regulate dryer output Volume controller

Illuminated pushbutton Intercom Pushbutton Lifting the sheet stop fingers 11S8

426

Location diagrams

Operators controls

Description

Feeder

Printing/coating unit

Delivery

Remark

Illuminated pushbutton Dampening rollers Pushbutton Suction air for suction tape + Pushbutton Suction air for suction tape Illuminated pushbutton Turning the ink fountain roller Varnish circulation

11S6 11H6 11S41

11S42

1...nS45

Varnish pump ON/OFF

Turning the pan roller

Draining the coating pan

Varnish flow rate to varnish pump

Spraying

Rinsing

Stopping the pan roller

2...nS57 2...nH57 11R1

Potentiometer Blast air at front lays

427

Location diagrams

Operators controls

428

Location diagrams

ZSP Control panel of control console

ZSP Control panel of control console

7 4 1

8 5 2 0

9 6 3

CPC

Control panel of central control console ZSP

Selector buttons Unit (from left to right): Entire press Delivery Printing unit Feeder Preselection display Actual value display Fine display of preselection/actual value display Fault display: Press not ready to run Warning Service display: Central lubrication Service 1 Service 2 Colour buttons Function buttons Adjustment buttons

q w

Emergency stop button Button Stop Command buttons (from left to right): Presetting Job change Progressives (colour separations) Washup Command control buttons Signal lamps (from left to right): Malfunction press (red) Malfunction control console (blue) Malfunction production run (yellow) Button Page up/down in the display Control console display Numeric keypad CPC keys (for presses without CPC equipment)

2 3 4 5 6

e r

7 8 9

t z u i

429

Location diagrams

ZSP Control panel of control console

430

Abbreviations

Abbreviations
Abbreviation Description Drive extension module Display board Display and key distribution board Job memory card unit Analog signal distribution module Control and distributor module EGK EE EEM Abbreviation Description Input/output plug-in unit Input/output board Input/output module Backplane of input/output plug-in unit Electronic plug-in unit Single-fault fail-safe extension module External equipment board Auxiliary drive input/output plug-in unit Backplane of auxiliary drive input/output plug-in unit Mains discharge board Backplane of electronic plug-in unit EPROM module Extension control cabinet Input/output control board Interference suppressor module Electronic ballast Front-corner alignment control Input/output distributor module Extension board Extension module External equipment supply board

AEM
ANZ ATV ASE AUM AVM

EAE
EAK EAM EAR

BAK
BAM BEK BFM BKM BLT BSM BVM

Brake control board Brake control module Control unit board Filter module of brushless power part Brake/ clutch module Brushless power part Control unit interface module Control unit distributor module

EHE EHR ELK ELR EPM ESG ESK ESM

CSM
CVK

CPC3 interface module CPC3 distributor board

EVG EVK EVM

DAM
DAK DAS DBE DGP DLW DNK DSK DSM

Double-sheet indication module Digital output board Speed ratio display system Double-sheet detector Display motherboard Diskette drive Display power supply board Display control board Speed control module Fans

EWK EWM EXK

FAM
FCA FCK FDK

Flat-cable output module Adaptor between telediagnosis board and CPC2S Flash memory controller board Telediagnosis board

431

Abbreviations

Abbreviation

Description Flat-cable input module Ink fountain board Ink fountain distributor Sensor for overshooting-sheet control Flat-cable connection module Ink zone display board Distribution board for ink zone keys

Abbreviation

Description Air pressure sensor module Light pen Power logic module Varnish pump control module Power part control module Light barrier Power part plug-in unit for brushless pile motors Lamp control module Backplane of power part plugin unit for brushless pile motors Power part plug-in unit Power part board Power part module Backplane of power part plugin unit Interconnection module Air distributor module Distribution box

FEM
FKK FKV FK FVM FZA FZT

LDM
LG LLM LPM LRM LS LSE LSM LSR

GKM
GRM GSM

Compact rectifier module Rectifier module Rectifier module with fuses LTE LTK LTM

HAE
HAK HAR HLM HSK HSQ HTM HVK HWI

Auxiliary drive plug-in unit Auxiliary drive board Backplane of auxiliary drive plug-in unit Auxiliary drive logic module Main drive control board Sheeter Auxiliary drive driver module Main current distributor board Encoder

LTR LUM LVM LVT

MAE
MAR MCM MEE MID

Motor drive plug-in unit Motor drive backplane Microcontroller module Motor drive/electronic plug-in unit Press display Measuring head Motor drive board Motor regulation board Measuring bar computer module Motor control board Measuring bar sensor module Measured-value acquisition board State indication board

IDS
ITF ITM IWM

Encoder Terminal interface IGBT driver module Earth-leakage monitor module

MK MOT MRK MRM MSK MSM MWE MZK

KID
KKM KLM KNT KOK KVM KVT

Compact information display Heat sink module Compact power module Compact power supply unit Communication board Terminal amplifier module Heat sink unit

432

Abbreviations

Abbreviation

Description Mains connection module Electronics supply board Supplementary module of power supply unit Power supply plug-in unit Power supply board Power supply module Power supply backplane Mains supply board NV-RAM module Power distributor of electronic plug-in unit

Abbreviation SBM SDM SEK SEM SIK SLA SLM SLT SM SMM SMR SNT

Description Power bridge module Servo-drive pushbutton module Safety input board Interface input module Actual current measuring board Suction air control Pile power module Converter power part Stepper motor Current measuring module Stepper motor control board Chopper-type power supply unit Memory analog board module Voltage regulator Voltage selector switch Power converter board Serial interface adapter Servo-drive plug-in unit Servo-drive control board Servo-drive distributor module Backplane of servo-drive plugin unit Interface adapter Pile control board Pile power part Pile control module Vacuum cleaner Supporting element of power converter Signal conversion module Control voltage distributor board Interface distributor module Connecting part of power converter Voltage fluctuation relay Setpoint module

NAM
NEK NSM NTE NTK NTM NTR NVK NVM NVTE

PBK
PD PEK PRZ PRM PSL PSM PU

Back-up battery board Printer Extension board for plate image reader Processor board Plate position detection module Positioning lamps Profibus interface module Printing unit SPM SPR SPW SRK SSA SSE SSK SSM SSR

REE
REK REM RER RGP RRM RSK RSM RWK

Computer plug-in unit Processor board Register module Backplane of computer plug-in unit Computer motherboard RGP computer module Plug-on control board Plug-on control module Backplane

STA STK STL STM STS STT SUM SVK SVM

SAK
SAM SAS

Memory analog board Interface output module Busbar system

SVT SW SWM

433

Abbreviations

Abbreviation

Description Button and display module Tacho input module Transistor power board Terminal Buttons for manual positioning of measuring head Transistor control board Transistor control module Driver/interface board Dryer control module Transistor driver board Keyboard coding module Key distributor board Encoder distribution module Tacho signal distribution system

Abbreviation ZRM ZSG ZSK ZSP ZT ZTK

Description ZSK computer module Central control cabinet Central control board Central control console Zenith terminal Central control board

TAM
TEM TLK TML TMP TRK TRM TSK TSM TTK TUM TVK TVM TVS

UFK
USM UVM

Filter board Interconnection module Converter and distributor module

VEN
VMM VP VSM VTL VTR VVK

Fan Distributor for measuring module Distributor board Amplifier module Distributor board for diskette drives Distributor board Ballast supply board

WDM ZID
ZMM

Resistance decade module

Control console display Double current-measuring module

434

Equipment identification

Equipment identification
To be able to clearly identify the electrical equipment, the following equipment identification is used:

Press model Position code Where on the press ... ? Identification letter or abbreviation Which equipment ... ? Number Distinguishes equipment of the same type

Example 1: 1LVT1

1 PU1

LVT Distribution box

1 1st distribution box (main distributor)

Example 2: 1S3

1 Printing unit 1

S Switch here: pushbutton Forward

3 Consecutive number of switch on PU 1

Example 3: E4

Blank Cannot be allocated to any unit

E Other equipment: motor / pneumatic system compressor

4 Consecutive number

Note: If a field of the equipment identification is not required or not defined, it is left blank.
In most cases the consecutive number corresponds to the inputs or outputs of the associated EAK.

435

Equipment identification

436

Position codes

Position codes
Overview of position codes

The position code indicates on which unit of the press the equipment in question is located. The position codes 1 to 10 are reserved for the printing units or the coating unit.
1 2 3 4 5 11 12 13 14 15 16 20 101

Printing unit 1 Printing unit 2 or coating unit Printing unit 3 or coating unit Printing unit 4 or coating unit

...

10

Feeder Delivery Central control console Sheeter HSQ Central control cabinet ZSG Extension control cabinet ESG Dryer Control unit CPC1

Example: Position codes on a Speedmaster

15 4 12 101 13 11 3 2 1

Speedmaster SM102

437

Position codes

438

Index

Index
A
Abbreviation, 435 Abbreviations, 431 Adjustment of format wheels 11M4, 47 Checking the operating range, 52 Fault message, 47 Interconnection diagram, 49 Place of installation, 48 Removal and installation, 50 Technical data, 48 Adjustment of pile support plate 11M8, 31, 33 Checking the operating range, 37 Interconnection diagram, 34 Place of installation, 33 Removal and installation, 35 Technical data, 33 Adjustment of printing pressure 1...nM5, 85 Checking the operating range, 95 Interconnection diagram for CU, 89 Interconnection diagram for PU, 88 Place of installation, 87 Removal and installation of motor, 90 Removal and installation of potentiometer, 92 Technical data, 87 Adjustment of pull lays 1M7/1M8, 96 Automatic positioning, 96 Checking the operating range, 103 Interconnection diagram 1M7, 99 Interconnection diagram 1M8, 100 Place of installation, 98 Precision adjustment of pull lay, 97 Removal and installation, 101 Technical data, 98 Admission of pressure, pneumatic system 15Y11 Pin assignment, 352 Place of installation, 351 Task, 351 Air supply cabinet E8, 381 Automatic misalignment control 11M7 Activation and inactivation, 252 Block diagram, 251 Checking the operating range, 257 Graphical representation, 253 Interconnection diagram, 255 Place of installation, 254 Removal and installation, 256 Sheet alignment, 251 Technical data, 254 automatic pile transport 11B35 checking the circuit state, 157 connection, 156 Layout, 155 place of installation, 155 -removal and installation, 156 task and function, 156

Automatic sheet arrival control 11M3 Activation and inactivation, 239 Block diagram, 238 Graphical representation, 240 Preset version, 247 Checking the operating range, 250 Interconnection diagram, 248 Place of installation, 247 Removal and installation, 249 Technical data, 247 Sheet alignment, 238 Sheet arrival control, 239 Standard version, 241 Checking the operating range, 246 Interconnection diagram, 242 Place of installation, 241 Removal and installation, 243 Technical data, 241 Autoplate, 267 Block diagram, 269 Fault display, 268 Method of functioning, 267 Sequence of functions, 270 auxiliary pile detection 11B11 checking the circuit state, 151 connection, 150 layout, 149 place of installation, 149 removal- and installation, 150 setting, 151 task and function, 150 auxiliary pile motor 11M2 layout, 146 pin assignment, 148 place of installation, 146 task and function, 147 Technical specifications, 147 auxiliary pile motor 12M2 layout, 192 pin assignment, 194 place of installation, 192 Task and function, 193 Technical specifications, 193

B
Blanket washup device GTW, 281 Blast air regulation at feeder 1M9, Manual blast air setting, 360 Blast air regulation at the feeder 1M9 Block diagram, 357 Characteristiccurvedependent blast air regulation, 358 Checking the operating range, 367 Layout and task, 362 Pin assignment, 363 Place of installation, 361 Removal and installation, 364 Technical data, 363 Block diagram, Sheet alignment, 207 Blower bar, see blower motor for dampening system, 322

Index

Blower motor for dampening system M45, 322 Blower motor for powder spray device 12M35, 377 bottom main pile limitation 11S34 checking the circuit state, 159 place of installation, 158 setting, 159 task and function, 158 bottom main pile limitation 12S34 checking the circuit state, 206 place of installation, 204 setting, 205 task and function, 204 Brushless main motor from 37KW, 12

C
Central control cabinet ZSG, 393 Equipment zone A Power supply, 394 Equipment zone B Partition wall, 395 Equipment zone C Mounting rack / control devices, 397 Equipment zone D Flat cable mounting plate, 398 Equipment zone E Swing frame, 399 GRM Rectifier module, 396 Location and layout, 393 Central dampening solution supply E40, 325 Central lubrication, 329 Basic concept, 329 Fault messages, 332 Grease lubrication Block diagram, 333 Function, 334 Layout, 334 Monitoring the lubrication system, 335 Motor for grease lubrication 12M47, 345 Place of installation, 334 Pressure relief valve of the motor , 337 Settings, 336 Triggering a lubrication process, 336 Oil lubrication Block diagram, 338 Changing the filter, 342 Distributing lubrication, 340 Filter unit, 341 Function, 340 Layout, 339 Place of installation, 339 Pressure relief valve of oil pump, 342 Triggering a lubrication process, 341 Service display, 330 changeover fast/slow 12B65 checking the circuit state, 197 connection, 196 layout, 195 place of installation, 195 -Removal and installation, 196 task and function, 196 Circumferential register SM/CD 102, 314 Coarse register monitoring, 271 Adjustment, 273 Connection, 271 Layout, 271

Place of installation, 271 Removal and installation, 272 Coarse register monitoring 1...nB48, Task/function, 272 Coating unit, Position code, 437 Control console Layout, 408 Location diagrams, 408 Control panel ZSP, Location diagrams, 429 Control panels Delivery, 421 Feeder, 419 Location diagrams, 417 Printing unit/coating unit, 420 Cooling and circulating unit E40, 325 Cover guide height adjustment 1M4, 67 Checking the operating range, 76 Interconnection diagram, 70 Place of installation, 69 Positioning, 67 Removal and installation of motor, 71 Removal and installation of potentiometer, 73 Technical data, 69

D
Dampening, 321 Dampening solution mixing unit E41, 328 Dampening system Blower motor, 322 Dampening solution sensor, 323 Delivery, Position code, 437 delivery pile control automatic pile height control, 170 auxiliary drive control, 165 block diagram (Preset), 161 block diagram (standard), 162 nonstop operation, 177 overview (Layout), 163 overview of components (drive side), 167 overview of components (operator side), 166 overview of motors, 168 overview of solenoidoperated valves, 169 overview of switches and sensors, 168 paper blockage, 185 press control, 164 removal of sample sheet, 184 safety circuit, 164 Transport of auxiliary pile, 175 transport of main pile (Preset), 171 transport of main pile (standard), 173 delivery upper edge of pile 12B129 checking the circuit state, 203 connection, 202 layout, 201 place of installation, 201 -removal and installation, 203 task and function, 202 Diagonal register SM/CD 102, 308 Doublesheet detector 1B11 Adjustment, 237 Block diagram, 231

Index

Connection, 235 Fault messages, 232 Layout, 234 Pin assignment, 235 Place of installation, 233 Removal and installation, 236 Sheet alignment, 231

I
Identification letter, 435 Impression cylinder washup device DZW, 292 Block diagram, 292 Inactivating pile centering 11B55, 28 Ink blade, Sensor monitoring the ink blade 1...nB43, 303 Ink fountain roller motor SM/CD 102, 305 Inking roller washup device FWW, 286 Inking unit temperature control, 382 SM/CD 102, 317 Inking unit temperature control E39, E39a, SM/CD 102, 318 Intercom WSA Function, 387 Layout, 386 IR slidein dryer, Switches monitoring the IR slidein dryer 12S9, a, b, c, 380

E
Encoder, Place of installation, 388 Encoder IDS, 388 Installation variants, 390 Pin assignment, 389 Removal and installation, 390 Equipment identification, 435 Extension control cabinet ESG, 437

F
Feeder, Position code, 437 Feeder pile control block diagram (Preset), 119 block diagram (Standard), 120 Overview of components (Standard), 125 feeder pile control automatic pile height control of auxiliary pile , 129 automatic pile height control of main pile (standard), 128 auxiliary drive control, 123 nonstop operation (Preset), 134 nonstop operation (standard), 137 overview (layout), 121 Overview of components (Preset), 124 overview of motors, 126 overview of switches and sensors, 126 pile height control of main pile (Preset), 127 press control, 122 safety circuit, 122 transport of auxiliary pile, 132 Transport of main pile, 130 Format adjustment Adjustment of format wheels 11M4, 47 Adjustment of printing pressure 1...nM5, 85 Cover guide height adjustment 1M4, 67 Pile stops 11M11/11M12, 59 Sheet joggers 12M6/12M7, 110 Sheet slowdown/format adjustment 12M5, 104 Suction head/format adjustment 11M6, 53

L
Lateral register SM/CD 102, 311 Level in coating pan LB32, 371 Location diagrams, 393 Control panel ZSP, 429 Control panels, 417 Delivery, 421 Feeder, 419 Printing unit/coating unit, 420 Motors, 413 Operators controls, 423 Position switches, 409 Sensors, 415 Solenoid valves, 411 ZSP Central control console, 408 Location diagrams , Central control cabinet ZSG, 393 Lubrication monitoring 1 12B47, 348 Lubrication monitoring 2 12B77, 348

M
M1 Directcurrent main motor, 7 Main drive Brushless main motor from 37KW, 12 Directcurrent main motor, 7 Motor terminal board, 15 Replacing the brake, 9 Replacing the carbon brushes, 10 Rotor position encoder, 13 main pile motor (Preset) 11M1 layout, 140 pin assignment, 142 place of installation, 140 task and function, 141 technical specifications, 141 main pile motor (standard) 11M1 Layout, 143 pin assignment, 145 place of installation, 143 task and function, 144 Technical specifications, 144

G
Grease lubrication, 333 Lubrication monitoring 1 12B47, 348 Lubrication monitoring 2 12B77, 348 GRM Rectifier module, Central control cabinet ZSG, 396

Index

main pile motor 12M1 (Preset) layout, 186 pin assignment, 188 place of installation, 186 Task and function, 187 Technical specifications, 187 main pile motor 12M1 (standard) layout, 189 pin assignment, 191 place of installation, 189 Task and function, 190 technical specifications, 190 Malfunctions in printing unit, 268 Misalignment control 11M7, Misalignment control, 252 Monitoring the ink blade, sensor 1...nB43, 303 Connection, 304 Layout, 303 Pin assignment, 304 Place of installation, 303 Removal and installation, 304 Task, 304 Monitoring the IR slidein dryer, Switches 12S9, a, b, c, 380 Motor for grease lubrication Pin assignment, 345 Place of installation, 345 Motor terminal board, 15 Motors Blower motor for powder spray device 12M35, 377 Location diagrams, 413 Washup brush motors M43, M50 ... M56, 296 Motors / functional units, Servodrive diagonal register SM/CD 102, 308 Motors / motordriven units Servodrive circumferential register SM/CD 102, 314 Servodrive ink fountain roller SM/CD 102, 305 Servodrive lateral register SM/CD 102, 311

N
Number, 435

O
Oil lubrication, 338 Pressure monitoring oil lubrication 1F33 (1 bar), 346 Pressure monitoring oil lubrication 1F34 (12 bars), 347 Oil pump M44, 343 Pin assignment, 344 Place of installation, 343 Operators controls, Location diagrams, 423

P
Pan roller motors 1...nM1, 321 Pile centering, 17 Activation and inactivation, 18 Block diagram, 17 Sensor Inactivating pile centering 11B55, 28 Sensor Pile centering 11B10, 19

Sensor 11B10, 20 Sensor 11B55, 29 Servodrive Pile centering 11M9, 21 Pile centering 11M9, 23 Checking the operating range, 27 Interconnection diagram, 24 Place of installation, 23 Removal and installation, 25 Technical data, 23 pile height control 12B69 checking the circuit state, 200 connection, 199 Layout, 198 place of installation, 198 -removal and installation, 199 setting, 200 Task and function, 199 Pile merging, 31 Adjustment of pile support plate 11M8, 31 Pile stops 11M11/11M12, 59 Checking the operating range, 66 Fault message, 60 Interconnection diagram 11M11, 62 Interconnection diagram 11M12, 63 Place of installation, 61 Prepiling, 60 Removal and installation, 64 Technical data, 61 Pin assignment Servodrive circumferential register SM/CD 102, 315 Servodrive diagonal register M4 SM/CD 102, 309 Servodrive ink fountain roller SM/CD 102, 306 Servodrive lateral register SM/CD 102, 312 Coarse register monitoring, 271 Plate clamping device Autoplate, 267 1...nB53 Coarse register monitoring, 271 Pneumatic system, Admission of pressure, pneumatic system 15Y11, 351 Pneumatic system compressor E4 Pin assignment, 355 Technical data, 355 Position code, 435 Position codes, 437 Position switches, Location diagrams, 409 Potentiometer, 308 Powder spray unit 12E2, 373 Powdering cycle switch 12S68, 379 Pressure monitoring oil lubrication 1F33 (1 bar), Place of installation, 346 Pressure monitoring oil lubrication 1F34 (12 bars), Place of installation, 347 Pressure sensor pneumatic system 15B14 Pin assignment, 354 Place of installation, 353 Printfree margin 1M2/1M3 Checking the operating range, 84 Interconnection diagram, 79 Place of installation, 78 Removal and installation of motor, 80 Removal and installation of potentiometer, 81 Technical data, 78 Printfree margin D.S./O.S. 1M2/1M3, 77

Index

Printing unit, Position code, 437 Pull lay control 1B9/1B10 Block diagram, 223 Checking the sensing distance, 230 Place of installation, 226 Sheet alignment, 223 Sheet infeed error/pull error, 224 Preset version, Adjustment, 227 Standard version, Adjustment, 229

R
Rotor position encoder, 13 Layout, 13 Pin assignment, 13

S
Sensor Inactivating pile centering 11B55 Adjustment, 29 Check, 29 Place of installation, 29 Sensor Pile centering 11B10, 20 Check, 20 Place of installation, 20 Removal and installation, 20 Sensor for dampening solution control B32, 323 Sensors Admission of pressure, pneumatic system 15Y11, 351 at the washup solution container B1, B54, B55, 301 Adjustment, 302 Connection, 301 Pin assignment, 301 Place of installation, 301 Removal and installation, 302 Level in coating pan LB32, 371 Location diagrams, 415 Monitoring the ink blade 1...nB43, 303 Sensors/switches, 1...nB53 Coarse register monitoring, 271 Service display Grease lubrication, 331 Oil lubrication, 330 Service display Washup, 278 Functions of the blanket washup device, 278 Functions of the impression cylinder washup device, 278 Functions of the inking roller washup device, 279 Servodrive Adjustment of format wheels 11M4, 47 Adjustment of pile support plate 11M8, 33 Adjustment of printing pressure 1...nM5, 85 Adjustment of pull lays 1M7/1M8, 96 Automatic misalignment control 11M7, 251 Automatic sheet arrival control 11M3 Preset version, 247 Standard version, 241 Blast air regulation at the feeder 1M9, 357 Cover guide height adjustment 1M4, 67 Pile centering 11M9, 21, 23

Pile stops 11M11/11M12, 59 Sheet joggers 12M6/12M7, 110 Sheet slowdown/format adjustment 12M5, 104 Suction head height adjustment 11M5, 40 Suction head/format adjustment 11M6, 53 Servodrive circumferential register SM/CD 102, 314 Servodrive diagonal register SM/CD 102, 308 Servodrive ink fountain roller SM/CD 102, 305 Servodrive lateral register SM/CD 102, 311 Sheet alignment, 207 Automatic misalignment control 11M7, 251 Automatic sheet arrival control 11M3, 238 Block diagram, 207 Degree values, 209 Doublesheet detector 1B11, 231 Pull lay control 1B9/1B10, 223 Sheet alignment control, 210 Sheet alignment control Adjustment, 219 Block diagram, 210 Misalignedsheet display (trend display), 214 Sheet alignment, 210 Sheet alignment error ANK sensors, 212 FK sensors, 213 Sheet alignment control 1B13/1B49, 215 Checking the circuit state, 222 Layout and task, 215 Pin assignment, 215 Place of installation, 215 Removal and installation, 216 Sheet joggers 12M6/12M7, 110 Checking the operating range, 117 Fault message, 111 Interconnection diagram 12M6, 113 Interconnection diagram 12M7, 114 Place of installation, 112 Removal and installation, 115 Technical data, 112 Sheet monitoring, 259 Sheet travel monitor 1...nB48/1...nB48a, 259 Sheet slowdown / format adjustment 12M5 Checking the operating range, 109 Interconnection diagram, 107 Place of installation, 106 Removal and installation, 108 Technical data, 106 Sheet slowdown/format adjustment 12M5, 104 Fault message, 105 Sheet travel monitor 1...9B48/1...9B48a, 259 Adjustment, 263 Components, 263 Place of installation, 262 Service display, 261 Size adjustment, 45 Block diagram, 45 Command Presetting, 46 Printfree margin D.S./O.S. 1M2/1M3, 77 Solenoid valves, Location diagrams, 411 Static electricity eliminator 11E3, Task, 385 Static electricity eliminator 12E3 Layout, 384

Index

Place of installation, 383 Suction head height adjustment 11M5, 39, 40 Checking the operating range, 43 Interconnection diagram, 41 Place of installation, 40 Removal and installation, 42 Technical data, 40 Suction head height control, 39 Suction head height adjustment 11M5, 39 Suction head/format adjustment 11M6, 53 Checking the operating range, 58 Fault message, 54 Interconnection diagram, 56 Place of installation, 55 Removal and installation, 57 Technical data, 55 Switches Monitoring the IR slidein dryer 12S9, a, b, c, 380 Powdering cycle 12S68, 379

Settings, 294 Inking roller washup device FWW Additional washing of printing plate and ink fountain roller, 289 Block diagram, 286 Example, 289 Flow chart, 290 Function, 287 Layout, 287 Settings, 288 Messages, 276 Selection of functions, 275 Service display, 278 Washup solution container, Warnings, 298 Washup solution container E9 Block diagram, 297 Layout, 299 Pin assignment, 300 Place of installation, 299 Sensors B1, B54, B55, 301 Task, 300 Warnings, 298

T
Temperature control, SM/CD 102. Siehe FarbwerkTemperierung

Z
Zentralschmierung, Oil lubrication, Circular lubrication, 340 Zero position Servodrive circumferential register SM/CD 102, 316 Servodrive diagonal register SM/CD 102, 310 Servodrive ink fountain roller SM/CD 102, 307 Servodrive lateral register SM/CD 102, 313

U
upper main pile limitation 11B33 checking the circuit state, 154 connection, 153 Layout, 152 place of installation, 152 removal and installation-, 153 setting, 154 task and function, 153

V
Varnish supply unit E4a, 369

W
Washup brush motors M43, M50 ... M56, 296 Pin assignment, 296 Place of installation, 296 Washup devices Blanket washup device GTW Block diagram, 281 Example, 285 Flow chart, 285 Function, 282 Layout, 282 Settings, 284 Control by command, 275 Impression cylinder washup device DZW, 292 Example, 295 Flow chart, 295 Function, 293 Layout, 293