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7 Main drive
7 M1 Direct-current main motor
12 M1 Brushless main motor
17 Pile centering
17 Block diagram
19 11B10 Pile centering
21 11M9 Pile centering
28 11B55 Inactivating pile centering
31 Pile merging
31 11M8 Adjustment of pile support plate
45 Size adjustment
45 Block diagram
47 11M4 Adjustment of format wheels
53 11M6 Suction head/format adjustment
59 11M11/11M12 Pile stops D.S./O.S.
67 1M4 Cover guide height adjustment
77 1M2/1M3 Print-free margin D.S./O.S.
85 1...nM5 Adjustment of printing pressure
96 1M7/1M8 Adjustment of pull lays
104 12M5 Sheet slowdown/format adjustment
110 12M6/12M7 Sheet joggers D.S./O.S.
1
2. Speedmaster CD102 Table of contents
2
2. Speedmaster CD102 Table of contents
321 Dampening
321 1...nM1 Pan roller motors
322 1...nM45 Blower motor for dampening system
323 1...nB32 Sensor ”Dampening solution control”
325 E40 Central dampening solution supply /
cooling and circulating unit
328 E41 Dampening solution mixing unit
3
2. Speedmaster CD102 Table of contents
4
2. Speedmaster CD102 Table of contents
431 Abbreviations
5
2. Speedmaster CD102 Table of contents
6
Main drive M1 Direct-current main motor
Main drive
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.
7
Main drive M1 Direct-current main motor
8
Main drive M1 Direct-current main motor
9
Main drive M1 Direct-current main motor
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 Turn off the main switch on the central
control cabinet ZSG and make sure no-one
can turn the power back on.
2 Remove all ventilation covers on the
installation side of the brake.
3 Disconnect the wires of the carbon brushes
from the terminals .
Note:
With certain motors it is necessary to turn the
brush-rocker ring for brush removal.
Before turning the brush-rocker ring , mark
its position in relation to the stator ( e.g.
colour line ) if no markings exist so far.
4 Loosen the retaining screws ( but do not
turn them out completely ) and turn the
brush-rocker ring ( see illustration on next
page).
5 Flip up the clamp-type brush holder and
take out all used carbon brushes .
Layout of brush-rocker ring (example)
10
Main drive M1 Direct-current main motor
11
Main drive M1 Brushless main motor
Á
Á
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
Layout
Pin base X2 / connection to BLT4
Safety screws of adjusting ring
Sensor
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
Pin assignment
X2 2 X2 Plug connection to ZSG (BLT4)
1 3
7 Pin Function
6 4
5 6 DC +15 V
7 15 V
Pin base X2, 7-pole
13
Main drive M1 Brushless main motor
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁ
ÁÁÁÁÁÁÁ
ÁÁ
ÁÁÁÁÁÁÁ
ÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
Removal
1 Turn off the main switch and make sure
no-one can turn the power back on.
2 Remove connector X2.
3 Remove the sensor (four fixing bolts).
4 Replace the sensor or rotating part.
Note:
Put the end-float washers back in place
between the rotating part and motor.
Installation
5 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.
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 tempera-
ture sensor
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 Plug connection in motor terminal box
Pin Function
1 5 2 6
1 Motor code 0
2 Motor code 1
3 Motor code
1 5
2 6 4 Temperature sensor
5 Brake +
15
Main drive M1 Brushless main drive
16
Pile centering Block diagram
Pile centering
Block diagram
The pile centering function comprises:
Pile centering Inactivating
11B10 pile centering – the sensor ”Pile centering” 11B10,
11B55 – the sensor ”Inactivating pile centering” 11B55”,
– the servo-drive ”Pile centering” 11M9”.
Pile centering
The pile centering function compensates for the
11M9
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
M
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
SSM1 SSM1 control system corrects the position of the paper pile
through the servo-drive ”Pile centering” 11M9”.
REK1 REK386
DSK
DNK SVM
MID11 MID12
ZID
Displays
17
Pile centering Block diagram
18
Pile centering 11B10 Pile centering
Á 11B10
Á
Where?
Á
– approx. 25 mm below the upper edge of the pile.
Á system:
Á
130 ± 2 mm
– if the difference between the required distance
and actual distance exceeds the tolerance limits,
– by activating the servo-drive ”Pile centering”
Required distance for pile centering 11M9.
No automatic control:
– within the tolerance limits of the required
distance.
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
11LVT1
black
2SSM1
X5: D4
X2: +8
X2: –8
blue
brown
Check
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1646 ± 70
130 2 mm
20
Pile centering 11M9 Pile centering
Automatic positioning
Condition:
Automatic pile centering is switched on in the
preselection display.
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”.
ÁÁÁ
ÁÁÁ
Toggle switch
ON - Main pile control activated.
ÁÁÁ
”Auxiliary pile on / off”
OFF - The pushbuttons ”Main pile centering” control
the servoĆdrive.
Pushbuttons – Maximum positioning range:
”Main pile centering” ± 35mm in relation to the centre of the feeder.
Plus button Plus button = movement towards D.S.
Minus button = movement towards O.S.
Minus button
The pile support frame and pile support plate can
move max. 35 mm in the same direction together.
Present position
22
Pile centering 11M9 Pile centering
Place of installation
11M9
Operator side
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
23
Pile centering 11M9 Pile centering
Interconnection diagram
X5
X10 SSR
SSR X10
X11 X12
X3 X4
X13 X14
SSR X14
Backplane of servo-
11 drive plug-in unit SSR
11LVT1
2SSM1: X2
X3 X4
X1
2SSM1: X4
X2
X5
2SSM1
Servo-drive distributor
module 2SSM1
11M9: X1 3 4
5
2 1
11M9
Servo-drive 11M9
24
Pile centering 11M9 Pile centering
ON
OFF
06 2048 ± 2
– Set the toggle switch ”Auxiliary pile ON/OFF” – Remove the servo-drive ”Pile centering”
to ”OFF”. 11M9.
– Select the service display ”SSK1”.
– Bring the pile support plate into its central
position (set to 2048±2 inc).
25
Pile centering 11M9 Pile centering
4)
07 2048 ± 2
1M9: X1
26
Pile centering 11M9 Pile centering
Condition:
The pile support plate is in its central position
(2048 inc).
Input Incremental value
– 35 mm 3686 " 23 inc
+ 35 mm 409 " 23 inc
27
Pile centering 11B55 Inactivating pile centering
Sensor 11B55
28
Pile centering 11B55 Inactivating pile centering
Place of installation
11B55
Adjustment
brown
black
blue
FAM64
XE: 55
+1
–1
11LVT1
Check
0010
29
Pile centering 11B55 Inactivating pile centering
30
Pile merging 11M8 Adjustment of pile support plate
Pile merging
ÁÁ
”Auxiliary pile on / off”
OFF the servoĆdrive 11M8.
31
Pile merging 11M8 Adjustment of pile support plate
ÁÁ
Toggle switch – Auxiliary pile control activated.
ON
ÁÁ
”Auxiliary pile on / off”
The pushbuttons ”Auxiliary pile centering” control
OFF the servoĆdrive 11M8.
Maximum positioning range:
Pushbuttons ± 30 mm in relation to the centre of the feeder.
”Main pile centering”
Plus button Plus button = movement towards D.S.
Minus button = movement towards O.S.
Minus button
The pile support frame and pile support plate can
move max. 35 mm in the same direction together.
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 = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
33
Pile merging 11M8 Adjustment of pile support plate
Interconnection diagram
X5
X10 SSR
SSR X10
X11 X12
X3 X4
X13 X14
SSR X13
Backplane of servo-
11 drive plug-in unit SSR
11LVT1
2SSM1: X1
X3 X4
X2 2SSM1: X3
X1 X5
2SSM1
Servo-drive distributor
module 2SSM1
11M8: X1 3 4
5
2 1
11M8
Servo-drive 11M8
34
Pile merging 11M8 Adjustment of pile support plate
ON
OFF
07 2048 ± 2
– Set the toggle switch ”Auxiliary pile ON/OFF” – Remove the servo-drive ”Adjustment of pile
to ”OFF”. support plate” 11M8.
– Select the service display ”SSK1”.
– Bring the pile support frame into its central
position (set to 2048±2 inc).
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)
06 2048 ± 2
1M8: X1
36
Pile merging 11M8 Adjustment of pile support plate
Condition:
The pile support frame is positioned in the centre
of the feeder.
Off-centre position: 00
37
Pile merging 11M8 Adjustment of pile support plate
38
Suction head height control 11M5 Suction head height adjustment
39
Suction head height control 11M5 Suction head height adjustment
Place of installation
11M5
Preset feeder
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
40
Suction head height control 11M5 Suction head height adjustment
Interconnection diagram
X5
X10 SSR
SSR X10
X11 X12
SSR X12 X3 X4
X13 X14
Backplane of servo-
11 drive plug-in unit SSR
11LVT1
1SSM1: X1
X3 X4
1SSM1: X4
X2
X1 X5
1SSM1
Servo-drive distributor
module 1SSM1
11M5: X1 3 4
5
2 1
11M5
Servo-drive 11M5
41
Suction head height control 11M5 Suction head height adjustment
1 2
20 mm
– Remove the servo-drive ”Suction head height – Set the distance (20 mm) at the suction head
adjustment” 11M5. guide rail.
4)
03 2456 ± 2
11M5: X1
42
Suction head height control 11M5 Suction head height adjustment
43
Suction head height control 11M5 Suction head height adjustment
44
Size adjustment Block diagram
Size adjustment
Block diagram
M M
SSK1/2/3
Displays
SAK ESK
SVM MID11 MID12
45
Size adjustment Block diagram
Command: ”PRESETTING”
46
Size adjustment 11M4 Adjustment of format wheels
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.
47
Size adjustment 11M4 Adjustment of format wheels
Place of installation
11M4
Operator side
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
48
Size adjustment 11M4 Adjustment of format wheels
Interconnection diagram
X5
X10 SSR
SSR X10
X11 X12
SSR X11 X3 X4
X13 X14
Backplane of servo-
11 drive plug-in unit SSR
11LVT1
1SSM1: X1
X3 X4
X2 1SSM1: X3
X1 X5
1SSM1
Servo-drive distributor
module 1SSM1
11M4: X1 3 4
5
2 1
11M4
Servo-drive 11M4
49
Size adjustment 11M4 Adjustment of format wheels
1 2
9.00
9.00
1020
720
1.00
3 4
ÁÁÁ
ÁÁÁ
ÁÁÁ
– Remove the servo-drive ”Adjustment of – Bring the format wheels into their central
format wheels” 11M4. 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.
ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
02
ÁÁÁÁÁÁÁÁÁÁÁ
3871 ± 2
11M4: X1
51
Size adjustment 11M4 Adjustment of format wheels
SM102:
Print-free margin: 10.00 mm 8.00 mm
Paper length: 720 mm 280 mm
Paper thickness: 1.50 mm 1.50 mm
Incremental value: 3876 ± 2 inc 288 ± 2 inc
CD102:
Service display ”Values, incremental values Print-free margin: 10.00 mm 8.00 mm
servo-drives”
Paper length: 720 mm 280 mm
Paper thickness: 2.00 mm 2.00 mm
Incremental value: 3886 ± 2 inc 288 ± 2 inc
52
Size adjustment 11M6 Suction head/format adjustment
Automatic positioning
Automatic positioning:
– is effected through the command ”Presetting”;
– depends on the entered sheet length.
53
Size adjustment 11M6 Suction head/format adjustment
54
Size adjustment 11M6 Suction head/format adjustment
Place of installation
11M6
Preset feeder
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
55
Size adjustment 11M6 Suction head/format adjustment
Interconnection diagram
X5
X10 SSR
SSR X10
X11 X12
SSR X12 X3 X4
X13 X14
Backplane of servo-
11 drive plug-in unit SSR
11LVT1
1SSM1: X2
X3 X4
X2
1SSM1: X4
X1 X5
1SSM1
Servo-drive distributor
module 1SSM1
11M6: X1 3 4
5
2 1
11M6
Servo-drive 11M6
56
Size adjustment 11M6 Suction head/format adjustment
Á Front
sheet stop
Governor
foot
Marking
3
2
1
– Remove the servo-drive ”Suction head/format Note:
adjustment” 11M6. To compensate for the backlash, the 720 mm
– Set the distance between the front sheet stop must be set from the max. possible distance.
and the marking on the governor foot to
720 mm.
4)
11M6: X1
04 462 ± 2
11M6: X1
57
Size adjustment 11M6 Suction head/format adjustment
58
Size adjustment 11M11/11M12 Pile stops D.S./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.
Manual positioning
Pushbutton Actuation of pushbutton ”Pile stops larger format”:
”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 – Control of servo-drives ”Pile stop D.S.” 11M11
”Pile stops smaller format” and ”Pile stop O.S.” 11M12,
– irrespective of the preset format, the pile stops
position to a smaller format.
59
Size adjustment 11M11/11M12 Pile stops D.S./O.S.
Prepiling
The lateral pile stops move apart when
– the pile is raised.
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 = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
61
Size adjustment 11M11/11M12 Pile stops D.S./O.S.
X5
X10 SSR
SSR X10
X15 X16
SSR X15 X3 X4
X17 X18
Backplane of servo-drive
11 plug-in unit SSR
3SSM2: X1 11LVT1
3SSM1: X2
X2
X1 X3
3SSM2
Servo-drive distributor
module 3SSM2
3 4
11M11: X1 5
2 1
11M11
Servo-drive 11M11
62
Size adjustment 11M11/11M12 Pile stops D.S./O.S.
X5
X10 SSR
SSR X10
X15 X16
SSR X15 X3 X4
X17 X18
Backplane of servo-
11 drive plug-in unit SSR
3SSM2: X1 11LVT1
3SSM2: X2
X2
X1 X3
3SSM2
Servo-drive distributor
module 3SSM2
11M12: X1
3 4
5
2 1
11M12
Servo-drive 11M12
63
Size adjustment 11M11/11M12 Pile stops D.S./O.S.
11M11
ÁÁÁ
ÁÁÁ
ÁÁÁ
11M12
ÁÁÁ ÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁ
– Remove the servo-drive ”Pile stop D.S.”
11M11 or ”Pile stop O.S.” 11M12.
D.S.
O.S.
O.S.
Á
ÁÁ
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
1020
720
1,00
65
Size adjustment 11M11/11M12 Pile stops D.S./O.S.
66
Size adjustment 1M4 Cover guide height adjustment
Positioning
The new desired position is always approached
from the direction of the widest gripper opening
(1.9 mm).
Example 1:
Actual position Reversal point
The new desired position is larger than the actual
position.
Example 2:
New desired
position Actual position The new desired position is smaller than the actual
position.
Example 2
Automatic positioning
Entering the paper thickness When the command ”Presetting” has been
enabled, the electronic control system positions the
cover guides on
67
Size adjustment 1M4 Cover guide height adjustment
Manual positioning
After actuating the button ”Cover guide height
adjustment”, the operator can make adjustments
Selecting the display with the left-hand +/– buttons.
68
Size adjustment 1M4 Cover guide height adjustment
Place of installation
ÁÁÁÁ ÉÉÉ
ÉÉ
ÉÉÉ
ÉÉ
ÉÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
69
Size adjustment 1M4 Cover guide height adjustment
Interconnection diagram
X10 X5
SSR
SSR X20
X21 X22
X3 X4
X23 X24
SSR X23
Backplane of servo-drive
1 plug-in unit SSR
2SSM1: X2 1LVT1
X3 X4
X1 2SSM1: X4
X2
X5
2SSM1
Servo-drive distributor
module 2SSM1
1M4: X1
1M4
Servo-drive 1M4
70
Size adjustment 1M4 Cover guide height adjustment
1
ÉÉÉ
ÉÉ
É
ÉÉÉ
ÉÉ
É
ÉÉÉ
0 1 ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉ 1M4
15Q66
ÉÉ
ÉÉ
2
ÉÉÉ
ÉÉÉÉ
ÉÉÉÉ
ÉÉÉ
1M4
ÉÉÉ
½
ÉÉÉ
ÉÉ
É
ÉÉÉ
ÉÉ
É
ÉÉÉ
ÉÉÉ
1M4
ÉÉÉ
71
Size adjustment 1M4 Cover guide height adjustment
4
ÉÉ
ÉÉ
É
ÉÉ
ÉÉ
É
ÉÉ 1
ÉÉÉ
1M4
red
ÉÉ
brown
1
blue 2 2
black
ÉÉÉÉ 3
ÉÉÉÉ
ÉÉÉ
1M4 0 1
ÉÉÉ
1 15Q66
72
Size adjustment 1M4 Cover guide height adjustment
1
2 310 . 0
3
1 0 1
15Q66
ÉÉÉ
É
ÉÉÉ
É
3 ÉÉÉ 1M4
ÉÉÉ
2
1
3
ÉÉÉÉ
ÇÇ
ÉÉÉÉ
ÇÇ
ÉÉÉÉ
ÇÇ
ÉÉÉ
2 ÉÉÉÉ
ÇÇ
ÉÉÉ ÉÉÉÉ
ÇÇ
1
ÉÉ ÉÉÉÉ
73
Size adjustment 1M4 Cover guide height adjustment
defec- new
tive
1 M4: X1
0 1
blue
beige
yellow black
black
red
15Q66
08 1016 ± 4
74
Size adjustment 1M4 Cover guide height adjustment
ÉÉÉ
É
ÉÉÉ
É
ÉÉÉ
É
ÉÉÉ
ÉÉÉ
ÉÉÉ
É
ÉÉÉ
É
ÉÉÉ
É
ÉÉÉ
1M4
ÉÉÉ
75
Size adjustment 1M4 Cover guide height adjustment
Standard version:
Servo-drive ”Cover guide height adjustment”
1M4
76
Size adjustment 1M2/1M3 Print-free margin D.S./O.S.
Minimum value
Maximum value
77
Size adjustment 1M2/1M3 Print-free margin D.S./O.S.
Place of installation
ÁÁÁÁ
1M2 = D.S.
1M3 = O.S.
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
78
Size adjustment 1M2/1M3 Print-free margin D.S./O.S.
Interconnection diagram
X5
X10 SSR
SSR X10
X15 X16
X3 X4
X17 X18
SSR X18
Backplane of servo-
1 drive plug-in unit SSR
1SSM1: X1 1LVT1
X3 X4
1SSM1 X3
X2
X1
X5
1SSM
1
Servo-drive distributor
module SSM 1
X3 SSM3 X3 SSM3
X1 X2 X1 X2
SSM3 SSM 1 SSR SSM3 SSM1 SSR
+ X3: 1 X5: A1 X1: 1 X10: B30 X3: 1 X5: B1 X1: 3 X10: B32
– X3: 2 X5: A2 X1: 2 X10: D30 X3: 2 X5: B2 X1: 4 X10: D32
10V X3: 3 X5: A3 X3: 3 X18: 3 X3: 3 X5: B3 X3: 8 X18: 8
X3: 4 X5: A4 X3: 4 X18: 4 X3: 4 X5: B4 X3: 7 X18: 7
0V X3: 5 X5: A5 X3: 5 X18: 5 X3: 5 X5: B5 X3:6 X18: 6
79
Size adjustment 1M2/1M3 Print-free margin D.S./O.S.
1
1
0 1
15Q66
1M2
(1M3) 2 3 2–4
1M2
(1M3)
2 2–4
80
Size adjustment 1M2/1M3 Print-free margin D.S./O.S.
1
1 216 . 0
2
0 1
15Q66
1M2
(1M3) 2 2–4
2
1
81
Size adjustment 1M2/1M3 Print-free margin D.S./O.S.
4
Pull rail
Front lay
defec- new
tive
0 1
15Q66
82
Size adjustment 1M2/1M3 Print-free margin D.S./O.S.
1M2 1M3
05 2048 ± 6 06 2048 ± 6
1M2
(1M3)
22–4
3
83
Size adjustment 1M2/1M3 Print-free margin D.S./O.S.
Standard version:
Servo-drive ”Print-free margin D.S.” 1M2
Servo-drive ”Print-free margin O.S.” 1M3
84
Size adjustment 1...nM5 Adjustment of printing pressure
Automatic positioning
When the paper thickness is entered under the
command ”Presetting”, the servo-drive automati-
cally positions to the value:
paper thickness – 0.1 mm = pressure.
Examples:
0.07 –0.1 = –0.03 ! –0.03 x –1 = 0.03
0.50 –0.1 = 0.40 ! 0.40 x –1 = –0.40
The correction factor (–1) ensures that the result is
shown correctly in the ”Actual value display”.
85
Size adjustment 1...nM5 Adjustment of printing pressure
Manual positioning
Note:
The software limits the maximum pressure to 0.55.
The max. pressure is composed of
Actual value/coarse display, adjustment of printing
pressure – 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 = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
87
Size adjustment 1...nM5 Adjustment of printing pressure
1SSM2: X1 1...8LVT1
1...8M5: X1
1SSM2 X2
X1 1...8M5: X1
X2
X3
Servo-drive 1...8M5
1SSM2
Servo-drive distributor
module 1SSM2
88
Size adjustment 1...nM5 Adjustment of printing pressure
PU3, PU5
X5
PU2, PU4 SSR X20 X20 X30 SSR
1SSM2: X1 2...9LVT1
2...9M5: X1
1SSM2 X2
X1 2...9M5: X1
X2
X3
Servo-drive 2...9M5
1SSM2
Servo-drive control
module 1SSM2
89
Size adjustment 1...nM5 Adjustment of printing pressure
1 2
1
0 1
2 1...8M5 X1
3 4
– Loosen the fixing bolts on the motor. – Remove the defective motor.
90
Size adjustment 1...nM5 Adjustment of printing pressure
5 6
7 8
1 brown brown
1
2
blue blue
2 1...8M5 X1
0 1
... 0.30
...-1.20
91
Size adjustment 1...nM5 Adjustment of printing pressure
1 2
1
0 1
1...8M5 X1
– Switch off the press. – Disconnect the potentiometer from 1...8M5 X1.
– Open the guard on the O.S.
3 4 4
1
2
– Loosen the stud on the gear wheel. – Turn the mechanism to the ”0” value of the
– Pull the gear wheel off the potentiometer. scale by means of the hexagon.
– Loosen the nut on the potentiometer.
– Replace the potentiometer.
92
Size adjustment 1...nM5 Adjustment of printing pressure
5 6
1...8M5 X1
1
blue 4 beige
black 5 yellow
red 6 black
2
0 1
7 8
1
PU1 ... PUn =
1234 ± 8 inc 2
93
Size adjustment 1...nM5 Adjustment of printing pressure
... 0.30
10
...-1.20
94
Size adjustment 1...nM5 Adjustment of printing pressure
95
Size adjustment 1M7/1M8 Adjustment of pull lays
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.
96
Size adjustment 1M7/1M8 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 = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
98
Size adjustment 1M7/1M8 Adjustment of pull lays
X5
X20 SSR
SSR X20
X21 X22
SSR X21 X3 X4
X23 X24
Backplane of servo-
1 drive plug-in unit SSR
11LVT1
1SSM1: X2
X3 X4
X2
1SSM1: X4
X1 X5
1SSM1
Servo-drive distributor
module 1SSM1
3 4
1M7: X1 5
2 1
1M7
99
Size adjustment 1M7/1M8 Adjustment of pull lays
X5
X20 SSR
SSR X20
X21 X22
SSR X22 X3 X4
X23 X24
Backplane of servo-drive
1 plug-in unit SSR
11LVT1
2SSM1: X1
X3 X4
X2 2SSM1: X3
X1 X5
2SSM1
Servo-drive distributor
module 2SSM1
3 4
1M8: X1 5
2 1
1M8
100
Size adjustment 1M7/1M8 Adjustment of pull lays
1Y47
– Remove the servo-drive ”Adjustment of pull – Actuate the solenoid valve 1Y47 manually
lay D.S.” 1M7 (or ”Adjustment of pull lay O.S.” and hold it in this position (pneumatic
1M8). clamping mechanism is open).
D.S.
1
2
2
1 3
O.S. 3
101
Size adjustment 1M7/1M8 Adjustment of pull lays
01 3055 ± 2 03 3055 ± 2
1M7: X1
1M8: X1
1020
1,00 720
102
Size adjustment 1M7/1M8 Adjustment of pull lays
103
Size adjustment 12M5 Sheet slowdown/format adjustment
Automatic positioning
Automatic positioning:
– is effected through the command ”Preset-
ting”,
– 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).
Manual positioning
Pushbuttons Actuation of one of the pushbuttons ”Sheet
”Sheet slowdown format” slowdown format”:
– the sheet slowdown positions irrespective of
Plus button the preset format,
– indication of the position in the delivery MID,
Minus button
– automatic positioning is stopped immediately.
Plus button = to max. 730 mm.
Minus button = to min. 270 mm.
104
Size adjustment 12M5 Sheet slowdown/format adjustment
105
Size adjustment 12M5 Sheet slowdown/format adjustment
Place of installation
12M5
Operator side
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
106
Size adjustment 12M5 Sheet slowdown/format adjustment
Interconnection diagram
X5
X10 SSR
SSR X10
X15 X16
SSR X16 X3 X4
X17 X18
Backplane of servo-drive
12
plug-in unit SSR
12LVT1
1SSM1: X1 X3 X4
1SSM1: X3
X2
X1 X5
1SSM1
Servo-drive distributor
module 1SSM1
3 4
5
12M5: X1
2 1
12M5
Servo-drive 12M5
107
Size adjustment 12M5 Sheet slowdown/format adjustment
3
1
2
12M5: X1
12 1370
Coupling part
108
Size adjustment 12M5 Sheet slowdown/format adjustment
109
Size adjustment 12M6/12M7 Sheet joggers D.S./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.
Manual positioning
Pushbuttons Actuation of one of the pushbuttons ”Sheet jogger
”Sheet jogger D.S.” D.S.”:
– the servo-drive ”Sheet jogger D.S.” 12M6 is
Plus button controlled,
– the sheet jogger on the D.S. positions irrespec-
Minus button
tive of the preset format.
110
Size adjustment 12M6/12M7 Sheet joggers D.S./O.S.
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 = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
112
Size adjustment 12M6/12M7 Sheet joggers D.S./O.S.
X5
X10 SSR
SSR X10
X15 X16
X3 X4
X17 X18
SSR X17
Backplane of servo-drive
12
plug-in unit SSR
12LVT1
1SSM1: X2 X3 X4
1SSM1: X4
X2
X1 X5
1SSM1
Servo-drive distributor
module 1SSM1
3 4
5
12M6: X1
2 1
12M6
Servo-drive 12M6
113
Size adjustment 12M6/12M7 Sheet joggers D.S./O.S.
X5
X10 SSR
SSR X10
X15 X16
X3 X4
X17 X18
SSR X17
Backplane of servo-drive
12
plug-in unit SSR
12LVT1
X3 X4
1SSM1: X2
1SSM1: X4
X2
X1 X5
1SSM1
Servo-drive distributor
module 1SSM1
3 4
5
12M7: X1
2 1
12M7
Servo-drive 12M7
114
Size adjustment 12M6/12M7 Sheet joggers D.S./O.S.
Cam follower
Control cam
– Remove the servo-drive ”Sheet jogger D.S.” – Inch the press until the cam follower of the
12M6 (or ”Sheet jogger O.S.” 12M7). sheet jogger has reached the highest point of
the control cam.
115
Size adjustment 12M6/12M7 Sheet joggers D.S./O.S.
4)
12M6: X1
12M7: X1
13 704 ± 2 14 704 ± 2
1020
720
1.00
116
Size adjustment 12M6/12M7 Sheet joggers D.S./O.S.
117
Size adjustment 12M6/12M7 Sheet joggers D.S./O.S.
118
Feeder pile control Block diagrams
Block diagrams
REK2
ESK
A LTK500 B
A STK1 B
A BAK B
Main Auxiliary
M M
pile pile
11M1 11M2
119
Feeder pile control Block diagrams
REK2
ESK
A STK1 B A STK2 B
Main Auxiliary
M M pile
pile
11M1 11M2
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
121
Feeder pile control Layout
Press control
The press control detects the signals of the
switches and sensors on the feeder via the inputs
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.
EAK_11
The ESK is provided with the following operation
set for controlling the individual pile motors:
– Pile stop (pile height control off)
REK2
– Pile up (slow)
– Pile down (slow)
ESK – Pile up, fast (at main pile only)
– Pile down, fast (at main pile only)
– Pile height control on
Auxiliary drive control – Rack mode (parameter: rack height)
Press control
Safety circuit
The SEK registers the signals of those switches
on the feeder which are relevant to safety. It
Inputs
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
SEK control.
122
Feeder pile control Layout
Control
LT LT Drive section Power part
123
Feeder pile control Overview of components
Overview of components
Preset feeder
11M1 11S56
11S34 11S65
11M2
11S37
11S31
11B35
11S32
11S36
11B33
11B11
11S39
124
Feeder pile control Overview of components
Standard feeder
11M1 11S33
11M2
11S34
11S37
11S36
11S32
11S65
11S31
11S35
11S39
125
Feeder pile control Overview of components
Motors
Equip- Function Preset Standard Remarks
ment
with without with without
non- non- non- non-
stop stop stop stop
11M1 Main pile drive (Preset) D D Brushless motor
11M1 Main pile drive (standard) D D Three-phase a.c. motor
11M2 Auxiliary pile drive D D
126
Feeder pile control Function
Function
Pile up (by the value set) The automatic pile height control on the feeder is
stopped under the following circumstances:
Sequence of main pile height control – 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 limita-
tion” 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)
127
Feeder pile control Function
128
Feeder pile control Function
129
Feeder pile control Function
130
Feeder pile control Function
131
Feeder pile control Function
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.
132
Feeder pile control Function
11S37
133
Feeder pile control Function
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
Automatic pile height control of main pile on Automatic pile height control of auxiliary pile off
– Automatic pile height control of main pile off – Auxiliary pile stop
– Awaiting starting point – Automatic pile height control of auxiliary pile on
– Main pile down, fast
11S39
11S34
11S24
11S24
11S37
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.
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).
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.
136
Feeder pile control Function
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
Automatic pile height control of main pile on Automatic pile height control of auxiliary pile off
Automatic pile height control of main pile off Automatic pile height control of auxiliary pile on
11S39
11S34
Automatic pile height control of main pile on Automatic pile height control of auxiliary pile off
Pile 11S29
merging
Auxiliary pile down
11S37
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).
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)
Place of installation
11M1
Layout
Motor electronics
Motor and brake
Gear unit
Male connector
140
Feeder pile control 11M1 Main pile motor (Preset)
Technical specifications
– Output: 0.18/0.36 kW
– Power supply: DC 120 V
– Speed (gear unit): 5.7/40 min–1
– Ratio: 100:1
– Resistor code: 2 (560 W)
141
Feeder pile control 11M1 Main pile motor (Preset)
Pin assignment
Pin Function
A1 X1 motor line (slow)
A B C B1 Y1 motor line (slow)
1 1
C1 Z1 motor line (slow)
2 2
3 3 A2 X2 motor line (fast)
4 4 B2 Y2 motor line (fast)
5 5 C2 Z2 motor line (fast)
C5 Brake (reference potential DC)
B5 Brake (DC +24 V)
B4 Hall 1
A5 Hall 2
Pin assignment on main pile motor (Preset) B3 Hall 3
A4 Resistor code
A3 PTC (temperature monitoring)
C4 Auxiliary supply of motor electronics UH
C3 Ground auxiliary supply
PE conductor
142
Feeder pile control 11M1 Main pile motor (standard)
Place of installation
11M1
Layout
Motor electronics
Motor and brake
Gear unit
Male connector
143
Feeder pile control 11M1 Main pile motor (standard)
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 min–1 (220V)
11.5/49.7 min–1 (265V)
– Ratio: 66:1
– Resistor code: 2 (560 W)
144
Feeder pile control 11M1 Main pile motor (standard)
Pin assignment
Pin Function
A1 Winding U1 (slow)
B1 Winding V1 (slow)
A B C
1 C1 Winding W1 (slow)
2 A2 Winding U2 (fast)
3 B2 Winding V2 (fast)
4 C2 Winding W2 (fast)
5 A3 N1, N2
B5 Brake (reference potential DC)
C5 Brake (DC +24 V)
B4 Hall 1
pin assignment of main pile motor (standard) A5 Hall 2
C3 Resistor code
B3 PTC (temperature monitoring)
C4 Auxiliary voltage of motor electronics UH
A4 Ground auxiliary voltage
PE conductor
145
Feeder pile control 11M2 Auxiliary pile motor
Place of installation
11M2
11M2
Layout
Motor electronics
Motor and brake
Gear unit
Male connector
146
Feeder pile control 11M2 Auxiliary pile motor
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 min–1 (220V)
13.9/58.7 min–1 (265V)
– Ration: 57:1
– Resistor code: 8 (56 kW)
147
Feeder pile control 11M2 Auxiliary pile motor
Pin assignment
Pin Function
A1 Winding U1 (slow)
B1 Winding V1 (slow)
A B C
1 C1 Winding W1 (slow)
2 A2 Winding U2 (fast)
3 B2 Winding V2 (fast)
4 C2 Winding W2 (fast)
5 A3 N1, N2
B5 Brake (reference potential DC)
C5 Brake (DC +24 V)
B4 Hall 1
Pin assignment main pile motor (standard) A5 Hall 2
C3 Resistor code
B3 PTC (temperature monitoring)
C4 Auxiliary voltage motor electronics UH
A4 Ground auxiliary voltage
PE conductor
148
Feeder pile control 11B11 Auxiliary pile detection
Place of installation
11B11
Layout
Sensor
Cable
149
Feeder pile control 11B11 Auxiliary pile detection
Connection
150
Feeder pile control 11B11 Auxiliary pile detection
Setting
ÁÁÁ
plate by 14 mm (see figure).
ÁÁÁÁ
ÁÁÁ
ÁÁÁÁÁÁÁÁ
14 –0.2 mm
ÁÁÁÁÁÁÁÁ
ÁÁÁ
Setting 11B11
Signal flow
151
Feeder pile control 11B33 Upper main pile limitation
Place of installation
11B33
Layout
Sensor
Cable
152
Feeder pile control 11B33 Upper main pile limitation
Connection
153
Feeder pile control 11B33 Upper main pile limitation
Setting
24 mm
Setting 11B33
Signal flow
154
Feeder pile control 11B35 Automatic pile transport
Place of installation
11B35
Layout
Sensor
Cable
155
Feeder pile control 11B35 Automatic pile transport
Connection
156
Feeder pile control 11B35 Automatic pile transport
Signal flow
157
Feeder pile control 11S34 Bottom main pile limitation
Place of installation
11S34
11S34
158
Feeder pile control 11S34 Bottom main pile limitation
Setting
Signal flow
Note:
The signal is also displayed on the service display
SEK.
159
Feeder pile control 11S34 Bottom main pile limitation
Components
160
Delivery pile control Block diagrams
Block diagrams
SEK EAK_12
Safety Press control
circuit
REK2
ESK
HAK_01 HAK_02
Auxiliary A B C A B C
drive control
A LTK500 B
A LTK50 B
A BAK B
Main M M Auxiliary
pile pile
12M1 12M2
161
Delivery pile control Block diagrams
REK2
ESK
HAK_01 HAK_02
Auxiliary A B C A B C
drive control
A STK1 B A LTK50 B
Main Auxiliary
M M
pile pile
12M1 12M2
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
163
Delivery pile control Layout
Press control
The press control records the signals of the
switches and sensors on the delivery and the
Inputs Outputs
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
EAK_12 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.
Safety circuit
The SEK detects the signals of the safety-relevant
switches on the delivery. It evaluates these signals
Inputs
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.
SEK
The signals of the safety circuit take priority over
the signals of the press control.
164
Delivery pile control Layout
Control
LT LT LT Drive section Power part
165
Delivery pile control Overview of components
Overview of components
Operator side
12S130
12S56 12S33
12S55 12Y14/15
12B69
12S34
12S131 12Y49
12S42
12S41 12S35
12B129a
12Y60/61 12Y11
12S34b 12Y13
12B129
12S42
12S117
12B65
166
Delivery pile control Overview of components
Drive side
12M1
12M2
12S39
12S55a
12S130a
12Y62
12S36
12S34a
12S38
167
Delivery pile control Overview of components
Motors
Equip- Function Preset Standard Remarks
ment with without with without
non- non- non- non-
stop stop stop stop
12M1 Main pile drive (Preset) D D Brushless motor
12M1 Main pile drive (standard) D D Three-phase a.c. motor
12M2 Auxiliary pile drive D D
168
Delivery pile control Overview of components
Solenoid-operated valves
Equip- Function Preset Standard Remarks
ment with without with without
non- non- non- non-
stop stop stop stop
12Y11 Sheet stop D D D D
12Y13 Sheet catcher D D D D
12Y14 Supporting cross bar on D D only with rake
12Y15 Supporting cross bar off D D only with rake
12Y49 Locking of sheet stops D D D D
12Y60 Rack delivery on D D only with board
12Y61 Rack delivery off D D only with board
12Y62 Suction air sheet catcher D D D D
169
Delivery pile control Function
Function
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”).
170
Delivery pile control Function
Main pile up
12S45
The upwards movement of the main pile is
controlled by means of the button ”main pile up”
(12S45) on the delivery operation panel. Depend-
ing 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
12S117/2 the ”automatic pile transport” (12B69), the
12B69 transport mechanism of the main pile stops.
slow
12S117/1
12B65 The upwards movement of the main pile is
interrupted under the following circumstances:
fast
– Actuation of an emergency stop switch
12S131 – Actuation of the ”overshooting control” switch
slow (12S38)
– Actuation of the ”sheet jogger” switch (12S35
Switching points of main pile up (Preset) or 12S36)
– Actuation of the ”monitoring suction drum”
switch (12S39)
Main pile up
– Actuation of the ”angular stop” switch
Permissible start condition (12S130)
12S45 (keep pressed) – Opening of the sheet stop (12Y11)
(only if no non-stop operation)
Main pile up, slow
– Actuation of the ”main pile down” button
12S131 (12S46)
Main pile up, fast The continuation of an interrupted pile transport is
12B65 or 12S117/1 only possible after elimination of the respective
cause.
Main pile up, slow
12B69 or 12S117/2
171
Delivery pile control Function
12B65 or 12S117/1
12S131
12S34
172
Delivery pile control Function
Main pile up
12S45
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),
12S33
the transport mechanism of the main pile stops.
12B69
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)
Switching points of main pile up (standard) – Actuation of the ”monitoring suction drum”
switch (12S39)
Main pile up – Actuation of the ”angular stop” switch
(12S130)
Permissible start condition
– Opening of the sheet stop (12Y11)
12S45 (keep pressed) (only if no non-stop operation)
Main pile up, fast – Actuation of the ”main pile down” button
(12S46)
12S33 or 12B69
An interrupted pile transport can only be continued
Main pile stop
after elimination of the respective cause.
173
Delivery pile control Function
12S46 (self-stopping mode after 1.5 s) An interrupted pile transport can only be continued
after elimination of the respective cause.
Main pile down, fast
12S131
12S34
174
Delivery pile control Function
12S55
– Actuation of the ”auxiliary pile down” button
(12S54)
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
12S56
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.
177
Delivery pile control Function
12S42
Automatic pile height control of main pile on Automatic pile height control of auxiliary pile on
12S46 (self-stopping)
12S131
12S45
12S131
Automatic pile height control of main pile off Automatic pile height control of auxiliary pile
Pile (pull out rake/board) off (pull out rake/board)
merging
Time delay 10 s – Rake: 12S42 free
– Board: 12S10 actuated
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 – Pile change: Inserting the rake/board (12S41)
12B129
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)
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) .
179
Delivery pile control Function
Pile merging
The main pile moves upwards until the corre-
sponding 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)
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.
12S42
12S41
180
Delivery pile control Function
12S42
12S42 free
181
Delivery pile control Function
– Await time (3 s)
– Extending cross bar (12Y14)
182
Delivery pile control Function
Guide rail
12S10
183
Delivery pile control Function
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)
184
Delivery pile control Function
Paper blockage
In case of a paper blockage, the paper supply is
Paper blockage blocked at the feeder. To trigger a paper blockage,
Permissible start condition
either main pile or auxiliary pile must meet one of
the following stop conditions.
Stop condition
Main pile:
Paper supply at feeder blocked
(Only if the delivery is not in non-stop operation)
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)
Place of installation
12M1
Layout
Motor electronics
Motor and brake
Gear unit
Male connector
186
Delivery pile control 12M1 Main pile motor (Preset)
Technical specifications
– Output: 0.18/0.36 kW
– Power supply: DC 120 V
– Speed (gear unit): 5.7/40 min–1
– Ratio: 100:1
– Resistor code: 2 (560 W)
187
Delivery pile control 12M1 Main pile motor (Preset)
Pin assignment
Pin Function
A1 X1 motor line (slow)
A B C B1 Y1 motor line (slow)
1 1
C1 Z1 motor line (slow)
2 2
3 3 A2 X2 motor line (fast)
4 4 B2 Y2 motor line (fast)
5 5 C2 Z2 motor line (fast)
C5 Brake (reference potential DC)
B5 Brake (DC +24 V)
B4 Hall 1
A5 Hall 2
Pin assignment of main pile motor (Preset) B3 Hall 3
A4 Resistor code
A3 PTC (temperature monitoring)
C4 Auxiliary voltage motor electronics UH
C3 Ground auxiliary voltage
PE conductor
188
Delivery pile control 12M1 Main pile motor (standard)
Place of installation
12M1
Layout
Motor electronics
Motor and brake
Gear unit
Male connector
189
Delivery pile control 12M1 Main pile motor (standard)
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 min–1 (220V)
11.5/49.7 min–1 (265V)
– Ratio: 66:1
– Resistor code: 2 (560 W)
190
Delivery pile control 12M1 Main pile motor (standard)
Pin assignment
Pin Function
A1 Winding U1 (slow)
B1 Winding V1 (slow)
A B C
1 C1 Winding W1 (slow)
2 A2 Winding U2 (fast)
3 B2 Winding V2 (fast)
4 C2 Winding W2 (fast)
5 A3 N1, N2
B5 Brake (reference potential DC)
C5 Brake (DC +24 V)
B4 Hall 1
Pin assignment of main pile motor (standard) A5 Hall 2
C3 Resistor code
B3 PTC (temperature monitoring)
C4 Auxiliary voltage of motor electronics UH
A4 Ground auxiliary voltage
PE conductor
191
Delivery pile control 12M2 Auxiliary pile motor
Place of installation
12M2
Layout
Gear unit
Motor
Motor electronics
Circular connector
192
Delivery pile control 12M2 Auxiliary pile motor
Technical specifications
– Output: 30 Watt
– Power supply: DC 48 V
– Speed (gear unit): 1 min–1
– Ratio: 2564:1
– Resistor code: 5 (5.6 kW)
193
Delivery pile control 12M2 Auxiliary pile motor
Pin assignment
Pin Function
1 X motor line
2 Y motor line
3 Z motor line
4 Hall C
6 Hall B
7 Auxiliary voltage of motor electronics UH
8 Hall A
9 Ground auxiliary voltage
11 Resistor code
12 –
Pin assignment auxiliary pile motor 13 –
14 –
PE conductor
194
Delivery pile control 12B65 Changeover fast/slow
Place of installation
12B65
Layout
Sensor
Cable
195
Delivery pile control 12B65 Changeover fast/slow
Connection
196
Delivery pile control 12B65 Changeover fast/slow
Signal flow
197
Delivery pile control 12B69 Pile height control
Place of installation
12B69
Layout
Sensor
Cable
198
Delivery pile control 12B69 Pile height control
Connection
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,
approx. 50 mm this position can be altered.
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
Signal flow
Note:
The signal is also displayed as status signal on the
Service display, signal E70 service display of the two respective HAK control
sections.
200
Delivery pile control 12B129 Delivery upper edge of pile
Place of installation
12B129a
12B129
Layout
Sensor
Cable
12B129
12B129a
201
Delivery pile control 12B129 Delivery upper edge of pile
Connection
12B129
12B129a
202
Delivery pile control 12B129 Delivery upper edge of pile
12B129
Signal flow
203
Delivery pile control 12S34 Bottom main pile limitation
Place of installation
12S34
204
Delivery pile control 12S34 Bottom main pile limitation
Setting
205
Delivery pile control 12S34 Bottom main pile limitation
Signal flow
206
Sheet alignment Block diagram
Sheet alignment
Block diagram
Double-sheet detector Sheet alignment control Pull lay control Double-sheet detector
SM74 / 52 SM102/CD102
D.S. O.S. D.S. O.S. D.S. O.S.
1B66 1B65 1B13 1B49 1B9 1B10 1B11
SUM1 SUM1
RL12 RL12 RL12 RL12 DBE
1AUM1
SSM1
M
SSM1
SSK EAK 1
IDS
Displays
SAK ESK
SVM MID11 MID12
207
Sheet alignment Block diagram
208
Sheet alignment Block diagram
209
Sheet alignment 1B13/1B49 Sheet alignment control
Block diagram
FÜK
– SM52 between 240_ and 20_ ,
– SM74 between 285_ and 40_ ,
Front
lays
ANK Paper
– SM102 between 222_ and 336_ ,
1B13/1B49 – SM102 with Preset between 192_
Interrogation points and 336_ ,
– CD102 between 200_ and 313_ ,
210
Sheet alignment 1B13/1B49 Sheet alignment control
O.S.
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 FÜK sensors and ANK sensors 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 = sensor detects paper
Symbol not lit = sensor does not detect paper
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
Early sheet
Late sheet
Misaligned sheet
212
Sheet alignment 1B13/1B49 Sheet alignment control
Note:
The press can be started again from the feeder even
if the FÜK 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.
Overshooting sheet
Extended functions
The extended functions are only active with the
inductive double-sheet detector of SM52 and
SM74.
213
Sheet alignment 1B13/1B49 Sheet alignment control
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
1B13
1B49
Pin assignment
ground
free free
+24K ANK–
FÜK+ FÜK–
ANK+
215
Sheet alignment 1B13/1B49 Sheet alignment control
1 2
1/2–1
3 4
O.S. D.S.
– Pull off the reflex sensor with the brass – Remove the amplifier.
block towards the front.
216
Sheet alignment 1B13/1B49 Sheet alignment control
5 6
7 8
217
Sheet alignment 1B13/1B49 Sheet alignment control
9 10
O.S. D.S.
11 12
1.5 – 2.0 mm
– Push the reflex sensor and brass block on the – Tighten the fixing bolt on the brass block.
guide pins through to the stop.
– Check the distance (1.5 – 2.0 mm).
218
Sheet alignment 1B13/1B49 Sheet alignment control
Adjustment
1 2
3 2
ÁÁÁÁ
– Bring the bending in the ”0” position. – Press the pushbutton ”Forward” until the
sheet stop fingers are raised.
3 4
219
Sheet alignment 1B13/1B49 Sheet alignment control
5 6
– Turn the handwheel back by one revo- – Place a sheet of paper of max. width
lution. (102cm) and approx. 20cm length against
the front lays.
7 8
MID MID
D.S. D.S.
O.S. O.S.
– Turn the adjusting screw until the ANK – Turn the adjusting screw until the ANK symbol
symbol on the MID just lights up. on the MID just lights up.
– Both ANK symbols on the MID must be lit.
220
Sheet alignment 1B13/1B49 Sheet alignment control
9 10
2 1/6
– Turn the handwheel clockwise for 1.3 mm – Both ANK symbols must be lit. The FÜK
+/–0.1 mm (2 1/6 revs), using the scale as a symbols must not be lit.
reference.
11
ANK
MID
10 mm D.S.
O.S.
Paper
221
Sheet alignment 1B13/1B49 Sheet alignment control
222
Sheet alignment 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
ZMK end position.
SM52 330_ SM52 42.5_
SM74 15_ SM74 72_ The following applies to the degrees listed (see
SM102 311_ SM102 3_
CD102 289_ CD102 341.5_
block diagram):
At and paper run:
1B9/1B10 Paper
–
the ZMK must not detect any paper.
– At and paper run:
the ZMK and ANK must detect paper.
Interrogation points
– At and no paper run:
the ZMK signal is not analyzed because the
sheet alignment control does not detect paper.
Pull lay control
D.S. O.S.
The reflex sensors on the drive and operator sides
serve for paper detection. Depending on the pull
1B9 1B10 direction only one of the two reflex sensors is
Audible signal
necessary for monitoring.
device 12 H 55 The pull direction is entered under the command
”Presetting”. Only the reflex sensor of the active pull
SUM1 SUM1
Audible signal lay is interrogated.
RL12 RL12
device 11 H 55
In the signal conversion modules SUM 1 the signals
of the reflex sensors are amplified. The circuit state
1 LVT 1 12 LVT 1 11 LVT 1 of each sensor is signalled by an LED on the
1EVM4 12EVM4 11EVM4
corresponding SUM 1
(LED is lit = reflex sensor detects paper).
EAK 1 EAK 12 EAK 11
SM52 only:
On SM52 the signals are amplified by the amplifiers
of the reflex sensors RL12.
223
Sheet alignment 1B9/1B10 Pull lay control
Paper
224
Sheet alignment 1B9/1B10 Pull lay control
1B9/1B10
Paper
Pull error
225
Sheet alignment 1B9/1B10 Pull lay control
Place of installation
1B9
1B10
226
Sheet alignment 1B9/1B10 Pull lay control
c) Edge for format adjustment 8 Turn the knurled head screw anticlock-
wise for another 10 notch positions
(= 0.3 mm; corresponds to approx. 1/4 rev.
of ).
227
Sheet alignment 1B9/1B10 Pull lay control
Reflex sensor
Knurled head screw
Knurled head screw
Locking nut
228
Sheet alignment 1B9/1B10 Pull lay control
Note:
The pull lay stop must not lie on the magnet
cover plate while the paper is being pulled.
229
Sheet alignment 1B9/1B10 Pull lay control
Pull lay
Sensing distance
230
Sheet alignment 1B11 Double-sheet detector
Block diagram
The double-sheet detector monitors sheet infeed at
Optical the feeder. It detects multiple sheets and irregulari-
sensor system ties in the sheet flow and thus prevents malfunc-
tions.
Transmitter
1āBā11āS An optical sensor system consisting of a transmitter
(1 B11 S) and a separate receiver (1 B11 E)
Receiver transmits light through the paper. The receiver
1āBā11āE supplies a signal. The amplitude of the signal
depends on the thickness and nature of the printing
material.
EAK 1
ZID – 336 _ (SM102),
– 313_ (CD102).
DNK
If the light does not pass through the paper at this
point, there are two or more sheets.
231
Sheet alignment 1B11 Double-sheet detector
232
Sheet alignment 1B11 Double-sheet detector
Place of installation
Control device
233
Sheet alignment 1B11 Double-sheet detector
Layout
Control device of double-sheet detector The LED lights up as soon as there are
DBE with operator’s controls two or more sheets.
1 B11 S Selector switch for adjustment of paper
Transmitter with connecting cable and thickness
fixing bracket
1 B11 E
Receiver with connecting cable and
fastening element
Cable to distribution box 1LVT1 at PU 1.
It comprises: Paper thick Control device off Paper thin
– 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
234
Sheet alignment 1B11 Double-sheet detector
X1 1LVT1 at
PU1
X3
1B11 Receiver
Connection principle
1 Ground 24 V –1 X2: – 1
2 +24 V +1 X2: +
3 – – 1 –
4 Signal XE 11 FEM 64 XE 11
5 – – –
235
Sheet alignment 1B11 Double-sheet detector
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.
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
if..
237
Sheet alignment 11M3 Automatic sheet arrival control
1SSM1
11M3
238
Sheet alignment 11M3 Automatic sheet arrival control
Preselection/coarse display
Symbol of the sheet arrival For the sheet arrival control the operator enters a
control in the ... fixed value.
The setting is made at the control console by means
actual value / coarse display of the right-hand +/–buttons.
239
Sheet alignment 11M3 Automatic sheet arrival control
Note:
The display is updated with a delay.
Actual value/fine display
240
Sheet alignment 11M3 Automatic sheet arrival control
(standard version)
Place of installation
ÁÁÁ
ÁÁÁ
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
241
Sheet alignment 11M3 Automatic sheet arrival control
(standard version)
Interconnection diagram
X5
X10 SSR
SSR X10
X11 X12
SSR X11 X3 X4
X13 X14
11
Backplane of servo-drive
11 plug-in unit SSR
1SSM2: X1 11LVT1
1SSM2: X2
X1 X2
X3
1SSM2
Servo-drive distributor
module 1SSM2
3 4
11M3: X1
5
2 1
11M3
Servo-drive 11M3
+ Pin 1 X5: A1 X1: 1 X10: B2 Motor +
– Pin 2 X5: A2 X1: 2 X10: D2 Motor –
10V Pin 3 X5: A3 X3: 3 X11: 3 10V
Pin 4 X5: A4 X3: 4 X11: 4 Tap
0V Pin 5 X5: A5 X3: 5 X11: 5
242
Sheet alignment 11M3 Automatic sheet arrival control
(standard version)
1 2
1
0 1
2
2
3 4
1
1
3
1 2
243
Sheet alignment 11M3 Automatic sheet arrival control
(standard version)
5 6
1 – 2 mm
7 8
1 3
2 1
22
5
4
0 1
244
Sheet alignment 11M3 Automatic sheet arrival control
(standard version)
9 10
11 12
245
Sheet alignment 11M3 Automatic sheet arrival control
(standard version)
13
246
Sheet alignment 11M3 Automatic sheet arrival control
(Preset version)
Place of installation
11M3
Operator side
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
247
Sheet alignment 11M3 Automatic sheet arrival control
(Preset version)
Interconnection diagram
X5
X10 SSR
SSR X10
X11 X12
SSR X11 X3 X4
X13 X14
Backplane of servo-
11 drive plug-in unit SSR
11LVT1
1SSM1: X1
X3 X4
X2 1SSM1: X3
X1 X5
1SSM1
Servo-drive distributor
module 1SSM1
3 4
11M3: X1
5
2 1
11M3
Servo-drive 11M3
248
Sheet alignment 11M3 Automatic sheet arrival control
(Preset version)
1 2
2.0 mm
(approx. 1 rev.)
– Remove the servo-drive ”Automatic sheet – Turn the mechanism against the upper stop.
arrival control” 11M3. – Set the distance ( 2.0 mm ).
01 3891 ± 2
11M3: X1
249
Sheet alignment 11M3 Automatic sheet arrival control
(Preset version)
250
Sheet alignment 11M7 Automatic misalignment control
1SSM1
11M7
Position of guide rail D.S. at Position of sheet The graphical representation on the left shows the
suction head mechanical principle of the misalignment correc-
Front lays
tion.
O.S. D.S.
251
Sheet alignment 11M7 Automatic misalignment control
Misalignment control
The misalignment control is automatically activated
when the operator switches off the automatic
misalignment control.
Symbol of the misalignment For the misalignment control the operator enters a
control in the ... fixed value.
The setting is made at the control console by means
actual value/coarse of the right-hand +/– buttons.
display Press model Setting range
252
Sheet alignment 11M7 Automatic misalignment control
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°
253
Sheet alignment 11M7 Automatic misalignment control
Place of installation
11M7
Preset feeder
Technical data
Motor data
– U = DC 24 V
– P = 5 W
Potentiometer data
– U = DC 10 V
– R = 10 K
254
Sheet alignment 11M7 Automatic misalignment control
Interconnection diagram
X5
X10 SSR
SSR X10
X11 X12
X3 X4
X13 X14
SSR X13
Backplane of servo-
11 drive plug-in unit SSR
11LVT1
2SSM1: X1
X3 X4
X2 2SSM1: X3
X1 X5
2SSM1
Servo-drive distributor
module 2SSM1
11M7: X1 3 4
5
2 1
11M7
Servo-drive 11M7
255
Sheet alignment 11M7 Automatic misalignment control
1 2
O.S.
O.S. D.S.
D.S.
Guide rails
– Remove the servo-drive ”Automatic – Position the guide rails of the forwarding
misalignment control” 11M7. suckers parallel to each other.
4)
05 2048 ± 2
11M7: X1
256
Sheet alignment 11M7 Automatic misalignment control
257
Sheet alignment 11M7 Automatic misalignment control
258
Sheet monitoring 1...nB48/1...nB48a Sheet travel monitor
Sheet monitoring
DNK
– At the same time, the reflex sensor 1...9B48
does not detect paper.
– The LED on the reflex sensor 1...9B48
ESK SVM DSK is not lit.
– Signal to control system.
– REK2 intervenes in press control.
REK2
Control lines
259
Sheet monitoring 1...nB48/1...nB48a Sheet travel monitor
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 corre-
sponding printing unit.
1) 2) 3) 4)
261
Sheet monitoring 1...nB48/1...nB48a Sheet travel monitor
Place of installation
1...nB48 1...nB48a
(middle of press) (operator side)
Impression cylinder
in printing unit
262
Sheet monitoring 1...nB48/1...nB48a Sheet travel monitor
Components
Reflex sensor 1...nB48
Reflex sensor
Control switch
Adjustment
1 4 + 7 9
3 9
263
Sheet monitoring 1...nB48/1...nB48a Sheet travel monitor
1 2
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.
3 4
1.0_
LED
LED
LED
– Turn the impression cylinder in the direction – Turn the impression cylinder back by 1.0°
of printing (see arrow) so that the LED just (see arrow).
lights up (reflex sensor detects cylinder – The LED is not lit.
surface).
5 6
1...nB48a
1...nLVT1
– Remove control switch 1...nB48a. – Fit the control switch and connect it with the
– Withdraw the plug from 1...nB48. reflex sensor (see circuit diagram).
264
Sheet monitoring 1...nB48/1...nB48a Sheet travel monitor
7 8
1...nB48a
Segment disk
0.8 – 1.0 mm
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ = =
ÁÁÁÁÁÁÁ
– ÁÁÁÁÁÁÁ
The segment disk must run in the middle of
the recess and must not contact the control
switch. – Select the service display ”Present input/
– Pay attention to both segments. output” of the corresponding printing unit.
9 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
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 pneu-
matic 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”.
Pressing bar
267
Plate clamping device Autoplate
Fault display
Button sequence
268
Plate clamping device Autoplate
Block diagram
n Y7 n Y 61 n Y 62 n Y 63
E4
n S59 n S 25a /
n S4 n S17 n H59 n S 25b
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”).
Actuation of
operator’s controls:
0.3 s 0.3 s
”Opening the
rear clamping bar”
n Y63 actuated
2.0 s
0.3 s
”Opening the 1.0 s
front clamping bar”
n Y62 actuated
0.5 s
1.8 s 0.5 s
”Pressing bar on / off”
n Y7 actuated
270
Plate clamping device 1...nB53 ”Coarse register monitoring”
Place of installation
Layout/connection
Sensor
Locking nut
Connecting cable
Core Function
brown DC 24V
blue ground 24V
black output signal
271
Plate clamping device 1...nB53 ”Coarse register monitoring”
Task/function
Positioning bolt
Sensor B53
The inductive sensor 1...nB53 registers the
manual coarse adjustment of the circumferential
register.
After each coarse adjustment of the circumferen-
tial 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.
Sensor and positioning bolt 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.
Positioning bolt
1.0 mm ± 0.5 mm Sensor B53
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.
273
Plate clamping device 1...nB53 ”Coarse register monitoring”
274
Washup devices Control by command ”Washup”
Washup devices
Selection of functions
Command
”Washup”
Printing unit
selection
The command
”Washup” can
be aborted any
time with the
button ”Delete”.
Only with
Input start-up
warning
275
Washup devices Messages
Messages
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.
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 In the displayed printing unit the ink blade is not
monitoring of ink blade fitted. The sensor nB43 is not damped.
277
Washup devices Service display ”Washup”
Spraying with washup solution Solenoid valves 1...nY52 and 1...nY55 actuated.
278
Washup devices Service display ”Washup”
279
Washup devices Service display ”Washup”
280
Washup devices Blanket washup device (GTW)
Block diagram
E4
E9
EAK
ZID
281
Washup devices Blanket washup device (GTW)
Layout
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
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)
283
Washup devices Blanket washup device (GTW)
Setting the number of cylinder revolutions and spray procedures for water and
washup solution
Button sequence
284
Washup devices Blanket washup device (GTW)
Example
Setting for water:
10 ¢ 10 cylinder revolutions
30% ¢ 3 spray procedures
Flow chart:
”Washing with washup solution and water”
1.2 s
Water (nY54)
0.7 s (0.3 s if vegetableĆbased)
Blanket
driving clutch (nY6)
Blanket
washup blade (nY53)
Revolutions 0 4 40 99 104
102
285
Washup devices Inking roller washup device (FWW)
Block diagram
E4
E9
EAK
Parallel data line
Serial data line
DSK REK2 ESK Control line
Washup solution or
water conduit
DNK2
Pneumatic line
ZID
286
Washup devices Inking roller washup device (FWW)
Layout
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
ÂÂÂ
ÂÂÂ
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
100% 16
90% 20
80% 24 revolutions
70% 28
60% 32
50% 36
L L
0% 56
288
Washup devices Inking roller washup device (FWW)
Example
Setting for water:
50 ¢ 50 cylinder revolutions
70% ¢ 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
80% of preselected cylinder
rollers (n Y9) revolutions if printing plate is
washed as well
Ink ductor (n Y10)
Water (nY44)
Revolutions 20 20 x x x 40 30 20
Preset spray procedures 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) as 1st section
above (with-
Ink ductor (n Y10) out water)
Ink blade
(n Y51)
Revolutions x1 x2 x2 40 30 20
Preset spray proce- Preset spray procedures water
dures washup solution
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
(nāYā11)
Inking form
rollers (nāYā9) 80% of preselected cylinder
revolutions if printing plate is
washed as well
Ink ductor (nāYā10)
Water (nY44) 8
0.4 s 0.4 s
(nāYā50)
Revolutions 80 30 20
x1 x1 x1 x1 x2 x2
Preset spray procedures Preset spray procedures
washup solution water
Preselected
cylinder revolutions
Preselected cylinder revolutions washup solution water
Flow chart: ”Washing with vegetable oil-based washup solution and water”
291
Washup devices Impression cylinder washup device (DZW)
Block diagram
E4
E9
EAK
Parallel data line
Serial data line
ZID
292
Washup devices Impression cylinder washup device (DZW)
Layout
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).
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
0% – 0.5 s
10% – 0.4 s
L L
50% 0
L L
90% + 0.4 s
100% + 0.5 s
294
Washup devices Impression cylinder washup device (DZW)
Example
Setting for water:
0 ¢ 0 cylinder revolutions
50% ¢ basic spray duration +/– 0 s
Flow chart:
”Washing with washup solution and water”
Impression cylinder
washup brush
2.0 s+/–x
(n Y41) 3.0 s+/–x 1.0 s+/–x
Spray duration
Water (nY43)
2.0 s+/–x 0.7s+/–x 0.7 s+/–x 0.5 s+/–x 1,0 s
Washup solution 0.5 s
(n Y42)
25 25 25 25 15 15 30
Revolutions Preselected
Preselected cylinder revolutions cylinder revolutions
washup solution water
295
Washup devices 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.
Pin assignment
Pin Function
296
Washup devices E9 Washup solution container
Block diagram
Pressure reducer with check valve
15K4M
Safety valve
15K4M Contactor, pneumatic system compressor
M4 Pneumatic system compressor
B1 Sensor ”Monitoring water”.
M4
B54 Sensor ”Monitoring washup solution,
blanket washup device”
B55 Sensor ”Monitoring washup solution,
inking roller washup device”
E9 Washup solution container
E9
F70 F70 Pressure switch
B1 B54 B55
EAK
ESK
REK
Pneumatic line
Control line
Parallel data line
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:
– production run display,
– display which appears after initiating the
command ”Washup”,
– fault display ”Entire press/warning”.
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”.
298
Washup devices E9 Washup solution container
Place of installation
Layout
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 Function
3 4 1 DC 24 V
2 24 V
5 3 ”Monitoring water”
2 1 4 ”Monitoring washup solution,
blanket washup device”
5 ”Monitoring washup solution,
inking roller washup device”
Plug E9-X1
300
Washup devices B1, B54, B55 Sensors at the washup
solution container
Place of installation
B1 Monitoring water
B54 Monitoring washup solution,
blanket washup device
B55 Monitoring washup solution,
inking roller washup device
Connection
Input at EAK :
0 ¢ level too low
1 ¢ level OK
Pin assignment
X1 white signal
+1 brown DC +24 V
301
Washup devices B1, B54, B55 Sensors 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.
upward ° NC contact
downward ± NO contact
302
Washup devices 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.
Layout
Sensor
Nut and locking nut
Connecting cable
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 Function
brown DC 24 V
blue ă 24 V
black signal
Pin assignment
Input 43 of EAKn:
(n = corresponding printing unit)
304
Inking unit Servo-drive ink fountain roller
Inking unit
Place of installation
D.S.
O.S.
305
Inking unit Servo-drive ink fountain roller
Technical data
Motor data
U = DC 12 V
Potentiometer data
U = DC 10 V
R = 10 k
Terminal assignment
Terminal Function
black 6 6 black 6 6 black
1
yellow
5 5 yellow
5 5 blue DC 12 V (motor)
beige beige red 2
4 4 4 4
yellow/green
3 3 yellow/green
3 3 4 DC 10 V (potentiometer)
brown brown black
blue
2 2
blue
2 2 5 potentiometer
1 1 1 1 red
6 Potentiometer tap
306
Inking unit Servo-drive ink fountain roller
Nut on servomotor
O.S. Gear wheel
Locking screw
Anti-rotation element
Retaining nut
307
Inking unit Servo-drive diagonal register 1...nM6
Place of installation
D.S.
O.S.
Speedmaster 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 k
Pin assignment
Pin Function
1
1
2 DC 24 V (motor)
3 4 2
5
3 3 DC 10 V (potentiometer)
2 1 4 Potentiometer tap
4 5 potentiometer
5
309
Inking unit Servo-drive diagonal register 1...nM6
Plug 1...nM6-X1
Fixing bolts
Hexagon nut
Block
Eccentric bolt
Servo-drive
310
Inking unit Servo-drive lateral register
Place of installation
The servo-drives for the lateral register are
located on the operator side of the printing units.
D.S.
O.S.
311
Inking unit Servo-drive lateral register
Technical data
Motor data
U = DC 12 V
Potentiometer data
U = DC 10 V
R = 10 k
Terminal assignment
Terminal Function
1
black black DC 12 V (motor)
yellow
6 6 red
2
beige
5 5 blue
4 DC 10 V (potentiometer)
4 4 5 potentiometer
yellow/green 6
brown
3 3 brown
Potentiometer tap
blue
2 2 blue
1 1
312
Inking unit Servo-drive lateral register
Nut
Gear wheel
Nut
2.2...2.27 mm
Nut
Anti-rotation element
Sleeve
2.2...2.27 mm
1 Positioning the lateral register to zero:
Turn the gear wheel with the help of the nut
until the distance of 2.2...2.27 mm is
obtained.
Note:
Lateral register O.S. Use a feeler gauge!
313
Inking unit Servo-drive circumferential register
Place of installation
O.S.
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 k
Terminal assignment
Terminal Function
1
black black DC 12 V (motor)
yellow
6 6 red
2
beige
5 5 blue
4 DC 10 V (potentiometer)
4 4 5 potentiometer
yellow/green 6
brown
3 3 brown
Potentiometer tap
blue
2 2 blue
1 1
315
Inking unit Servo-drive circumferential register
Nut
6.2...6.3 mm
6.2...6.3 mm Gear wheel
Locking screw
Anti-rotation element
Nut
316
Inking unit Inking unit temperature control
317
Inking unit 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.
Pin Function
3 Phase U
7 Phase V
1 6
9 Phase W
2 7
PE conductor
3 8
4 9 Remain- –
ing pins
5 10
318
Inking unit E39 Inking unit temperature control
1 Phase U
2 Phase V
3 Phase W
PE conductor
Remain- –
ing pins
4Ćpole
cable
319
Inking unit E39 Inking unit temperature control
320
Dampening 1...nM1 Pan roller motors
Dampening
1...nM1-X3
Pin assignment
6 Pin Function
7 5
8 4 1 X motor line
1
3 2 Y motor line
9
3 Z motor line
10 14 4 Hall-effect sensor, signal C
5 Hall-effect sensor, tacho signal
11 13
12 6 Hall-effect sensor, signal B
2
7 DC 15 V
Connector 1...nM1-X3, pins in plug insert 8 Hall-effect sensor, signal A
9 Ground of DC 15 V
10 –
11 Motor code
12 –
13 –
14 –
PE
321
Dampening 1...nM45 Blower motor for dampening system
Pin assignment
Pin Function
1 Enable message
2 Ground 24 V
3 DC 24 V
1
2
3
322
Dampening 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
Layout/connection
Core Function
brown DC 24 V
blue ground 24 V
black message
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
ÁÁÁÁ
breakers are in the control cabinet of the printing
press. For details please refer to the manufacturer’s
ÁÁÁÁ manual.
ÁÁÁÁ
ÁÁÁÁ
E40-X1: power supply
ÁÁÁÁ
E40-X2: serial interface
X1 X2
Á
Á
X2
Á
Á
X1
325
Dampening E40 Central dampening solution supply/
cooling and circulating unit
Pin Function
3 Phase U
1 6
7
9
Phase V
Phase W
*)
2 7 PE conductor
3 8
Remain- –
4 9 ing pins
5 10
326
Dampening E40 Central dampening solution supply/
cooling and circulating unit
E40-X1
2 AC 230 V
4 Zero 230 V
1 6
2 7 PE conductor
3 8
Remain- –
4 9 ing pins
5 10
327
Dampening E41 Dampening solution mixing unit
328
Central lubrication Basic concept
Central lubrication
Basic concept
Distinction
Two lubrication systems supply the press with
lubricant:
329
Central lubrication Service display
Service display
Button sequence
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”).
Service display ”Oil lubrication”
Number of cylinder revolutions at which
automatic oil lubrication is initiated.
330
Central lubrication Service display
Grease lubrication
7 Sensor ”Lubrication monitoring 2” – 12 B77
(bearing lubrication) (flashes if sensor is not
actuated).
8 Sensor ”Lubrication monitoring 1” – 12 B47
(chain lubrication) (flashes if sensor is not
actuated).
9 Motor grease lubrication 12M47.
ß Number of cylinder revolutions since the last
chain lubrication. After completion of lubrication
the counter is automatically zeroed.
331
Central lubrication Fault messages
Fault messages
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.
The audible signal devices 11H55 While lubrication is in progress, a warning signal
and 12H55 give out a warning 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
Grease line
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
Motor ”Grease lubrication” 12 M 47
Grease reservoir
Pressure relief valve
Lubrication monitoring 2–12 B77 (bearing
lubrication)
Lubrication monitoring 1–12 B47 (chain
lubrication)
Progressive distributor
Changeover grease lubrication 12 Y78
(between bearing and chain lubrication)
Function
When the press is switched on, the grease lubrica-
tion 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 lubrica-
tion circuit.
334
Central lubrication Grease lubrication
335
Central lubrication Grease lubrication
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!
336
Central lubrication Grease lubrication
337
Central lubrication Oil lubrication
Oil lubrication
Block diagram
15 Q 66
15 Q 44
1F33
15X3 M44 Y67
1F34
11H55
12H55
Oil line
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
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
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
Filter unit
Optical differential pressure indicator
341
Central lubrication Oil lubrication
342
Central lubrication 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.
343
Central lubrication M44 Oil pump
Pin assignment
Pin Function
Plug M44-X1
344
Central lubrication 12M47 Motor for grease lubrication
Place of installation
The motor for grease lubrication 12M47 is located
on the D.S. of the delivery.
Pin assignment
Plug 12M47-X1
Pin Function
3
1 DC 24 V
1
2 Grease lubrication delivery chains
2
3 –
PE
PE –
Plug 12M47-X1
345
Central lubrication 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.
346
Central lubrication 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.
347
Central lubrication 12B47 Lubrication monitoring 1
12B77 Lubrication monitoring 2
Layout
The sensor 12 B47 for chain lubrication monitoring
and the sensor 12 B77 for bearing lubrication moni-
toring are of identical design.
LED
Sensor
Locking nut
Receptacle
Plug
Stop pin
Sleeve
Distributor
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
47 or 77 black signal
+1 brown DC 24 V
–1 blue
349
Central lubrication 12B47 Lubrication monitoring 1
12B77 Lubrication monitoring 2
350
Pneumatic system 15Y11 Admission of pressure, pneumatic system
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
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 Function
1 DC 24 V
1 2 Signal 4 mA ... 20 mA
3 3 –
PE –
PE
2
Plug 15Y11-X1
352
Pneumatic system 15B14 Pressure sensor ”Pneumatic system”
Place of installation
15B14
353
Pneumatic system 15B14 Pressure sensor ”Pneumatic system”
Pin assignment
Plug 15B14-X1
Pin Function
3
1 1 DC 24 V
2 2 Sensor signal 4 mA ... 20 mA
PE 3 –
PE –
354
Pneumatic system E4 Pneumatic system compressor
Technical data
Technical data, see operating instructions 71.102.9100
Pin assignment
Pin Function
Plug E4-X1
355
Pneumatic system E4 Pneumatic system compressor
356
Suction and blast air 1M9 Blast air regulation at the feeder
Block diagram
The blast air regulation at the feeder adapts the
Displays blast air pressure at the suction head to the press
speed and ensures that the printing material is
MID11 ZID
fanned.
MID12 DNK The blast air pressure is regulated by servo-drive
1M9 which controls a relief valve.
DSK The blast air pressure depends on two factors:
IDS – the thickness of the stock (e.g. paper
calliper);
– the production speed (preset speed).
In the operator program of CPTronic the blast air
EAK ESK SVM regulation can be switched on and off.
”Automatic blast air regulation switched on”
means:
characteristic-curve-dependent blast air regulation.
SSK SAK REK2 The blast air pressure is automatically adapted by
the CPTronic operator program on the basis of the
entered paper thickness and the preset press
1SSM1 speed.
By pressing the right-hand +/– buttons on the
1M9 control console the characteristic curve stored in
the CPTronic control system can be modified
manually.
M
”Automatic blast air regulation switched off”
Blast air regulation means:
manual blast air setting.
Legend: Data lines
The blast air pressure is set independently of the
Control lines paper thickness and preset speed.
It can be modified with the right-hand +/– buttons
Block diagram: blast air regulation at the feeder on the control console.
The blast air regulation at the feeder does not
intervene in the press control.
357
Suction and blast air 1M9 Blast air regulation at the feeder
358
Suction and blast air 1M9 Blast air regulation at the feeder
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0 3000 6000 9000 12000 15000
n [sheets / h]
359
Suction and blast air 1M9 Blast air regulation at the feeder
0.8
0.6
0.4
0.2
20 40 60 80 100
ZID display [%]
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.
361
Suction and blast air 1M9 Blast air regulation at the feeder
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 k
Pin assignment
Contact Assignment
+ 1 Motor, + (DC 24 V)
1
M –
2
2
3
Motor, – (DC 24 V)
Potentiometer, + (DC 10 V)
+
3
3 4 Potentiometer wiper
4
5 Potentiometer, – (DC 10 V)
4
2
1 5
–
5
363
Suction and blast air 1M9 Blast air regulation at the feeder
(4×)
364
Suction and blast air 1M9 Blast air regulation at the feeder
Note:
Also refer to the section ”Manual blast air
setting”.
Note:
While doing this, do not place the servo-
drive on the threaded spindle .
365
Suction and blast air 1M9 Blast air regulation at the feeder
Note:
Take care that the pin of the threaded spindle is
not turned more than "90° while doing this.
(4×)
e Fasten the servo-drive with the four
fixing bolts .
Note:
See also the next section ”Checking the
operating range”.
(4×)
366
Suction and blast air 1M9 Blast air regulation at the feeder
Note:
The incremental values may differ from the
displayed percent values / air pressure by up to
"4 increments.
367
Suction and blast air 1M9 Blast air regulation at the feeder
368
Other components E4a Varnish supply unit
Other components
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
E4a-X21 cable leads to the varnish supply unit, plug
E4a-X21.
The varnish supply unit is remotely controlled with
E4a-X22 a cable. This cable is connected to plug E4a-X22.
Pin assignment
E4a-X1
Pin Function
A1 –
A B C
A2 Phase L1
1
A3 –
2 A4 AC 230 V
3 A5 –
B1 –
4 B2 –
5 B3 Phase L2
B4 –
B5 –
C1 –
C2 Phase L3
C3 –
Plug E4a-X1, coming from the control cabinet C4 –
C5 Zero 230 V
PE conductor
369
Other components E4a Varnish supply unit
E4a-X21
Pin Function
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 ).
370
Other components 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.
371
Other components L-B32 Level in coating pan
Layout, adjustment
Coating pan
Pan roller
Sensor
Sensor holder
Level controller
Adjusting screws
108 mm
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
approx. 10 mm
of the pan roller in the varnish should be approx.
10 mm.
372
Other components 12E2 Powder spray unit
Pin Function
A2 L2
B3 L1
C2 L3
A4 AC 230 V
C5 Zero 230 V
PE
373
Other components 12E2 Powder spray unit
Pin Function
3 1 Ground
4 2 2 DC 24 V
3 Signal
5 1 4 Ground
5 –
374
Other components 12E2 Powder spray unit
Pushbutton ”Forward”/ 2 Inch the press until the front edge of the
”Backward” sheet is below the spray nozzles of the
powder tube.
Sheet of
paper
Required position of
front edge of sheet
375
Other components 12E2 Powder spray unit
Variable degree
can be changed by entering another
degree value.
Standard degree
– cannot be changed
– depends on the press model.
Entering the degree value 5 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 jumps back to
the standard degree value .
376
Other components 12M35 Blower motor for powder spray device
12E2-X1
Layout
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
377
Other components 12M35 Blower motor for powder spray device
Note:
When you loosen the lower fixing bolts of the
casing cover, the compressed-air cooler becomes
loose as well. Hold it tight.
27mm
min.
378
Other components 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.
379
Other components 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.
ÂÂÂÂÂÂÂÂÂ
ÂÂÂÂÂÂÂÂÂ
ÂÂÂÂÂÂÂÂÂ
ÂÂÂÂÂÂÂÂÂ
ÂÂÂÂÂÂÂÂÂ
Place of installation of safety switch ”Monitoring
the IR slide-in dryer”
Sensor
Openings for switching element
Switching element (fitted on slide-in dryer)
Marking Function
21-22 NC contact
13-14 NO contact
380
Other components 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
381
Other components 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 manufacturer’s
manual is available.
E39-X1: power supply
Pin Function
3 AC 230 V, phase U
6 1
7 AC 230 V, phase V
7 2
8 3 9 AC 230 V, phase W
9 4 PE
10 5
382
Other components 12E3 Static electricity eliminator
Attention:
Cut off the power supply before working on the
device!
Place of installation
383
Other components 12E3 Static electricity eliminator
Layout
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.
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
Loudspeaker
Microphone
Volume controller
Illuminated pushbutton
Intercom at feeder
Intercom at delivery
386
Other components WSA Intercom
Function
Secondary board with terminal strip
11WSA-X2/ 12WSA-X2
Main board
Connection for volume controller
Connection for microphone
Connection for secondary board 11WSA-
X1/ 12WSA-X1
Connection for illuminated pushbutton
Changeover switch main/secondary intercom
387
Other components IDS Encoder
IDS Encoder
Place of installation
Encoder IDS
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
The encoder generates three pulse signals:
5V
Track A – track A,
0V
– track B,
5V – track 0.
Track B
0V Track B is staggered by 90° in relation to track A.
5V Per revolution track 0 generates one zero pulse.
Track 0 The inverted signals are also available from all 3
0V tracks.
Pulse signals from the encoder Tracks A and B each generate 1024 pulses per
revolution.
Pin assignment
Pin Function
M, G, H DC+5V
G E
F
A, L, D 5V
H
M
D C Track A/
J B Track A
L
C F Track B/
A
K
B E Track B
K Track 0/
J Track 0
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.
ÁÁÁÁ 3
ÁÁÁÁ
ÁÁ 1
Encoder IDS
ÁÁ
390
Other components IDS Encoder
Positioning to zero
6
15Q66
ÁÁ
ÁÁ 7
ÁÁ
Fitting the new encoder IDS
ÁÁ
391
Other components IDS Encoder
Note:
If the value 000.0 is not displayed in the MID,
continue with step q.
Á 9
ÁÁÁÁÁÁÁÁ w
ÁÁÁÁÁÁÁÁ
Turn the adjusting screw until 000.0 is
ÁÁÁÁÁÁÁÁ
displayed in the MID.
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
Á e
w
Á q
Precision adjustment of the encoder IDS
392
Location diagrams ZSG Central control cabinet
Location diagrams
Equipment zone E
”Swing frame”
393
Location diagrams ZSG Central control cabinet
394
Location diagrams ZSG Central control cabinet
SLT
15Q61 Flat switch
”Transformer protection, secondary”
15Q62 Flat switch
”Transformer protection, secondary”
15Q37 Circuit-breaker
”Feeder / delivery main pile”
(not for Preset version)
15Q38 Circuit-breaker
GRM5 GRM24 GRM48 GRM120-2
”Feeder auxiliary pile”
15K37M Contactor ”Pile control”
STK1 (without Preset) /
LSR (with Preset)”
15K38M Contactor
”Pile control”
STK1 (with Preset) /
STK2 (without Preset)”
15K48A Contactor ”Power supply
15Q61 15Q37 15K37M 15K48A 15Q65
connecting part of power converter”
15Q2 Motor circuit-breaker
”Air supply cabinet E 8”
15Q65 Motor circuit-breaker
15Q62 15Q38 15K38M 15Q2
”Transformer protection, primary”
SLT
395
Location diagrams ZSG Central control cabinet
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 F3 (GRM120) – 32 A, slow-blowing
3 x ca. AC 26 V 3 x ca. AC 100 V
ca. DC 33 V ca. DC 50 V
396
Location diagrams ZSG Central control cabinet
Earth-leakage monitor
Q39 Q39a Q40 Q44 Q22a Q80
IWM module
K39M K39aM K46A K61A K50M K51M K52M K53M K54M K55M K56M K43M
Terminal amplifier module
Flat-cable output module
64 outputs
Flat-cable input module
KVM FAM 64 FEM 64
64 inputs
Optocoupler 15U2
15X4
Terminal strips
15X3
Amplifier module
397
Location diagrams ZSG Central control cabinet
13,15 5, 6 3, 4 1, 2 11,12
Flat cables from the press units
398
Location diagrams ZSG Central control cabinet
ÍÍÍÍ
REE2 REE2 Computer plug-in unit 2
ÍÍÍÍ
EHE2 auxiliary drive plug-in unit 2
ÍÍÍÍ
ÍÍÍÍ
LTE – 2 - 5 PUs, with Preset
ÍÍÍÍ
REE2 Computer plug-in unit 2
ÍÍÍÍ
EHE2 Input/output
auxiliary drive plug-in unit 2
LTE Power part plug-in unit
Swing frame for presses with 2- 5 PUs SSE2/LSE Servo-drive plug-in
unit 2/ power part plug-in unit for
brushless pile motors
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
ÍÍÍÍ
ÍÍÍÍ
REE2 REE2 Computer plug-in unit 2
ÍÍÍÍ
EAE Input/output plug-in unit
EAE
ÍÍÍÍ
HAE2 Auxiliary drive plug-in unit 2
ÍÍÍÍ
LTE
– 6 - 7 PUs, with Preset,
ÍÍÍÍ
delivery
ÍÍÍÍ REE2
EAE
Computer plug-in unit 2
Input/output plug-in unit
Swing frame for presses with 6- 8 PUs HAE2 Auxiliary drive plug-in unit 2
LTE 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 Computer plug-in unit 2
EAE Input/output plug-in unit
HAE2 Auxiliary drive plug-in unit 2
LTE 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
ÍÍÍÍ delivery
ÍÍÍÍ
REE2
REE2 Computer plug-in unit 2
ÍÍÍÍEAE
ÍÍÍÍ
EAE Input/output plug-in unit
ÍÍÍÍ
EHE2 Input/output
EHE2 auxiliary drive plug-in unit 2
ÍÍÍÍ
ÍÍÍÍ
LTE Power part plug-in unit
LTE
ÍÍÍÍ
SSE2/LSE Servo-drive plug-in unit 2/
ÍÍÍÍ
power part plug-in unit for brushless
pile motors
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
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.
RGPĆcomputer
module
Computer
motherboard
402
Location diagrams ZSG Central control cabinet
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 auxiliary drive plug-in unit for input/ output boards EAK 2). Boards of the same
presses with ≥ 9 printing units type are interchangeable.
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
Note:
All electronic boards of the same type in the swing
Auxiliary drive plug-in unit for presses with 6- 8 frame are identical in design (e.g. power supply
printing units boards NTK , auxiliary drive boards HAK 2). Boards
of the same type are interchangeable.
404
Location diagrams ZSG Central control cabinet
ÍÍ Í ÍÍ Í presses.
ÍÍ
ÅÅ ÍÅ ÍÍ
Å ÍÅ LTK500 Power part board
ÅÅ Å Å Å
LTK50 Power part board
STK_2 Pile control board
STK_1 Pile control board
Power part plug-in unit for presses with ≤ 7 printing
units, without Preset, with auxiliary pile at feeder Note:
and delivery 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.
ÍÍ Í ÍÍ Í ÍÍ
ÍÍ
Å ÍÅ ÍÍ
Å ÍÅ ÍÍ
Å
LTK50 Power part board
Å Å Å Å Å
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
Power part plug-in unit for presses with 8- 9 print-
pile at the delivery
ing units, with Preset, with auxiliary pile at the
feeder
STK_1 Pile control board
ÍÍ
Å ÍÅ ÍÍ
Å ÍÅ ÍÍ
Å
presses except for those with:
– 8 - 9 printing units, with Preset, without
Å Å Å Å Å
auxiliary pile at the feeder.
405
Location diagrams ZSG Central control cabinet
Servo-drive plug-in unit for a press with 2- 7 PUs, NTK24 Power supply board
without Preset SSK2 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.
Í
The servo-drive plug-in unit / power part plug-in unit
Í
for brushless pile motors SSE 2/ LSE is required for
presses with:
Å
Å
– 2 - 5 PUs, with Preset (only one NTK 24 and
two SSK 2s),
– 2 PUs, with Preset, without CPC,
– 6 - 7 PUs, with Preset,
Servo-drive plug-in unit/power part plug-in unit for – 8 - 9 PUs, with Preset, without non-stop
brushless pile motors for presses with 6- 7 PUs, delivery
with Preset
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
Í
for brushless pile motors SSE 2 / LSE2 is required
Å
for presses with:
Å
– 8 - 9 PUs, with Preset, with auxiliary pile at the
delivery
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
Layout
Console plate
Door
Overall view
408
Location diagrams Position switches
Position switches
2S29 1S29
11S39
12S55 12S55a
12S40 3...9S28
12S44
12S38 12S56 12S39 12S37 3...9S29
12S33
12S35 12S36 3...9S24
12S422) 12S130a 12S34 12S9
12S421) 12S130 12S65a
3...9S20
12S41 3...9S37
12S117
12B129a
12B129 12S34b 12S43
12S34a
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
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12S55 12S55a
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12S44 12S40 3...9S28
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12S68 12S37
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12S56 3...9S29
12S35 12S36
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12S34 12S37a 3...9S24
12S42 12S39 12S9
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12S65a 3...9S20
12S411)
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12S65 12S34b 3...9S37
12S412) 12S34a 12S43
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12S9c 12S9b 12S9a
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
1 Version with rake
2 Version with board
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 11Y66
1Y45
15Y11 11Y16
1Y15
11Y15
2Y12 1Y12
1Y16
2Y48 1Y48
back
2Y2 1Y2 1Y50
2Y63 1Y44
2Y9 1Y9 1Y63 1Y52
2Y62 1Y54
2Y10 1Y10 1Y62 1Y55
2Y11 2Y61 1Y11 1Y61 1Y43
1Y42
2Y13 2Y7 1Y13 1Y7 front
2Y53 2Y51 1Y53 1Y51
2Y39/2Y40 1Y47 1Y39/1Y40 or
back
1Y52
1Y55
1Y42
1Y54
1Y43
front
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
12Y11
12Y60/ 12Y49
12Y61
12Y13
12Y4
3...9Y12
12Y78 4...9Y67
3...9Y48
12Y62
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12Y14/
12Y15
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12Y11
12Y60/
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12Y49
12Y61
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12Y13
3...9Y12
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12Y4
4...9Y67
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
3...9Y48
12Y78
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12Y62
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
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
11M12
2M45 1M45 11M2 11M1
Lateral register Lateral register
11M6
2M1 1M1
2M6 1M6 1M4 11M7
1M8 11M5
2M5 1M5
Circumferen- Circumferen-
1M7
tial register tial register
11M3
M52 M51 1M2
1M4 1M3
11M9
11M8
1M9
12M2
12M7 12M6
12M3
12M47 M44
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
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12M2
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
3...9M2
12M5 12M1
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12M7 12M6
12M3
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12M47 M44
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
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
15B14 11B10
11B35
1B11 11B55
1B13 1B9
2B48 1B48
2B48a 1B48a 1B10 11B33
HWI
1B49 11B11
3...9B32
12B129
12B69
12B129a 12B65
12B77 12B47
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
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
3...9B32
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12B129
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12B69
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12B129a 12B65
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
12B77 12B47
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
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 F
C C
D D
A B
H
C F
G
417
Location diagrams Control panels
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
H
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
C
F
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
G
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Extended delivery with coating unit
418
Location diagrams Control panels
Feeder
A Press control
B Pile control
Preset feeder
419
Location diagrams Control panels
420
Location diagrams Control panels
Delivery
H Press control
H Pile control
Preset version
421
Location diagrams Control panels
Preset version
422
Location diagrams Operator’s controls
Operator’s controls
423
Location diagrams Operator’s controls
Pushbutton 1...nS23
”Crawl speed”
Pushbutton 12S10
”Pile board on/off” 12H10
424
Location diagrams Operator’s controls
„Washing dampening/varnishing
rollers”
Illuminated pushbutton 12S25...
”– dampening” 12S32
Pushbuttons 11S117
”Blast air regulation” 11S118
Pushbuttons 11S44
”Suction head height” 11S44a
11S45
11S45a
Pushbuttons 11S46
”Suction head format” 11S47
Pushbuttons 11S58
”Main pile centering” 11S58a
11S59
11S59a
Pushbuttons 11S59
”Auxiliary pile centering” 11S60
Pushbutton 11S63
”Pile stops – larger format”
Pushbutton 11S62
”Pile stops – smaller format”
Pushbutton ”Pile stops D.S.” 11S9
Pushbuttons 11S48
”Format wheels” 11S57
Pushbuttons 12S68
”Sheet slowdown format” 12S69
425
Location diagrams Operator’s controls
Pushbuttons 12S61
”Sheet slowdown speed” 12S62
Pushbuttons 12S73
”Sheet jogger D.S.” 12S74
Pushbuttons 12S75
”Sheet jogger O.S.” 12S76
Potentiometer to DSM5
regulate the displayed fans
Potentiometer to DSM3
regulate the displayed fans
Potentiometer to DSM6
regulate the displayed fans
Potentiometer to DSM2
regulate the displayed fans
Potentiometer to DSM1
regulate the displayed fans
Potentiometer to DSM4
regulate the displayed fans
Potentiometer to
regulate dryer output
Volume controller
Illuminated pushbutton
”Intercom”
Pushbutton 11S8
”Lifting the sheet stop fingers”
426
Location diagrams Operator’s controls
Varnish circulation
Spraying
Rinsing
427
Location diagrams Operator’s controls
428
Location diagrams ZSP Control panel of control console
7 8 9
4 5 6
1 2 3
0
CPC
429
Location diagrams ZSP Control panel of control console
430
Abbreviations
Abbreviations
431
Abbreviations
432
Abbreviations
433
Abbreviations
VEN Fan
VMM Distributor for measuring
module
VP Distributor board
VSM Amplifier module
VTL Distributor board for diskette
drives
VTR Distributor board
VVK Ballast supply board
434
Equipment identification
Equipment identification
Press model
Identification letter or
Position code Number
abbreviation
Example 1: 1LVT1
1 LVT 1
Example 2: 1S3
1 S 3
Example 3: E4
Blank E 4
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
1 Printing unit 1
5 ... 10
11 Feeder
12 Delivery
14 Sheeter HSQ
20 Dryer
Example:
Position codes on a Speedmaster
15
4 3 2 1
12
101 13 11
Speedmaster SM102
437
Position codes
438
Index
1
Index
Blower motor for dampening system M45, 322 Place of installation, 271
Blower motor for powder spray device 12M35, 377 Removal and installation, 272
bottom main pile limitation 11S34 Coarse register monitoring 1...nB48, – Task/function,
– checking the circuit state, 159 272
– place of installation, 158 Coating unit, – Position code, 437
– setting, 159 Control console
– task and function, 158 – Layout, 408
bottom main pile limitation 12S34 – Location diagrams, 408
– checking the circuit state, 206 Control panel ZSP, – Location diagrams, 429
– place of installation, 204 Control panels
– setting, 205 – Delivery, 421
– task and function, 204 – Feeder, 419
Brushless main motor from 37KW, 12 – Location diagrams, 417
– Printing unit/coating unit, 420
Cooling and circulating unit E40, 325
C Cover guide height adjustment 1M4, 67
– Checking the operating range, 76
Central control cabinet ZSG, 393 – Interconnection diagram, 70
– Equipment zone A ”Power supply”, 394 – Place of installation, 69
– Equipment zone B ”Partition wall”, 395 – Positioning, 67
– Equipment zone C ”Mounting rack / control devices”, – Removal and installation of motor, 71
397 – Removal and installation of potentiometer, 73
– Equipment zone D ”Flat cable mounting plate”, 398 – Technical data, 69
– Equipment zone E ”Swing frame”, 399
– GRM Rectifier module, 396
– Location and layout, 393
Central dampening solution supply E40, 325 D
Central lubrication, 329 Dampening, 321
– Basic concept, 329 Dampening solution mixing unit E41, 328
– Fault messages, 332 Dampening system
– Grease lubrication – Blower motor, 322
– Block diagram, 333 – Dampening solution sensor, 323
– Function, 334 Delivery, – Position code, 437
– Layout, 334 delivery pile control
– Monitoring the lubrication system, 335 – automatic pile height control, 170
– Motor for grease lubrication 12M47, 345 – auxiliary drive control, 165
– Place of installation, 334 – block diagram (Preset), 161
– Pressure relief valve of the motor , 337 – block diagram (standard), 162
– Settings, 336 – non–stop operation, 177
– Triggering a lubrication process, 336 – overview (Layout), 163
– Oil lubrication – overview of components (drive side), 167
– Block diagram, 338 – overview of components (operator side), 166
– Changing the filter, 342 – overview of motors, 168
– Distributing lubrication, 340 – overview of solenoid–operated valves, 169
– Filter unit, 341 – overview of switches and sensors, 168
– Function, 340 – paper blockage, 185
– Layout, 339 – press control, 164
– Place of installation, 339 – removal of sample sheet, 184
– Pressure relief valve of oil pump, 342 – safety circuit, 164
– Triggering a lubrication process, 341 – Transport of auxiliary pile, 175
– Service display, 330 – transport of main pile (Preset), 171
changeover fast/slow 12B65 – transport of main pile (standard), 173
– checking the circuit state, 197 delivery upper edge of pile 12B129
– connection, 196 – checking the circuit state, 203
– layout, 195 – connection, 202
– place of installation, 195 – layout, 201
– -Removal and installation, 196 – place of installation, 201
– task and function, 196 – -removal and installation, 203
Circumferential register SM/CD 102, 314 – task and function, 202
Coarse register monitoring, 271 Diagonal register SM/CD 102, 308
Adjustment, 273 Double–sheet detector 1B11
Connection, 271 – Adjustment, 237
Layout, 271 – Block diagram, 231
2
Index
– Connection, 235 I
– Fault messages, 232
– Layout, 234 Identification letter, 435
– Pin assignment, 235 Impression cylinder washup device DZW, 292
– Place of installation, 233 – Block diagram, 292
– Removal and installation, 236 Inactivating pile centering 11B55, 28
– Sheet alignment, 231 Ink blade, – Sensor monitoring the ink blade 1...nB43,
303
Ink fountain roller motor SM/CD 102, 305
Inking roller washup device FWW, 286
E Inking unit temperature control, 382
Encoder, – Place of installation, 388 – SM/CD 102, 317
Encoder IDS, 388 Inking unit temperature control E39, E39a, – SM/CD
– Installation variants, 390 102, 318
– Pin assignment, 389 Intercom WSA
– Removal and installation, 390 – Function, 387
Equipment identification, 435 – Layout, 386
Extension control cabinet ESG, 437 IR slide–in dryer, – Switches monitoring the IR slide–in
dryer 12S9, –a, –b, –c, 380
F
Feeder, – Position code, 437
L
Feeder pile control Lateral register SM/CD 102, 311
– block diagram (Preset), 119 Level in coating pan L–B32, 371
– block diagram (Standard), 120 Location diagrams, 393
– Overview of components (Standard), 125 – Control panel ZSP, 429
feeder pile control – Control panels, 417
– automatic pile height control of auxiliary pile , 129 – Delivery, 421
– automatic pile height control of main pile (standard), – Feeder, 419
128 – Printing unit/coating unit, 420
– auxiliary drive control, 123 – Motors, 413
– non–stop operation (Preset), 134 – Operator’s controls, 423
– non–stop operation (standard), 137 – Position switches, 409
– overview (layout), 121 – Sensors, 415
– Overview of components (Preset), 124 – Solenoid valves, 411
– overview of motors, 126 – ZSP Central control console, 408
– overview of switches and sensors, 126 Location diagrams , – Central control cabinet ZSG, 393
– pile height control of main pile (Preset), 127 Lubrication monitoring 1 – 12B47, 348
– press control, 122 Lubrication monitoring 2 – 12B77, 348
– safety circuit, 122
– transport of auxiliary pile, 132
– Transport of main pile, 130 M
Format adjustment
– Adjustment of format wheels 11M4, 47 M1 Direct–current main motor, 7
– Adjustment of printing pressure 1...nM5, 85 Main drive
– Cover guide height adjustment 1M4, 67 – Brushless main motor from 37KW, 12
– Pile stops 11M11/11M12, 59 – Direct–current main motor, 7
– Sheet joggers 12M6/12M7, 110 – Motor terminal board, 15
– Sheet slowdown/format adjustment 12M5, 104 – Replacing the brake, 9
– Suction head/format adjustment 11M6, 53 – Replacing the carbon brushes, 10
– Rotor position encoder, 13
main pile motor (Preset) 11M1
– layout, 140
G – pin assignment, 142
Grease lubrication, 333 – place of installation, 140
– Lubrication monitoring 1 – 12B47, 348 – task and function, 141
– Lubrication monitoring 2 – 12B77, 348 – technical specifications, 141
GRM Rectifier module, – Central control cabinet ZSG, main pile motor (standard) 11M1
396 – Layout, 143
– pin assignment, 145
– place of installation, 143
– task and function, 144
– Technical specifications, 144
3
Index
4
Index
5
Index
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