CD102.pdf
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Important safety instructions
Observe the general and press-specific safety instructions in the operating manual. At first start-up or after the exchange of equipment or components check the correct functioning of all safety equipment. Control cabinet and machine housing have to be locked while the press is in operation. They may only be opened for repair purposes. Make sure that the main power switch is turned off and that there is no voltage applied to the press before you open the control cabinet or the machine housing. If it is necessary to repair the press while it is connected to the mains supply, please pay attention to general safety precautions. Never exchange components and units while the press is connected to the mains supply. Safety equipment must not be modified. Do not remove earth conductors. If it is necessary to disconnect these conductors, please remember to reconnect them after you are finished. If extra accessories not corresponding to Heidelberg specifications are installed or mounted, Heidelberg does not accept any liability whatsoever. In each case these accessories must be controlled or locked in a way that no hazards can arise when the press and its devices are operated.
Observe these handling instructions when you replace electronic boards with electrostatically sensitive devices (ESDs)!
Attention:
Handling and replacing electronic boards +80°C
–25°C Storage: NEVER below –25°C NEVER above +80°C
ALWAYS pack into the protective container for ESDs.
NEVER replace when power is on.
NEVER use force to insert.
Protective measures for ESDs to be observed when replacing electronic boards
DISCHARGE static charges.
UNPACK from the protective container for ESDs.
REPLACE electronic boards.
PACK into the protective container for ESDs.
2. Speedmaster CD102
Table of contents
2. Speedmaster CD 102 7
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
39
Suction head height control
39
11M5 Suction head height adjustment
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 – 438
1
2. Speedmaster CD102
2
Table of contents
119
Feeder pile control
119
Block diagrams
121
Layout
124
Overview of components
127
Function
140
11M1 Main pile motor (Preset)
143
11M1 Main pile motor (standard)
146
11M2 Auxiliary pile motor
149
11B11 Auxiliary pile detection
152
11B33 Upper main pile limitation
155
11B35 Automatic pile transport
158
11S34 Bottom main pile limitation
161
Delivery pile control
161
Block diagrams
163
Layout
166
Overview of components
170
Function
186
12M1 Main pile motor (Preset)
189
12M1 Main pile motor (standard)
192
12M2 Auxiliary pile motor
195
12B65 Changeover fast/slow
198
12B69 Pile height control
201
12B129 Delivery upper edge of pile
204
12S34 Bottom main pile limitation
207
Sheet alignment
207
Block diagram
210
1B13/ 1B49 Sheet alignment control
223
1B9/1B10 Pull lay control
231
1B11 Double-sheet detector
238
11M3 Automatic sheet arrival control
241
11M3 Automatic sheet arrival control (standard version)
247
11M3 Automatic sheet arrival control (Preset version)
251
11M7 Automatic misalignment control
2. Speedmaster CD102
Table of contents
259
Sheet monitoring
259
1...nB48/ 1...nB48a Sheet travel monitor
267
Plate clamping device
267
Autoplate
271
1...nB53 ”Coarse register monitoring”
275
Washup devices
275
Control by command ”Washup”
276
Messages
278
Service display ”Washup”
281
Blanket washup device (GTW)
286
Inking roller washup device (FWW)
292
Impression cylinder washup device (DZW)
296
M43, M50 ... M56 Washup brush motors
297
E9 Washup solution container
301
B1, B54, B55 Sensors at the washup solution container
303
1...nB43 Monitoring the ink blade
305
Inking unit
305
Servo-drive ink fountain roller
308
Servo-drive diagonal register 1...nM6
311
Servo-drive lateral register
314
Servo-drive circumferential register
317
Inking unit temperature control
318
E39 Inking unit temperature control
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
329
Central lubrication
329
Basic concept
330
Service display
332
Fault messages
333
Grease lubrication
338
Oil lubrication
343
M44 Oil pump
345
12M47 Motor for grease lubrication
346
1F33 Pressure monitoring oil lubrication 1 bar
347
1F34 Pressure monitoring oil lubrication 12 bars
348
12B47 Lubrication monitoring 1 and 12B77 Lubrication monitoring 2
4
351
Pneumatic system
351
15Y11 Admission of pressure, pneumatic system
353
15B14 Pressure sensor ”Pneumatic system”
355
E4 Pneumatic system compressor
357
Suction and blast air
357
1M9 Blast air regulation at the feeder
369
Other components
369
E4a Varnish supply unit
371
L-B32 Level in coating pan
373
12E2 Powder spray unit
377
12M35 Blower motor for powder spray device
379
12S68 Switch ”Powdering cycle”
380
12S9, -a, -b, -c Monitoring the IR slide-in dryer
381
E8 Air supply cabinet
382
E39 Inking unit temperature control
383
12E3 Static electricity eliminator
386
WSA Intercom
388
IDS Encoder
2. Speedmaster CD102
Table of contents
393
Location diagrams
393
ZSG Central control cabinet
408
ZSP Central control console
409
Position switches
411
Solenoid valves
413
Motors
415
Sensors
417
Control panels
423
Operator’s controls
429
ZSP Control panel of control console
431
Abbreviations
435
Equipment identification
437
Position codes
5
2. Speedmaster CD102
6
Table of contents
Main drive
M1 Direct-current main motor
Main drive M1 Direct-current main motor Layout The dc main motor is a dc shunt motor. Its layout varies depending on the manufacturer, motor power and type of construction. The illustration below shows one example of the components of the main motor M1.
Representation of a dc main motor M1
Installation area of fan impeller Ventilation cover Terminal box for main motor M1 ( contains all connections for M1 ) Hoop for manual release of brake Terminal box of brake Brake Y1 Installation area of carbon brushes and commutator Motor support rails or motor baseplate
7
Main drive
M1 Direct-current main motor
Make sure the motor is disconnected from the power supply before working on it!
Attention:
Make certain to leave a minimum gap of 6 mm in the terminal box between neighbouring conducting parts carrying different potentials! Shut the terminal box tight! Terminal box of ”SIEMENS” main motor
Entries for motor connecting cables Connection PE conductor Connection armature circuit + / A1 Connection armature circuit – / A2 Connection field circuit + / F1 Connection field circuit – / F2 Connector X1 / connection to optocoupler module 15U5 (monitoring of carbon brushes) and brake control module BAM ( BAM-X1) Connector X2 / connection to interference suppressor module ESM ( motor coding ) Connecting cable to brake Y1
Terminal box of a ”SIEMENS” main motor Terminal box of ”BAUMÜLLER” main motor
Terminal box of a ”BAUMÜLLER” main motor
8
Connection PE conductor Connector X1 / connection to optocoupler module 15U5 (monitoring of carbon brushes) and brake control module BAM ( BAM-X1) Connector X2 / connection to interference suppressor module ESM ( motor coding ) Connection field circuit – / F2 Connection field circuit + / F1 Connection armature circuit + / A1 Connection armature circuit – / A2 Entries for motor connecting cables
Main drive
M1 Direct-current main motor
Removal and installation of brake
Connecting cable of brake Terminal box of brake Fixing bolts of brake Brake of main motor M1
Removal of defective brake
Turn off the main switch on the central control cabinet ZSG and make sure no-one can turn the power back on. Disconnect the connecting cable terminal box of the brake. Loosen the fixing bolts
from the
of the brake.
Pull the brake off the main motor shaft.
Brake at main motor
Connecting cable of brake Terminal box of brake Fixing bolts of brake Brake of main motor M1 Square driver of motor shaft
Installation of the new brake
Place the new brake on the square driver the motor shaft.
of
uniformly. Connect the connecting cable of the brake to the terminal box . Tighten the fixing bolts
Main motor with brake removed
9
Main drive
M1 Direct-current main motor
Removal/installation of carbon brushes
Ventilation covers of main motor Terminals of carbon brushes Carbon brushes Clamp-type carbon brush holder Brush-rocker ring
Removal of carbon brushes
Note: Always replace all carbon brushes of the main motor. All carbon brushes should be from the same set of spare parts to guarantee that they are all from the same material.
Ventilation covers of main motor
1 2 3
Turn off the main switch on the central control cabinet ZSG and make sure no-one can turn the power back on. Remove all ventilation covers installation side of the brake.
on the
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.
Layout of brush-rocker ring (example)
10
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 .
Main drive
M1 Direct-current main motor
Carbon brush connections Carbon brushes Clamp-type carbon brush holder Brush-rocker ring Fixing bolts for brush-rocker ring
Installation of new carbon brushes When replacing a set of carbon brushes, clean all the cooling-air paths, e.g. with dry, oil-free compressed air. Any deposits of carbon dust on the insulating parts of the commutator and the brush-rocker ring must be removed completely, e.g. by cleaning these parts with a non-linting cloth.
Fastening the brush-rocker ring (example)
Insert the new carbon brushes and connect them to the terminals. Close the clamp-type brush holder .
Note: The carbon brushes must rest correctly on the commutator and run smoothly in the brush boxes.
If the brush-rocker ring was turned before, it must be brought back in its initial position and locked after replacement of the carbon brushes. Pay attention to the markings! Screw down the covers
again.
Note: The ventilation slots in the ventilation covers must point downward to maintain the type of protection.
11
Main drive
M1 Brushless main motor
M1 Brushless main motor Construction with terminal board (from 37kW)
Á Á
Main motor M1 with terminal box
12
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
Main drive
M1 Brushless main motor
Rotor position encoder The rotor position encoder consists of three components: –
sensor,
–
rotating part,
–
adjusting ring.
Do not loosen the safety screws of the adjusting ring of the rotor position encoder! Displacement of the adjusting ring results in displacement of the rotor position encoder in relation to the actual position of the rotor of the main motor. If the adjusting ring is not in its normal position or defective, the main motor must be replaced!
Attention:
Layout
ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ
Pin base X2 / connection to BLT4 Safety screws of adjusting ring Sensor Adjusting ring
Front view of rotor position encoder Pin assignment
X2
2 1
3
X2
7 6
Pin 4
5
Plug connection to ZSG (BLT4) Function
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 Rotor position encoder of main motor M1
Motor casing / brake Adjusting ring End-float washers (not always provided) Motor shaft Rotating part Connector M1-X2 Sensor part
Removal
1 2 3 4
Turn off the main switch and make sure no-one can turn the power back on. Remove connector X2. Remove the sensor (four fixing bolts). Replace the sensor or rotating part.
Note: Put the end-float washers back in place between the rotating part and motor. Installation
5
14
Reinstall all parts and connect the rotor position encoder.
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 temperature sensor
Terminal box of main motor BAUMÜLLER 37KW Please note: The terminal studs of the motor terminal board and the eye rings of the connecting cables have different diameters. Thus the cables cannot be mixed up. Terminal N is used for measuring purposes only.
Pin assignment X1 1
2
5
6
Pin and socket bases, 6-pole
2
1
Pin
6
5
Plug connection in motor terminal box Function
1
Motor code 0
2
Motor code 1
3
Motor code
4
Temperature sensor
5
Brake +
6
Brake –
15
Main drive
16
M1 Brushless main drive
Pile centering
Block diagram
Pile centering Block diagram The pile centering function comprises: Pile centering
Inactivating pile centering
11B10
11B55
–
the sensor ”Pile centering” 11B10,
–
the sensor ”Inactivating pile centering” 11B55”,
–
the servo-drive ”Pile centering” 11M9”.
Pile centering
The pile centering function compensates for the lateral displacement of the paper pile at the feeder. The sensor ”Pile centering” 11B10 senses the lateral edge of the pile. The required distance between the sensor and the lateral pile edge is 130 " 2 mm. If the difference between the required and actual distance exceeds the tolerance limits, the electronic control system corrects the position of the paper pile through the servo-drive ”Pile centering” 11M9”.
11M9
M
SSM1
SSM1
SSK
EAK 1
If the pile support plate reaches the sensor ”Inactivating pile centering” 11B35 during its upward movement, the electronic control system stops the automatic control. Automatic control is resumed as soon as
SAK
ESK
REK1
–
the pile support plate is below the sensor 11B35 and
–
the sensors 11B10 and 11B35 detect paper or
–
the pile support plate lies on the floor (position switch 11S34 actuated).
REK386
DSK
DNK
SVM
MID11
ZID
MID12
Displays
Legend:
Data line Control lines
Block diagram for pile centering 17
Pile centering
Block diagram
Activating and inactivating pile centering
Selecting the display
Symbol ”Pile centering on / off”
Activating and inactivating pile centering: –
in the preselection display,
–
by means of the function button.
If the symbol is lit, pile centering is active.
18
Pile centering
11B10 Pile centering
11B10 Pile centering The sensor 11B10:
Á Á Á Á Á Á
11B10
–
senses the lateral pile edge (actual distance),
–
with the required distance = 130 ± 2 mm.
Where? –
approx. 25 mm below the upper edge of the pile.
Automatic control through the electronic control system: 130 ± 2 mm
–
if the difference between the required distance and actual distance exceeds the tolerance limits,
–
by activating the servo-drive ”Pile centering” 11M9.
Required distance for pile centering
No automatic control: –
within the tolerance limits of the required distance.
Output signal of sensor 11B10: –
analog voltage,
–
digitization on the SSK1.
Signal flow: –
Sensor 11B10
–
Servo-drive distributor module (11LVT: 2SSM1)
–
backplane SSR: X14
–
servo-drive control board SSK1.
19
Pile centering
11B10 Pile centering
Place of installation
11B10
PU1 and Preset feeder
Removal and installation
black
11LVT1 2SSM1 X5: D4 X2: +8 X2: –8
blue brown
Check
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
1646 ± 70
130 2 mm
20
Pile centering
11M9 Pile centering
11M9 Pile centering Automatic positioning Condition: Automatic pile centering is switched on in the preselection display. The servo-drive 11M9 positions the pile support frame at the feeder. The sensor 11B10 senses the lateral edge of the pile. If the difference between the required distance and the actual distance exceeds the tolerance limits, the servo-drive control board SSK regulates the servo-drive 11M9. If the pile support plate reaches the sensor 11B35 while moving up, the electronic control system stops the automatic control.
Manual positioning for feeder without NON-STOP facility: Condition: Automatic pile centering is switched off in the preselection display.
Plus button
The pushbuttons Main pile centering control the servo-drive 11M9. Maximum positioning range: +/– 30 mm in relation to the centre of the feeder.
Minus button
Plus button
= movement towards D.S.
Minus button
= movement towards O.S.
Pushbuttons ”Main pile centering”
21
Pile centering
11M9 Pile centering
NON-STOP feeder The positioning of the pile support plate by means of pushbuttons depends on the position of the toggle switch ”Auxiliary pile on/off”.
Toggle switch ”Auxiliary pile on / off”
ÁÁÁ ÁÁÁ ÁÁÁ
ON
-
Main pile control activated.
OFF
-
The pushbuttons ”Main pile centering” control the servoĆdrive.
–
Maximum positioning range: ± 35mm in relation to the centre of the feeder.
Pushbuttons ”Main pile centering” Plus button
Plus button = Minus button =
Minus button
movement towards D.S. movement towards O.S.
The pile support frame and pile support plate can move max. 35 mm in the same direction together. Toggle switch in position ”ON”: Toggle switch ”Auxiliary pile on / off”
ON
–
Auxiliary pile control activated.
OFF
–
The pushbuttons ”Auxiliary pile centering” control the pile support frame.
–
Maximum positioning range: ± 35mm in relation to the centre of the feeder.
Pushbuttons ”Auxiliary pile centering” Plus button
The pile support frame and pile support plate can move max. 35 mm in the same direction together.
Minus button
Indication of position in MID
11
2 0
Indication of position of pile support frame
22
During manual positioning, the electronic control system indicates the present position of the pile support frame in the press display MID. The displayed value represents the absolute position in relation to the centre of the feeder.
Present position Position code
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
X13
X4
X14
SSR X14
Backplane of servodrive plug-in unit SSR
11 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
+ – 10V 0V
24
Pin 1 Pin 2 Pin 3 Pin 4
X5: C1 X5: C2 X5: C3 X5: C4
X2: X2: X4: X4:
Pin 5
X5: C5
X4: 5
1 2 3 4
X10: X10: X14: X14:
B14 D14 3 4
X14: 5
Pile centering
11M9 Pile centering
Removal and installation
ON OFF
06
–
2048 ± 2
Set the toggle switch ”Auxiliary pile ON/OFF” to ”OFF”. Select the service display ”SSK1”. Bring the pile support plate into its central position (set to 2048±2 inc).
– –
–
Remove the servo-drive ”Pile centering” 11M9.
–
Set the distance between the side frame and the pile support frame to 83 mm. 25
Pile centering
11M9 Pile centering
4)
07
2048 ± 2 1M9: X1
– – –
Fit the motor baseplate and gear wheel. Connect plug 11M9: X1. Set to 2048±2 inc.
–
26
Install the servo-drive.
Pile centering
11M9 Pile centering
Checking the operating range
Servo-drive ”Pile centering” 11M9
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
Service display ”Values, incremental values servodrives”
27
Pile centering
11B55 Inactivating pile centering
11B55 Inactivating pile centering If the pile support plate reaches the sensor 11B55 during 11B55
–
”Production run” or
–
”Paper run”,
the electronic control system switches the pile centering function off. The remaining sheets on the pile are still printed. For the pile change, the operator lowers the pile support plate and places paper on it. If the sensors –
”Automatic pile transport 11B35” and
–
”Inactivating pile centering 11B55”
detect the paper, the preselected pile centering function is active again.
Sensor 11B55
28
Pile centering
11B55 Inactivating pile centering
Place of installation
11B55
Adjustment
brown
black
11LVT1
FAM64 XE: 55 +1 –1
blue
Check
0010
29
Pile centering
30
11B55 Inactivating pile centering
Pile merging
11M8 Adjustment of pile support plate
Pile merging 11M8 Adjustment of pile support plate The servo-drive 11M8 is only installed at the NON–STOP feeder of Preset presses. The servo-drive 11M8 positions the pile support plate at the feeder. The positioning of the pile support plate depends on the position of the toggle switch ”Auxiliary pile on/off”.
Toggle switch ”Auxiliary pile on / off”
Pushbuttons ”Auxiliary pile centering” Plus button Minus button
Pushbutton ”Main pile down”
ÁÁ ÁÁ ÁÁ
Toggle switch in position ”Off” ON OFF
–
Main pile control activated.
The pushbuttons ”Auxiliary pile centering” control the servoĆdrive 11M8. Maximum positioning range: ± 30 mm in relation to the centre of the feeder. Plus button Minus button
= movement towards D.S. = movement towards O.S.
The pile support frame and pile support plate can move max. 35 mm in the same direction together. When the pile support plate reaches the position switch 11S39 ”Pile support plate limitation” while moving down, the electronic control system positions –
the pile support plate (through 11M8)
–
the pile support frame (through 11M9)
relative to the centre of the feeder. During positioning, the function ” Main pile down” is blocked. Approx. 30 seconds after the beginning of positioning, the electronic control system releases the function ”Main pile down” again.
31
Pile merging
Toggle switch ”Auxiliary pile on / off”
Pushbuttons ”Main pile centering” Plus button Minus button
11M8 Adjustment of pile support plate
ÁÁ ÁÁ
Toggle switch in position ”ON” ON
–
Auxiliary pile control activated.
OFF
The pushbuttons ”Auxiliary pile centering” control the servoĆdrive 11M8. Maximum positioning range: ± 30 mm in relation to the centre of the feeder. Plus button Minus button
= movement towards D.S. = movement towards O.S.
The pile support frame and pile support plate can move max. 35 mm in the same direction together. During the downward movement, the servo-drive 11M8 positions
Pushbutton ”Main pile down”
–
the pile support plate
relative to the centre of the feeder. As soon as the pile support plate lies on the ground (position switch 11S34 actuated), this function is stopped. The pile support plate cannot be positioned anymore. NON-STOP mode: When pile centering is active, the electronic control system regulates the pile support frame. To ensure that the pile support plate keeps its position on the floor, it is displaced by the same value as the pile support frame, however in the opposite direction.
32
Pile merging
11M8 Adjustment of pile support plate
Place of installation
11M8
Operator side
Technical data Motor data –
U
=
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
X13
X4
X14
SSR X13
Backplane of servodrive plug-in unit SSR
11 11LVT1 2SSM1: X1 X3 X4
2SSM1: X3
X2 X1
X5
2SSM1
Servo-drive distributor module 2SSM1
11M8: X1
3
4 5
2
1
11M8
Servo-drive 11M8
+ – 10V 0V
34
Pin 1 Pin 2 Pin 3 Pin 4
X5: B1 X5: B2 X5: B3 X5: B4
X1: X1: X3: X3:
Pin 5
X5: B5
X3: 6
3 4 8 7
X10: X10: X13: X13:
B12 D12 8 7
X13: 6
Pile merging
11M8 Adjustment of pile support plate
Removal and installation
ON
OFF
07
–
2048 ± 2
Set the toggle switch ”Auxiliary pile ON/OFF” to ”OFF”. Select the service display ”SSK1”. Bring the pile support frame into its central position (set to 2048±2 inc).
– –
–
Remove the servo-drive ”Adjustment of pile support plate” 11M8.
Frame .
Guide –
Set the distance between the pile support plate guide and the pile support frame to 31.5 mm. 35
Pile merging
11M8 Adjustment of pile support plate
4)
06
2048 ± 2 1M8: X1
– – – –
Mount the servo-drive on the motor baseplate. Fit the gear wheel. Connect plug 11M8: X1. Set to 2048 inc.
–
36
Tighten the chain.
Pile merging
11M8 Adjustment of pile support plate
Checking the operating range
Servo-drive ”Adjustment of pile support plate” 11M8
Condition: The pile support frame is positioned in the centre of the feeder. Off-centre position: 00
Service display ”Values, incremental values servo-drives”
Input
Incremental value
– 30 mm
3461 " 23 inc
+ 30 mm
634 " 23 inc
37
Pile merging
38
11M8 Adjustment of pile support plate
Suction head height control
11M5 Suction head height adjustment
Suction head height control 11M5 Suction head height adjustment The servo-drive 11M5 positions the suction head vertically. The servo-drive can be controlled with the pushbuttons ”Suction head height”. Pushbuttons ”Suction head height” Plus button Minus button
Actuation of one of the pushbuttons: –
suction head positions vertically,
–
positioning range +/– 20 mm,
–
indication of position in feeder MID.
Plus button Minus button
= suction head moves up (+ 20 mm). = suction head moves down (– 20 mm).
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 X13
X4
X14
Backplane of servodrive plug-in unit SSR
11 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
+ – 10V 0V
Pin 1 Pin 2 Pin 3 Pin 4
X5: C1 X5: C2 X5: C3 X5: C4
X2: X2: X4: X4:
Pin 5
X5: C5
X4: 5
1 2 3 4
X10: X10: X12: X12:
B6 D6 3 4
X12: 5
41
Suction head height control
11M5 Suction head height adjustment
Removal and installation
1
2
20 mm
–
Remove the servo-drive ”Suction head height adjustment” 11M5.
–
Set the distance (20 mm) at the suction head guide rail.
3 4)
03
2456 ± 2
11M5: X1
– – 42
Connect plug 11M5: X1. Set to 2456 ±2 inc.
Suction head height control
11M5 Suction head height adjustment
4
–
Install the servo-drive.
Checking the operating range
Servo-drive ”Suction head height adjustment” 11M5 Input
Incremental value
– 20
880 " 4 inc
+ 20
3215 " 4 inc
Service display ”Values, incremental values servodrives”
43
Suction head height control
44
11M5 Suction head height adjustment
Size adjustment
Block diagram
Size adjustment Block diagram Adjustment of format wheels 11M4
SSM
Sheet slowdown/ format adjustment 12M5
SSM
M
M Adjustment of pull lay D.S. 1M7
Suction head/ format adjustment 11M6
SSM
SSM
M
M
Adjustment of pull lay O.S. 1M8
Pile stop D.S. 11M11 SSM
SSM
M
M
Cover guide height adjustment 1M4
Pile stop O.S. 11M12
SSM
SSM
M
M
Adjustment of printing pressure 1...nM5
Sheet jogger D.S. 12M6 SSM
SSM M
M Sheet jogger O.S. 12M7 SSM M
SSK1/2/3
Displays
SAK
REK1
Legend:
Data line
ESK
REK386
SVM
MID11
MID12
DSK
DNK
ZID
Control lines
Block diagram size adjustment 45
Size adjustment
Block diagram
Command: ”PRESETTING”
To avoid damage to the press, make sure nothing is in the way of the following servo-drives when the command ”Presetting” is active: –
suction head,
–
pile stops D.S. and O.S.,
–
format wheels,
–
pull lays D.S. and O.S.,
–
sheet slowdown,
–
sheet joggers D.S. and O.S.
Selecting the command As a result of the inputs in this command mode, various servo-drives on the press are positioned automatically. 1020
After command enabling the electronic control system positions the following servo-drives: On the feeder
720 1.00
Command in control console display ZID
–
Suction head/format adjustment
–
Pile stops D.S. and O.S.
–
Adjustment of format wheels
On printing unit / coating unit –
Adjustment of pull lays D.S. and O.S.
–
Cover guide height adjustment
–
Adjustment of printing pressure
On the delivery
46
–
Sheet slowdown/format adjustment
–
Sheet joggers D.S. and O.S.
Size adjustment
11M4 Adjustment of format wheels
11M4 Adjustment of format wheels The servo-drive 11M4 positions the format wheels on the feeder. Automatic positioning Automatic positioning: –
is effected through the command ”Presetting”;
–
depends on inputs into CPTRONIC, such as: paper length, paper thickness, front lay adjustment (smallest value);
–
depends on inputs into CPC1-04, such as: coating unit register.
Positioning accuracy: ± 0.25 mm. End of automatic positioning:
Pushbuttons ”Format wheels” Plus button
–
when the new desired position has been reached,
–
when one of the pushbuttons ”Format wheels” is actuated.
Manual positioning Actuation of one of the pushbuttons ”Format wheels”: –
the format wheels are repositioned irrespective of the preset format,
–
indication of the position in the feeder MID,
–
when the command ”Presetting” is active, automatic positioning is stopped immediately.
Minus button
Plus button
= movement towards maximum format.
Minus button = movement towards minimum format.
Fault message in the ZID Adjustment of format wheels
The symbol appears in the display ”Feeder/Warning”. The symbol appears: –
during positioning while the press is on ”Run”.
The symbol goes off: –
when positioning is over and the press is on ”Run”,
–
when one of the pushbuttons ”Format wheels” is actuated and the press is on ”Run”.
47
Size adjustment
11M4 Adjustment of format wheels
Place of installation
11M4
Operator side
Technical data Motor data –
U
=
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 X13
X4
X14
Backplane of servodrive plug-in unit SSR
11 11LVT1 1SSM1: X1 X3 X4
X2 X1
1SSM1: X3
X5
1SSM1
Servo-drive distributor module 1SSM1
11M4: X1
3
4 5
2
1
11M4
Servo-drive 11M4
+ – 10V 0V
Pin 1 Pin 2 Pin 3 Pin 4
X5: B1 X5: B2 X5: B3 X5: B4
X1: X1: X3: X3:
Pin 5
X5: B5
X3: 6
3 4 8 7
X10: B4 X10: D4 X11: 8 X11: 7 X11: 6
49
Size adjustment
11M4 Adjustment of format wheels
Removal and installation
1
2
9.00 9.00
1020
720 1.00
–
Set the print-free margin to 9 mm.
– – – –
3
Enter the paper thickness Enter the paper width Enter the paper length Enable the command ”Paper
(1.0 mm). (1020 mm). (720 mm). size adjustment”.
4
ÁÁÁ ÁÁÁ ÁÁÁ
–
50
Remove the servo-drive ”Adjustment of format wheels” 11M4.
–
Bring the format wheels into their central position.
Size adjustment
11M4 Adjustment of format wheels
5
. Format wheels
. Sheet of paper
.
–
Set the distance ( 722.5 mm ) between the front lays and format wheels.
6
02
– – –
ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ
11M4: X1
3871 ± 2
Attach the gear wheel to the motor shaft. Connect plug 11M4: X1. Set to 3871 " 2 inc.
51
Size adjustment
11M4 Adjustment of format wheels
7
–
Install the servo-drive.
Checking the operating range
Servo-drive ”Adjustment of format wheels” 11M4
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 servo-drives”
Print-free margin: 10.00 mm
8.00 mm
Paper length:
720 mm
280 mm
Paper thickness:
2.00 mm
2.00 mm
Incremental value: 3886 ± 2 inc
52
288 ± 2 inc
Size adjustment
11M6 Suction head/format adjustment
11M6 Suction head/format adjustment The servo-drive 11M6 positions the suction head to the entered paper length. Automatic positioning Automatic positioning: –
is effected through the command ”Presetting”;
–
depends on the entered sheet length.
Positioning accuracy: ± 0.30 mm. Automatic positioning range: –
max. 720 mm,
–
min. 500 mm because of danger of collision with the lateral pile stops,
–
in the case of sheet lengths below 500 mm, the suction head stops at the lower limit (500 mm),
–
manual positioning if the sheets are shorter (less than 500 mm).
End of automatic positioning: –
when the new desired position has been reached,
–
when the lower limit (500 mm) of the positioning range has been reached,
–
when one of the pushbuttons ”Suction head format” is actuated.
Manual positioning Pushbuttons ”Suction head format” Plus button Minus button
Actuation of one of the pushbuttons ”Suction head format”: –
the servo-drive ”Suction head/ format adjustment” 11M6 is controlled,
–
the suction head positions irrespective of the preset format,
–
indication of the position in the feeder MID,
–
automatic positioning is stopped immediately.
Plus button
= to max. 730 mm.
Minus button = to min. 280 mm.
53
Size adjustment
11M6 Suction head/format adjustment
Fault message in the ZID Suction head/format adjustment
The symbol appears in the display ”Feeder/Warning”. The symbol appears: –
during positioning while the press is on ”Run”,
–
when the lower limit is reached during automatic positioning.
The symbol goes off:
54
–
when positioning is over and the press is on ”Run”,
–
when one of the pushbuttons ”Suction head format” is actuated and the press is on ”Run”.
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 X13
X4
X14
Backplane of servodrive plug-in unit SSR
11 11LVT1 1SSM1: X2 X3 X4
1SSM1: X4
X2 X1
X5
1SSM1
Servo-drive distributor module 1SSM1
11M6: X1
3
4 5
2
1
11M6
Servo-drive 11M6
+ – 10V 0V
56
Pin 1 Pin 2 Pin 3 Pin 4
X5: D1 X5: D2 X5: D3 X5: D4
X2: X2: X4: X4:
Pin 5
X5: D5
X4: 6
3 4 8 7
X10: X10: X12: X12:
B8 D8 8 7
X12: 6
Size adjustment
11M6 Suction head/format adjustment
Removal and installation
1
Á
Front sheet stop
Governor foot Marking
3 2 –
Remove the servo-drive ”Suction head/format adjustment” 11M6. Set the distance between the front sheet stop and the marking on the governor foot to 720 mm.
–
1
Note: To compensate for the backlash, the 720 mm must be set from the max. possible distance.
2 4)
11M6: X1 04
462 ± 2
11M6: X1 – –
Connect plug 11M6: X1. Set to 462 ±2 inc. 57
Size adjustment
11M6 Suction head/format adjustment
3
–
Install the servo-drive.
Checking the operating range
Servo-drive ”Suction head/format adjustment” 11M6
Paper length
Service display ”Values, incremental values servo-drives”
58
Incremental value
280 mm
3634 " 2 inc
730 mm
389 " 2 inc
Size adjustment
11M11/11M12 Pile stops D.S./O.S.
11M11/11M12 Pile stops D.S./O.S. The servo-drive 11M11 positions the pile stop on the D.S. The servo-drive 11M12 positions the pile stop on the O.S. Automatic positioning Automatic positioning: –
is effected through the command ”Presetting”,
–
depends on the inputs into CPTRONIC, such as: sheet width, off-centre position, preselected pull direction.
Positioning accuracy: ± 0.3 mm. End of automatic positioning: –
when the new desired position has been reached,
–
when one of the pushbuttons ”Pile stops larger format” or ”Pile stops smaller format” is actuated.
Manual positioning Pushbutton ”Pile stops larger format”
Actuation of pushbutton ”Pile stops larger format”: –
Control of servo-drives ”Pile stop D.S.” 11M11 and ”Pile stop O.S.” 11M12,
–
irrespective of the preset format, the pile stops position to a larger format.
Actuation of pushbutton ”Pile stops smaller format”: Pushbutton ”Pile stops smaller format”
–
Control of servo-drives ”Pile stop D.S.” 11M11 and ”Pile stop O.S.” 11M12,
–
irrespective of the preset format, the pile stops position to a smaller format.
Actuation of one of the pushbuttons: –
indication of the position in the feeder MID,
–
the off-centre position can be up to ± 50 mm,
–
automatic positioning is stopped immediately.
Plus button
= to max. 1040 mm.
Minus button = to min. 420 mm.
59
Size adjustment
11M11/11M12 Pile stops D.S./O.S.
Fault message in the ZID Pile stop D.S.
The symbols appear in the display ”Feeder/Warning”. The symbols appear:
Pile stop O.S.
–
during positioning while the press is on ”Run”.
The symbols go off: –
when positioning is over and the press is on ”Run”,
–
when one of the pushbuttons ”Pile stop D.S.” or ”Pile stop O.S.” is actuated and the press is on ”Run”.
Prepiling This function can only be activated in the preselection display. To inactivate it, press the corresponding button once more.
Selecting the display
The lateral pile stops move together when –
the pile support plate moving down is stopped by means of the button ”Pile stop” and
–
the pile support plate is in front of the position switch ”Pile support plate limitation” 11S39.
The distance between the stops is: sheet width entered + 5 mm O.S., + 5 mm D.S. The ”5 mm O.S. + 5 mm D.S.” are added to the entered value by the electronic control system.
The lateral pile stops move apart when –
the pile is raised.
The distance between the stops is: sheet width entered + 25 mm O.S., + 25 mm D.S. The ”25 mm O.S. + 25 mm D.S.” are added to the entered value by the electronic control system.
60
Symbol ”Prepiling”
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.
Interconnection diagram 11M11 X5
X10
SSR
SSR X10 X15
X16
SSR X15
X3 X17
X4
X18
Backplane of servo-drive plug-in unit SSR
11 3SSM2: X1
11LVT1
3SSM1: X2 X2 X1
X3
3SSM2
Servo-drive distributor module 3SSM2
11M11: X1
3
4 5
2
1
11M11
Servo-drive 11M11
+ – 10V 0V
62
Pin 1 Pin 2 Pin 3 Pin 4
X5: A1 X5: A2 X5: A3 X5: A4
X1: X1: X3: X3:
Pin 5
X5: A5
X3: 5
1 2 3 4
X10: X10: X15: X15:
B18 D18 3 4
X15: 5
Size adjustment
11M11/11M12 Pile stops D.S./O.S.
Interconnection diagram 11M12 X5
X10
SSR
SSR X10 X15
X16
SSR X15
X3 X17
X4
X18
Backplane of servodrive plug-in unit SSR
11 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
+ – 10V 0V
Pin 1 Pin 2 Pin 3 Pin 4
X5: B1 X5: B2 X5: B3 X5: B4
X1: X1: X2: X2:
Pin 5
X5: B5
X2: 6
3 4 8 7
X10: X10: X15: X15:
B20 D20 8 7
X15: 6
63
Size adjustment
11M11/11M12 Pile stops D.S./O.S.
Removal and installation
11M11
ÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁ
11M12
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. D.S.
Á ÁÁ
D.S./O.S. = 180 mm –
64
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.
Size adjustment
11M11/11M12 Pile stops D.S./O.S.
09
3015 ± 2
10
1072 ± 2 11M11: X1 11M12: X1
– – –
Fit the motor baseplate and gear wheel. Connect plug 11M11: X1 (or 11M12: X1). 11M11 (D.S.) = set to 3015±2 inc. 11M12 (O.S.) = set to 1072±2 inc.
1020
720 1,00
–
Install the servo-drive.
– – –
Select the command ”Presetting”. Press the button ”Input”. The servo-drives position to the displayed format.
65
Size adjustment
11M11/11M12 Pile stops D.S./O.S.
Checking the operating range
Servo-drive ”Pile stop D.S.” 11M11 Servo-drive ”Pile stop O.S.” 11M12
Position the pile stops manually to the maximum format (press the button ”Pile stops larger format”). Incremental value for 11M11: 3231 ± 2 inc Incremental value for 11M12: 856 ± 2 inc Position the pile stops manually to the minimum format (press the button ”Pile stops smaller format”).
Service display ”Values, incremental values servo-drives”
66
Incremental value for 11M11: 783 ± 2 inc Incremental value for 11M12: 3304 ± 2 inc
Size adjustment
1M4 Cover guide height adjustment
1M4 Cover guide height adjustment For cover guide height adjustment a servo-drive is installed on the operator side of the 1st printing unit. With this servo-drive the cover guides (gripper opening) on the transfer gripper are adjusted. By means of a mechanical device (eccentric bush) gripper opening can be adjusted within a range from 0.1 mm to 1.9 mm.
Positioning The new desired position is always approached from the direction of the widest gripper opening (1.9 mm). Actual position
Reversal point
Example 1: The new desired position is larger than the actual position.
0
New desired position 1.9mm
Example 1
When the new desired position has been entered, the servo-drive first positions to the reversal point and then to the new desired position . Example 2:
New desired position
0
Actual position
1.9mm
The new desired position is smaller than the actual position. When the new desired position has been entered, the servo-drive moves to the new desired position.
Example 2 Automatic positioning Entering the paper thickness
When the command ”Presetting” has been enabled, the electronic control system positions the cover guides on CD102 and SM102 (only with REK386): –
to twice the paper thickness entered plus 0.1 mm (max. 1.9 mm),
SM74 and SM52: –
to twice the paper thickness entered (max. 1.9 mm).
67
Size adjustment
1M4 Cover guide height adjustment
Manual positioning
Selecting the display
After actuating the button ”Cover guide height adjustment”, the operator can make adjustments with the left-hand +/– buttons.
Actual value/coarse display, cover guide height adjustment
68
Indication of the present value of the cover guide height adjustment
Size adjustment
1M4 Cover guide height adjustment
Place of installation
ÁÁÁÁ
ÉÉÉ ÉÉ ÉÉÉ ÉÉ ÉÉÉ ÉÉ ÉÉ ÉÉ ÉÉ
Printing unit 1 and feeder
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 X5
X10
SSR
SSR X20
X21
X22 X3
X23
X4
X24
SSR X23
Backplane of servo-drive plug-in unit SSR
1 1LVT1
2SSM1: X2 X3
X4
X1
2SSM1: X4 X2 X5
2SSM1
Servo-drive distributor module 2SSM1
1M4: X1
1M4
Servo-drive 1M4
70
+ – 10V
1 2 4 5
X5: D1 X5: D2 X5: D3 X5: D4
X2: X2: X4: X4:
0V
6
X5: D5
X4: 6
3 4 8 7
X20: X20: X23: X23:
B12 D12 8 7
X23: 6
Size adjustment
1M4 Cover guide height adjustment
Removal and installation of motor
1 0
1
ÉÉÉ ÉÉÉ ÉÉ ÉÉ ÉÉ
15Q66
ÉÉÉ ÉÉ É ÉÉÉ ÉÉ É ÉÉÉ ÉÉÉ 1M4
2
ÉÉÉ ÉÉÉÉ ÉÉÉÉ ÉÉÉ ÉÉÉ
½
1M4
3
ÉÉÉ ÉÉ É ÉÉÉ ÉÉ É ÉÉÉ ÉÉÉ ÉÉÉ
1M4
71
Size adjustment
1M4 Cover guide height adjustment
4
brown blue
ÉÉ ÉÉ É ÉÉ ÉÉ É ÉÉ ÉÉÉ ÉÉ
red 1 2
2 black
1
1M4
5
ÉÉÉÉ ÉÉÉÉ ÉÉÉ ÉÉÉ 1
1M4
0
1
15Q66
2
72
3
Size adjustment
1M4 Cover guide height adjustment
Removal and installation of potentiometer
1 2
310 . 0
3 1
0
1
15Q66
2
ÉÉÉ É ÉÉÉ É ÉÉÉ ÉÉÉ
3
1M4
2 1
3
1
ÉÉÉ ÉÉÉ ÉÉ
2
ÉÉÉÉ ÇÇ ÉÉÉÉ ÇÇ ÉÉÉÉ ÇÇ ÉÉÉÉ ÇÇ ÉÉÉÉ ÇÇ ÉÉÉÉ
73
Size adjustment
1M4 Cover guide height adjustment
4
defective
new
5
1 M4: X1
beige
yellow
black
0
1
blue black red
15Q66
6
08
74
1016 ± 4
Size adjustment
1M4 Cover guide height adjustment
7
ÉÉÉ É ÉÉÉ É ÉÉÉ É ÉÉÉ ÉÉÉ
8
ÉÉÉ É ÉÉÉ É ÉÉÉ É ÉÉÉ ÉÉÉ
1M4
75
Size adjustment
1M4 Cover guide height adjustment
Checking the operating range Preset version:
Servo-drive ”Cover guide height adjustment” 1M4 Paper thickness
Incremental value
0.01 mm
676 " 4 inc
1.00 mm
3260 " 4 inc
Service display ”Values, incremental values servo-drives” Standard version:
Service display ”Values, incremental values servo-drives”
76
Servo-drive ”Cover guide height adjustment” 1M4 Paper thickness
Incremental value
0.01 mm
676 " 4 inc
1.00 mm
3260 " 4 inc
Size adjustment
1M2/1M3 Print-free margin D.S./O.S.
1M2/1M3 Print-free margin D.S./O.S. Running direction of paper
Front lays 2mm
The print-free margin on the sheet is adjusted by means of two servo-drives. These servo-drives change the position of the front lay stop. The front lays are fitted on a shaft which, for adjustment of the print-free margin, can be adjusted parallel or at an angle (to the feed table). For this purpose, one servo-drive is installed on the drive side and one on the operator side. With these two servo-drives the front lays can be influenced in such a way that the print-free margin measures between 10 mm and 12 mm. The adjustment is made at the central control console.
Graphical representation in the ZID
Selecting the display Graphical representation ”Print-free margin” Minimum value Maximum value Current value D.S. Current value O.S.
Actual value/fine display ”Print-free margin” Print-free margin O.S.
To adjust the print-free margin, press the corresponding function button. Then make the adjustment within a range from 10.0 mm to 12.0 mm by means of the left-hand +/– buttons.
Print-free margin D.S. and O.S. Print-free margin D.S.
77
Size adjustment
1M2/1M3 Print-free margin D.S./O.S.
Place of installation
ÁÁÁÁ
1M2 = D.S. 1M3 = O.S.
Printing unit 1 and feeder
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
X17
X4
X18
SSR X18
Backplane of servodrive plug-in unit SSR
1 1LVT1
1SSM1: X1 X3
X4
1SSM1 X3 X2 X1 X5
1SSM 1
Servo-drive distributor module SSM 1
X3 X1
X3 X1
SSM3 X2
1M2
+ – 10V 0V
SSM3 X2
1M3
SSM3 X3: 1 X3: 2 X3: 3 X3: 4
SSM 1 X5: A1 X5: A2 X5: A3 X5: A4
X3: 5
X5: A5 X3: 5
X1: X1: X3: X3:
1 2 3 4
SSR X10: X10: X18: X18:
B30 D30 3 4
X18: 5
Servo-drives 1M2 and 1M3 SSM3 X3: 1 X3: 2 X3: 3 X3: 4
SSM1 X5: B1 X5: B2 X5: B3 X5: B4
X3: 5
X5: B5 X3:6
X1: X1: X3: X3:
3 4 8 7
SSR X10: B32 X10: D32 X18: 8 X18: 7 X18: 6
79
Size adjustment
1M2/1M3 Print-free margin D.S./O.S.
Removal and installation of motor
1 1 0
1
4 15Q66
1M2 (1M3)
2
3
2–4
2
1 1M2 (1M3)
80
2 3
2–4
Size adjustment
1M2/1M3 Print-free margin D.S./O.S.
Removal and installation of potentiometer
1 1
216 . 0
2 0
1 15Q66
2
3 1M2 (1M3)
2
2–4
1
3
2 1 81
Size adjustment
1M2/1M3 Print-free margin D.S./O.S.
4 Pull rail
.
Front lay
5
defective
new
6 0
1 15Q66
82
Size adjustment
1M2/1M3 Print-free margin D.S./O.S.
7
05
1M2 2048 ± 6
06
1M3 2048 ± 6
8
9
1 1M2 (1M3)
22–4 3
83
Size adjustment
1M2/1M3 Print-free margin D.S./O.S.
Checking the operating range Preset version:
Servo-drive ”Print-free margin D.S.” 1M2 Servo-drive ”Print-free margin O.S.” 1M3 Input
Incremental value
8 mm
3850 " 4 inc
10 mm
246 " 4 inc
Service display ”Values, incremental values servo-drives” Standard version:
Service display ”Values, incremental values servo-drives”
84
Servo-drive ”Print-free margin D.S.” 1M2 Servo-drive ”Print-free margin O.S.” 1M3 Input
Incremental value
8 mm
3850 " 4 inc
10 mm
246 " 4 inc
Size adjustment
1...nM5 Adjustment of printing pressure
1...nM5 Adjustment of printing pressure The servo-drive ”Adjustment of printing pressure” changes the gap between blanket cylinder and impression cylinder. The rotation of the drive is transmitted to the blanket cylinder via a worm gear and a gear segment. The operator thus influences the pressure exerted on the print sheet during the printing process. Automatic positioning When the paper thickness is entered under the command ”Presetting”, the servo-drive automatically positions to the value: paper thickness – 0.1 mm = pressure.
Examples: 0.07 –0.1 = 0.50 –0.1 =
–0.03 ! –0.03 x –1 = 0.03 0.40 ! 0.40 x –1 = –0.40
The correction factor (–1) ensures that the result is shown correctly in the ”Actual value display”.
Explanation of the display
Paper thickness entered Symbol for the paper thickness entered Upper adjustment limit for the printing pressure (max. gap between blanket cylinder and impression cylinder). SM102 = – 0.75 mm, CD102, CU on SM102 = – 1.20 mm. Graphical representation of the printing pressure Present value of the printing pressure ”0” position of the printing pressure Lower adjustment limit (0.3 mm) for the printing pressure (min. gap between blanket cylinder and impression cylinder)
85
Size adjustment
1...nM5 Adjustment of printing pressure
Manual positioning
Selecting the display
Graphical representation of the adjustment of the printing pressure The servo-drive can be positioned manually with the right-hand +/– buttons. If no printing unit has been selected in the ”Printing unit/actual value display”, all drives respond. If only one drive is to be positioned, the corresponding printing unit must be selected before.
Actual value/coarse display, adjustment of printing pressure
86
Note: The software limits the maximum pressure to 0.55. The max. pressure is composed of –
the automatic positioning value (0.10) and
–
the manual positioning value (max. 0.45).
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
Interconnection diagram for printing unit 1...nM5 PU1, PU3, PU5 PU2, PU4
SSR X20
PU6, PU7, PU8
SSR X30
PU1 PU2 PU3 PU4 PU5 PU6 PU7 PU8
= = = = = = = =
SSR SSR SSR SSR SSR SSR SSR SSR
X24 X25 X26 X27 X28 X31 X32 X33
X20
X25
X27
SSR
X26 X3
X4
X28
Backplane of servo-drive plug-in unit SSR
1...8
1SSM2: X1
X5
X30
1...8LVT1
1...8M5: X1
1SSM2 X2 X1
1...8M5: X1 X2
X3
Servo-drive 1...8M5
1SSM2
Servo-drive distributor module 1SSM2 1...8M5:X1 1SSM 2 + – 10V 0V
88
1 2 4 5
X3: X3: X3: X3:
A1 A2 A3 A4
6 X3: A5 1...8M5:X1 1SSM 2
+ – 10V
1 2 4 5
X3: X3: X3: X3:
0V
6
X3: A5
A1 A2 A3 A4
X1: X1: X2: X2:
1 2 3 4
X2: 5
X1: X1: X2: X2:
1 2 3 4
X2: 5
SSR PU1 X20: B14 X20: B14 X24: 3 X24: 4
PU2 X20: X20: X25: X25:
B18 D18 3 4
PU3 X20: X20: X26: X26:
B22 D22 3 4
PU4 X20: X20: X27: X27:
B26 D26 3 4
X24: 5 SSR PU5 X20: B30 X20: D30 X28: 3 X28: 4
X25: 5
X26: 5
X27: 5
PU6 X30: X30: X31: X31:
PU7 X30: X30: X32: X32:
PU8 X30: X30: X32: X32:
X28: 5
X31: 5
B2 D2 3 4
B6 D6 3 4
X32: 5
B10 D10 3 4
X32: 5
Size adjustment
1...nM5 Adjustment of printing pressure
Interconnection diagram for coating unit 2...nM5 PU3, PU5 PU2, PU4
SSR X20
PU6, PU7, PU8
SSR X30
PU2 PU3 PU4 PU5 PU6 PU7 PU8 PU9
= = = = = = = =
SSR SSR SSR SSR SSR SSR SSR SSR
X25 X26 X27 X28 X31 X32 X33 X34
X20
X25
X5
X30
SSR
X26 X3
X27
X4
X28
Backplane of servo-drive plug-in unit SSR 2..9 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 2...9M5:X1 1SSM 2 + – 10V 0V
1 2 4 5
X3: X3: X3: X3:
A1 A2 A3 A4
6 X3: A5 2...9M5:X1 1SSM 2
+ – 10V
1 2 4 5
X3: X3: X3: X3:
0V
6
X3: A5
A1 A2 A3 A4
X1: X1: X2: X2:
1 2 3 4
X2: 5
X1: X1: X2: X2:
1 2 3 4
X2: 5
SSR PU2 X20: X20: X25: X25: X25: SSR PU6 X30: X30: X31: X31:
B18 D18 3 4
PU3 X20: X20: X26: X26:
5
X26: 5
X27: 5
X28: 5
B2 D2 3 4
PU7 X30: X30: X32: X32:
PU8 X30: X30: X32: X32:
PU9 X30: X30: X34: X34:
X31: 5
B22 D22 3 4
B6 D6 3 4
X32: 5
PU4 X20: X20: X27: X27:
B26 D26 3 4
B10 D10 3 4
X32: 5
PU5 X20: X20: X28: X28:
B30 D30 3 4
B14 D14 3 4
X34: 5
89
Size adjustment
1...nM5 Adjustment of printing pressure
Removal and installation of motor
1
2 1 0
1
2
– –
Switch off the press. Open the guard on the O.S.
1...8M5 X1
–
Disconnect 1...8M5 X1.
4
3
1
2 3
– 90
Loosen the fixing bolts on the motor.
–
Remove the defective motor.
Size adjustment
1...nM5 Adjustment of printing pressure
5
6
3 2 1
–
Install the new motor.
–
Tighten the fixing bolts.
8
7 1
brown
1
brown
2 blue
blue
2 0
1...8M5 X1
1
... 0.30 ...-1.20
– –
Connect the motor. Start the press.
The value on the display changes in positive direction (0.30). The value on the display changes in negative direction (–1.20).
91
Size adjustment
1...nM5 Adjustment of printing pressure
Removal and installation of potentiometer
2
1 1 0
1 1...8M5 X1
2
– –
Switch off the press. Open the guard on the O.S.
3
–
Disconnect the potentiometer from 1...8M5 X1.
4
4
0
3
2 – – – –
92
1
Loosen the stud on the gear wheel. Pull the gear wheel off the potentiometer. Loosen the nut on the potentiometer. Replace the potentiometer.
–
Turn the mechanism to the ”0” value of the scale by means of the hexagon.
Size adjustment
1...nM5 Adjustment of printing pressure
5
6
1...8M5 X1
1 blue black red
4 5 6
beige yellow black
2 0
– –
1
Connect the new potentiometer. Start the press.
–
Select service display 2.
8
7
1 PU1 ... PUn = 1234 ± 8 inc
2 3 4
–
Set the potentiometer to 1234 ± 8 inc.
– –
Fasten the potentiometer. Put the gear wheel back in place and fasten it with the stud.
93
Size adjustment
1...nM5 Adjustment of printing pressure
9
... 0.30
–
Check the operating range: 0.30 = 616 ± 8 inc
10
...-1.20
–
94
Check the operating range: –1.20 = 3550 ± 8 inc
Size adjustment
1...nM5 Adjustment of printing pressure
Checking the operating range Preset version
Servo-drive ”Adjustment of printing pressure” 1M5 Input
Incremental value
+ 0.30
616 " 8 inc
– 1.20
3550 " 8 inc
Service display ”Values, incremental values servo-drives”
95
Size adjustment
1M7/1M8 Adjustment of pull lays
1M7/1M8 Adjustment of pull lays The servo-drive 1M7 positions the pull lay on the D.S. The servo-drive 1M8 positions the pull lay on the O.S.
Automatic positioning Automatic positioning: –
is effected through the command ”Presetting”,
–
depends on the inputs into CPTRONIC, such as sheet width, off-centre position, pull direction, precision adjustment of pull lay.
After actuation of the input button, the electronic control system positions:
1M7 1M8
–
the pull lay in use to the sheet width entered,
–
the pull lay not in use 15 mm outside the entered sheet width.
A pneumatic clamping mechanism locks the pull lay in position. The pneumatic clamping mechanism opens after actuation of the input button for the command ”Presetting”. The pneumatic clamping mechanism closes: –
when the pull lay is in the new position,
–
if the new position is not reached in less than 4 minutes (fault message 7FFF in Dyn-test).
The electronic control system determines the position of each pull lay via two potentiometers: Potentiometer for precision adjustment
Servo-drives ”Adjustment of pull lays”
96
–
during coarse positioning through the potentiometer in the servo-drive,
–
during precision positioning through the potentiometer near the servo-drive.
Size adjustment
1M7/1M8 Adjustment of pull lays
Precision adjustment of pull lay
Selecting the display
Symbol and indication of the current value for the precision adjustment of the pull lay
The symbol shows the active pull lay: Arrow pointing up
= pull lay on D.S. active
Arrow pointing down = pull lay on O.S. active With the right-hand +/– buttons the active pull lay can be precision-adjusted. Adjustment is possible within a range of ± 5 mm in relation to the preset format.
Actual value/coarse display, ”Adjustment of pull lays”
97
Size adjustment
1M7/1M8 Adjustment of pull lays
Place of installation
1M7 1M8
1Y47
Potentiometer for precision adjustment
Operator side
Technical data Motor data –
U
=
DC 24 V
–
P
=
5 W
Potentiometer data –
U
=
DC 10 V
–
R
=
10 K
98
Size adjustment
1M7/1M8 Adjustment of pull lays
Interconnection diagram 1M7 X5
X20
SSR
SSR X20 X21
X22
SSR X21
X3 X23
X4
X24
Backplane of servodrive plug-in unit SSR
1 11LVT1 1SSM1: X2 X3
X4
1SSM1: X4
X2 X1
X5
1SSM1
Servo-drive distributor module 1SSM1
1M7: X1
3
4 5
2
1
1M7
Potentiometer (for precision adjustment)
Servo-drive 1M7 (with potentiometer for coarse adjustment) + – 10V 0V
Pin Pin Pin Pin
1 – 2 3 4
Pin 5
X5: X5: X5: X5:
C1 C2 C3 C4
X5: C5
X2: X2: X4: X4:
1 2 3 4
X4: 5
X20: X20: X21: X21:
B2 D2 3 4
X21: 5
X5: D3 X5: D4
X4: 8 X4: 7
X21: 8 X21: 7
X5: D5
X4: 6
X21: 6
99
Size adjustment
1M7/1M8 Adjustment of pull lays
Interconnection diagram 1M8 X5
X20
SSR
SSR X20
X21
X22
SSR X22
X3 X23
X4
X24
Backplane of servo-drive plug-in unit SSR
1 11LVT1 2SSM1: X1 X3 X4
2SSM1: X3
X2 X1
X5
2SSM1
Servo-drive distributor module 2SSM1 3
1M8: X1
4 5
2
1
1M8
Potentiometer (for precision adjustment)
Servo-drive 1M8 (with potentiometer for coarse adjustment) + – 10V 0V
100
Pin Pin Pin Pin
1 2 3 4
Pin 5
X5: X5: X5: X5:
A1 A2 A3 A4
X5: A5
X1: X1: X3: X3:
1 2 3 4
X3: 5
X20: X20: X22: X22:
B6 D6 3 4
X22: 5
X5: B3 X5: B4
X3: 8 X3: 7
X22: 8 X22: 7
X5: B5
X3: 6
X22: 6
Size adjustment
1M7/1M8 Adjustment of pull lays
Removal and installation
1Y47
–
Remove the servo-drive ”Adjustment of pull lay D.S.” 1M7 (or ”Adjustment of pull lay O.S.” 1M8).
2 1 O.S.
–
–
2
–
Actuate the solenoid valve 1Y47 manually and hold it in this position (pneumatic clamping mechanism is open).
1
D.S.
3 3
Set the distance between the side frame D.S. (or O.S.) and the inside of the pull lay stop to 55 mm. Let go of the solenoid valve 1Y47.
Note: Because of the backlash, the distance between the side frame and pull lay stop must first be smaller than 55 mm. Then the correct value of 55 mm must be set.
101
Size adjustment
1M7/1M8 Adjustment of pull lays
01
3055 ± 2
03
3055 ± 2
1M7: X1 1M8: X1 – – – –
Fit the gear wheel. Connect plug 1M7: X1 (or 1M8: X1). 1M7 (D.S.) = set to 3055±2 inc. 1M8 (O.S.) = set to 3055±2 inc.
1020
1,00
–
102
Install the servo-drive.
– – –
720
Select the command ”Presetting”. Press the button ”Input”. The servo-drives position to the displayed format.
Size adjustment
1M7/1M8 Adjustment of pull lays
Checking the operating range
Servo-drive ”Adjustment of pull lay D.S.” 1M7 Servo-drive ”Adjustment of pull lay O.S.” 1M8
Only compare the new servo-drive with the indicated values. Maximum sheet width Precision adjustment: 0.00 mm (2048 inc) Sheet width: 1040 mm Off-centre position: 00
Service display ”Values, incremental values servo-drives”
For 1M7: pulling towards D.S. Incremental value: 3155 ± 4 inc For 1M8: pulling towards O.S. Incremental value: 3155 ± 4 inc Minimum sheet width Precision adjustment: 0.00 mm (2048 inc) Sheet width: 420 mm Off-centre position: 00 For 1M7: pulling towards D.S. Incremental value: 933 ± 4 inc For 1M8: pulling towards O.S. Incremental value: 933 ± 4 inc
103
Size adjustment
12M5 Sheet slowdown/format adjustment
12M5 Sheet slowdown/format adjustment The servo-drive 12M5 positions the sheet slowdown at the delivery to the entered sheet length. Automatic positioning Automatic positioning: –
is effected through the command ”Presetting”,
–
depends on the entered sheet length.
Positioning accuracy: ± 0.50 mm. Positioning range: –
max. 720 mm,
–
min. 500 mm (because of danger of collision with the sheet joggers),
–
in the case of sheet lengths below 500 mm, the suction head stops at the lower limit (500 mm),
–
manual positioning if the sheets are shorter (less than 500 mm).
End of automatic positioning: –
when the new desired position has been reached,
–
when the lower limit (500 mm) of the positioning range has been reached,
–
when one of the pushbuttons ”Sheet slowdown format” is actuated.
Manual positioning Pushbuttons ”Sheet slowdown format”
Actuation of one of the pushbuttons ”Sheet slowdown format”: –
the sheet slowdown positions irrespective of the preset format,
–
indication of the position in the delivery MID,
–
automatic positioning is stopped immediately.
Plus button Minus button
Plus button
= to max. 730 mm.
Minus button = to min. 270 mm.
104
Size adjustment
12M5 Sheet slowdown/format adjustment
Fault message in the ZID Sheet slowdown/format adjustment
The symbol appears in the display ”Delivery/ Warning”. The symbol appears: –
during positioning while the press is on ”Run”,
–
when the lower limit is reached during automatic positioning.
The symbol goes off: –
when positioning is over and the press is on ”Run”,
–
when one of the pushbuttons ”Sheet slowdown format” is actuated and the press is on ”Run”.
105
Size adjustment
12M5 Sheet slowdown/format adjustment
Place of installation
12M5
Operator side
Technical data Motor data –
U
=
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 X17
X4
X18
Backplane of servo-drive plug-in unit SSR
12 12LVT1 X3 X4
1SSM1: X1
1SSM1: X3 X2 X1
X5
1SSM1
Servo-drive distributor module 1SSM1 3
4 5
12M5: X1
2
1
12M5
Servo-drive 12M5
+ – 10V 0V
12M5:X1 Pin 1 Pin 2 Pin 3 Pin 4
1SSM 1 X5: B1 X5: B2 X5: B3 X5: B4
X1: X1: X3: X3:
Pin 5
X5: B5
X3: 6
3 4 8 7
SSR X10: X10: X16: X16:
B24 D24 8 7
X16: 6
107
Size adjustment
12M5 Sheet slowdown/format adjustment
Removal and installation Rear paper stop
2
1
3
1
2
Front paper stop
–
–
Remove the servo-drive ”Sheet slowdown / format adjustment” 12M5.
Set the distance between the front and rear paper stops to 600 mm.
Note: To compensate for the backlash, the 600 mm must be set from the max. possible distance.
3
12M5: X1
12
1370
Coupling part – – – 108
Mount the coupling part. Connect plug 12M5: X1. Set to 1370 inc.
Size adjustment
12M5 Sheet slowdown/format adjustment
4
–
Install the servo-drive.
Checking the operating range
Servo-drive ”Sheet slowdown / format adjustment” “ 12M5 Paper length Incremental value 280 mm
3540 " 3 inc
720 mm
556 " 3 inc
730 mm
498 " 3 inc
Service display ”Values, incremental values servo-drives”
109
Size adjustment
12M6/12M7 Sheet joggers D.S./O.S.
12M6/12M7 Sheet joggers D.S./O.S. The servo-drive 12M6 positions the sheet jogger on the D.S. The servo-drive 12M7 positions the sheet jogger on the O.S. Automatic positioning Automatic positioning: –
is effected through the command ”Presetting”,
–
depends on the inputs into CPTRONIC, such as: sheet width, off-centre position.
Positioning accuracy: ± 1.0 mm. End of automatic positioning: –
when the new desired position has been reached,
–
when one of the pushbuttons ”Sheet jogger D.S.” or ”Sheet jogger O.S.” is actuated.
Manual positioning Pushbuttons ”Sheet jogger D.S.”
Actuation of one of the pushbuttons ”Sheet jogger D.S.”: –
the servo-drive ”Sheet jogger D.S.” 12M6 is controlled,
–
the sheet jogger on the D.S. positions irrespective of the preset format.
Plus button Minus button Pushbuttons ”Sheet jogger O.S.”
Actuation of one of the pushbuttons ”Sheet jogger O.S.”: –
the servo-drive ”Sheet jogger O.S.” 12M7 is controlled,
–
the sheet jogger on the O.S. positions irrespective of the preset format.
Plus button Minus button
Actuation of one of the pushbuttons ”Sheet jogger”: –
indication of the position in the delivery MID,
–
the off-centre position can be up to ± 50 mm,
–
automatic positioning is stopped immediately.
Plus button = to max. 1040 mm. Minus button = to min. 420 mm.
110
Size adjustment
12M6/12M7 Sheet joggers D.S./O.S.
Fault message in the ZID Sheet jogger D.S.
The symbols appear in the display ”Delivery/ Warning”. The symbols appear:
Sheet jogger O.S.
–
during positioning while the press is on ”Run”.
The symbols go off: –
when positioning is over and the press is on ”Run”,
–
when one of the pushbuttons ”Sheet jogger D.S.” or ”Sheet jogger O.S.” is actuated and the press is on ”Run”.
111
Size adjustment
12M6/12M7 Sheet joggers D.S./O.S.
Place of installation
D.S. = 12M6 O.S. = 12M7
Delivery
Technical data Motor data –
U
=
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.
Interconnection diagram 12M6 X5
X10
SSR
SSR X10 X15
X16 X3
X17
X4
X18
SSR X17
Backplane of servo-drive plug-in unit SSR
12 12LVT1 X3 X4
1SSM1: X2
1SSM1: X4 X2 X1
X5
1SSM1
Servo-drive distributor module 1SSM1 3
4 5
12M6: X1
2
1
12M6
Servo-drive 12M6
+ – 10V 0V
12M6:X1 Pin 1 Pin 2 Pin 3 Pin 4
1SSM 1 X5: C1 X5: C2 X5: C3 X5: C4
X2: X2: X4: X4:
Pin 5
X5: C5
X4: 5
1 2 3 4
SSR X10: X10: X17: X17:
B26 D26 3 4
X17: 5
113
Size adjustment
12M6/12M7 Sheet joggers D.S./O.S.
Interconnection diagram 12M7 X5
X10
SSR
SSR X10 X15
X16 X3
X17
X4
X18
SSR X17
Backplane of servo-drive plug-in unit SSR
12
12LVT1 1SSM1: X2
X3
X4
1SSM1: X4 X2 X1
X5
1SSM1
Servo-drive distributor module 1SSM1 3
4 5
12M7: X1
2
1
12M7
Servo-drive 12M7
+ – 10V 0V
114
12M7:X1 Pin 1 Pin 2 Pin 3 Pin 4
1SSM 1 X5: D1 X5: D2 X5: D3 X5: D4
X2: X2: X4: X4:
Pin 5
X5: D5
X4: 6
3 4 8 7
SSR X10: X10: X17: X17:
B28 D28 8 7
X17: 6
Size adjustment
12M6/12M7 Sheet joggers D.S./O.S.
Removal and installation
Cam follower
Control cam
–
Remove the servo-drive ”Sheet jogger D.S.” 12M6 (or ”Sheet jogger O.S.” 12M7).
–
Inch the press until the cam follower of the sheet jogger has reached the highest point of the control cam.
–
Set the distance between the sheet jogger D.S. (or O.S.) and the side frame D.S. (or O.S.) to 55 mm. 115
Size adjustment
12M6/12M7 Sheet joggers D.S./O.S.
4)
12M6: X1 12M7: X1
13
– – –
704 ± 2
14
704 ± 2
Fit the gear wheel. Connect plug 12M6: X1 (or 12M7: X1). 12M6 (D.S.) = set to 704±2 inc. 12M7 (O.S.) = set to 704±2 inc.
1020
720 1.00
– – – –
116
Install the servo-drive.
Select the command ”Presetting”. Press the button ”Input”. The servo-drives position to the displayed format.
Size adjustment
12M6/12M7 Sheet joggers D.S./O.S.
Checking the operating range
Servo-drive ”Sheet jogger D.S.” 12M6 Servo-drive ”Sheet jogger O.S.” 12M7
The indicated values are valid for both servodrives. Sheet width: 1040 mm Incremental value: 704 ± 3 inc Sheet width: 420 mm Incremental value: 3392 ± 3 inc
Service display ”Values, incremental values servo-drives”
117
Size adjustment
118
12M6/12M7 Sheet joggers D.S./O.S.
Feeder pile control
Block diagrams
Feeder pile control Block diagrams Block diagram (Preset)
Pile height
Switches and sensors
Controls
SEK
Safety circuit
EAK_11
Press control
REK2
ESK
Auxiliary drive control
Main pile
A
HAK_01 B
C
A A
LTK500 BAK
B B
A
HAK_02 B
C
A
STK1
B
M
M
11M1
11M2
Auxiliary pile
Preset feeder with auxiliary pile
119
Feeder pile control
Block diagrams
Block diagram (Standard)
Pile height
Switches and sensors
Controls
SEK
Safety circuit
EAK_11
Press control
REK2
ESK
Auxiliary drive control
Main pile
A
HAK_01 B
C
A
HAK_02 B
C
A
STK1
B
A
STK2
B
M
M
Auxiliary pile
11M1
11M2
Standard feeder with auxiliary pile
120
Feeder pile control
Layout
Layout Overview The pile control of the feeder is used to control the main pile and auxiliary pile. It consists of the following functional units: –
Press control: Detection and evaluation of input signals for controlling the pile drives
–
Safety circuit: Detection and evaluation of safety signals for the emergency shutdown of pile drives
–
Auxiliary drive control: Control of pile motors
The following components are part of the pile control: SEK
Safety input board
EAK_11 Input/output board on board slot 11 (signal acquisition feeder) REK2
Processor board on board slot 2 (press control)
ESK
Input/output control board
HAK_01 Auxiliary drive board on board slot 1 HAK_02 Auxiliary drive board on board slot 2 STK1
Pile control board on board slot 1
STK2
Pile control board on board slot 2
BAK
Brake control board
LTK500
Power part board 500W
121
Feeder pile control
Layout
Press control
Inputs
The press control detects the signals of the switches and sensors on the feeder via the inputs of EAK_11. REK2 evaluates these signals and generates control signals for the pile motors. The control signals for pile motors are passed on to the auxiliary drive control via the ESK.
EAK_11 The ESK is provided with the following operation set for controlling the individual pile motors: REK2
ESK
Auxiliary drive control
–
Pile stop (pile height control off)
–
Pile up (slow)
–
Pile down (slow)
–
Pile up, fast (at main pile only)
–
Pile down, fast (at main pile only)
–
Pile height control on
–
Rack mode (parameter: rack height)
Press control
Safety circuit
Inputs
SEK
The SEK registers the signals of those switches on the feeder which are relevant to safety. It evaluates these signals and if necessary it generates control signals for the emergency shutdown of the pile drives. These control signals are directly passed on to the auxiliary drive control. The signals of the safety circuit always take priority over the signals of the press control.
Auxiliary drive control
Safety circuit
122
The ESK is provided with the following operation set for controlling the individual pile motors: –
Pile drive enabled
–
Pile up blocked
–
Pile down blocked
Feeder pile control
Layout
Auxiliary drive control
Safety circuit
HAK_01
Press control
HAK_02
The auxiliary drive control conditions the control signals of SEK and ESK and regulates the individual pile drives. Each drive is assigned with a control section (component of a HAK) and a power part (dependent on the motor used). Depending on the press version, the assignments listed in the following are possible - see also ”block diagrams”.
LT
LT
Drive
Control section
Power part
M
M
Main pile (Preset)
HAK01 Part A
BAK+LTK500 Part A
11M1
11M2
Main pile (standard)
HAK01 Part A
STK1 Part A
Auxiliary pile
HAK01 Part C
STK2 Part A
Auxiliary drive control
The signal of the governor foot for controlling the pile heights is conditioned in the power parts of the main pile and of the auxiliary pile. Both power parts pass the conditioned signal to the relevant control section. See chapter ”Control systems / auxiliary drive control” for further information on auxiliary drive control.
123
Feeder pile control
Overview of components
Overview of components Preset feeder
11M1
11S56
11S65
11S34
11M2
11S37 11S31
11B35
11S32
11S36
11B33 11B11 11S39
Components on the Preset feeder
124
Feeder pile control
Overview of components
Standard feeder 11M1
11S33
11M2 11S34 11S37 11S36 11S32
11S65 11S31
11S35
11S39
Components on the standard feeder
125
Feeder pile control
Overview of components
Motors Equipment
11M1 11M1 11M2
Function
Main pile drive (Preset) Main pile drive (standard) Auxiliary pile drive
Preset with nonstop D
Standard
without nonstop D
D
with nonstop D D
Remarks
without nonstop D
Brushless motor Three-phase a.c. motor
Switches and sensors Equipment
Function
11B11 11S31 11S32 11S33 11B33 11S34 11B35 11S35 11S36 11S37
Auxiliary pile detection Suction head limitation Upper pile safety Upper main pile limitation Upper main pile limitation Bottom main pile limitation Automatic pile transport Automatic pile transport Upper limitation of auxiliary pile Bottom limitation of auxiliary pile Pile support plate limitation Switching off the auxiliary pile Pile height control (governor foot)
11S39 11S56 11S65
126
with nonstop D D D D D D
Preset without nonstop D D
D D D
D D D
D
D
D D D
D
D
D
D
D
D
D
D D D
D D D D D
Standard with without nonnonstop stop
Remarks
Feeder pile control
Function
Function Pile height control of main pile (Preset) The automatic pile height control of the main pile on the feeder is activated as soon as one of the following conditions is met: 11S65 11B35
Switching points of main pile height control Pile height control Governor foot is positioned vertically 11S65 detects too little paper Pile up (by the value set)
Sequence of main pile height control
–
The sensor ”automatic pile transport” (11B35) detects paper when raising the main pile (actuation of the button ”main pile up”, 11S24)
–
The press turns, the feeder is engaged and the sensor ”automatic pile transport” (11B35) detects paper
With the automatic pile height control, the pile is controlled so that the upper edge is always at the level of the governor foot (11S65) - with governor foot in vertical position. As soon as the sensor detects too little paper on the pile, the pile is moved upwards by a presettable height (the ”pile lift increment at the feeder” can be adjusted between 0.5 mm and 2.5 mm on the ZID). The position of the governor foot can be altered by means of the suction head height control. The automatic pile height control on the feeder is stopped under the following circumstances: –
actuation of an emergency stop switch
–
actuation of the ”suction head limitation” switch (11S31)
–
actuation of the ”upper pile safety” switch (11S32)
–
actuation of the ”upper main pile limitation” switch (11B33)
–
actuation of the ”upper auxiliary pile limitation” switch (11S36) (only in case of non-stop)
–
actuation of the ”pile stop” button (11S26)
–
actuation of the ”main pile down” button (11S25)
–
Sheeter in operation (extra accessory)
–
The sensor ”automatic pile transport” (11B35) does not detect any paper (only during the first 30 sheets in the closed loop control)
127
Feeder pile control
Function
Automatic pile height control of main pile (standard) The automatic main pile height control on the feeder is activated as soon as one of the following conditions is met: 11S65 11S35
Switching points of the automatic main pile height control Automatic pile height control Governor foot is positioned vertically
–
The sensor ”automatic pile transport” (11S35) detects paper when raising the main pile (actuation of the button ”main pile up”, 11S24)
–
The press turns, the feeder is engaged and the switch ”automatic pile transport” (11S35) detects paper
The pile is controlled by the automatic pile height control so that its upper edge is always at the level of the governor foot (11S65) - with vertically positioned governor foot. As soon as the sensor detects too little paper on the pile, the pile is raised by the adjustable height (the ”pile lift increment on the feeder” can be set between 0.5 mm and 2.5 on the ZID). The position of the governor foot can be adjusted (manually) via the suction head height control.
11S65 detects too little paper Pile up (by preset value)
Sequence of the automatic pile height control for the main pile
128
The automatic pile height control on the feeder is stopped under the following circumstances: –
actuation of an emergency stop switch
–
actuation of the ”suction head limitation” switch (11S31)
–
actuation of the ”upper pile safety” (11S32)
–
actuation of the ”upper main pile limitation” switch (11S33)
–
actuation of the ”upper auxiliary pile limitation” switch (11S36) (only in case of non-stop)
–
actuation of the ”pile stop” button (11S26)
–
actuation of the ”main pile down” switch (11S25)
–
sheeter in operation (extra accessory)
–
The sensor ”automatic pile transport” (11S35) does not detect any paper (only during the first 30 sheets in the closed-loop control)
Feeder pile control
Function
Automatic pile height control of auxiliary pile
11S65 11B35
Switching points of the automatic pile height control of auxiliary pile Automatic pile height control Governor foot is positioned vertically 11S65 detects too little paper Pile up (by preset value)
Sequence of the automatic pile height control for the auxiliary pile
The automatic pile height control of auxiliary pile on the feeder is activated as soon as the toggle switch is in position ”auxiliary pile on” (11S27) and the sensor/switch ”automatic pile transport” (Preset: 11B35, standard: 11S35) detects paper. The pile is controlled by the automatic pile height control so that the upper edge of the pile is always at the level of the governor foot (11S65) - with governor foot positioned vertically. As soon as the sensor detects too little paper on the pile, the pile is raised by an adjustable height (the ”pile lift increment on the feeder” can be adjusted between 0.5 mm and 2.5 mm on the control console display ZID). The position of the governor foot can be altered via the suction head height control.
The automatic pile height control at the feeder is stopped under the following circumstances: –
actuation of an emergency stop switch
–
actuation of the ”suction head limitation” button (11S31)
–
actuation of the ”upper pile safety” switch (11S32)
–
actuation of the ”upper auxiliary pile limitation” switch (11S36)
–
actuation of the ”pile stop” button (11S26)
–
actuation of the ”auxiliary pile down” button (11S29)
–
unloading the ”auxiliary pile detection” sensor (11B11) (only with Preset)
–
sheeter in operation (extra accessory)
–
The sensor ”automatic pile transport” (11B35) does not detect any paper.
129
Feeder pile control
Function
Transport of main pile Main pile up
11S24
The main pile can only be raised manually if the automatic pile height control of the main pile is not active.
11B33
fast
The upwards movement of the main pile is controlled via the button ”main pile up” (11S24) on the feeder operation panel. If one of the following circumstances is met upon actuation of the button, the main pile moves upwards: –
The toggle switch (11S27) is in position ”auxiliary pile on”
–
The sensor ”auxiliary pile detector” (11B11) is damped (only in case of non-stop with Preset)
–
The toggle switch is in position ”auxiliary pile off” (11S27) and the ”automatic pile transport” (Preset: 11B35, standard: 11S35) detects no paper
Switching points of main pile up Main pile up Permissible start condition 11S24 (keep pressed) Main pile up, fast – Preset: 11B33 or 11B35 – Standard: 11S33 or 11S35 Main pile stop
Sequence of main pile up
When the pile support plate reaches the ”upper main pile limitation” (Preset: 11B33, standard: 11S33) or when the ”automatic pile transport” (Preset: 11B35, standard: 11S35) detects paper, the transport of the main pile stops. The upwards movement of the main pile is interrupted under the following circumstances: –
actuation of an emergency stop switch
–
actuation of the ”suction head limitation” switch (11S31)
–
actuation of the ”upper pile safety” switch (11S32)
–
actuation of the ”upper auxiliary pile limitation” switch (11S36) (only in case of non-stop)
–
actuation of the ”main pile down” button (11S25)
–
actuation of the ”pile stop” button (11S26)
–
sheeter in operation (extra accessory)
The pile transport can only be continued if the respective cause has been eliminated.
130
Feeder pile control
Function
Main pile down 11S25 11S26
The downward movement of the main pile is controlled via the button ”main pile down” (11S25) on the feeder operation panel. The speed is changed (slow/fast) depending on the position of the main pile. The button ”main pile down” (11S25) is furnished with a self-stopping mode. If the button is actuated, the main pile moves downwards at fast speed. When it reaches the ”pile support plate limitation” (11S39), the main pile stops.
fast
11S39 slow 11S34
Switching points of main pile down Main pile down Permissible start condition 11S25 (self-stopping mode) Main pile down, fast 11S39 – Preset: main pile stop and automatic centering of the pile support plate – Standard: main pile stop
In case of the preset version, the pile support plate is automatically centered in this position (maximum duration: 25 s). During this centering process, the control does not respond to the actuation of the ”main pile down” button (11S25). If the ”main pile down” button (11S25) is actuated again, the main pile (without self-stopping) moves further downwards at slow speed. When it reaches the ”bottom main pile limitation” (11S34), the main pile stops. The downward movement of the main pile is interrupted if one of the following conditions is met: –
actuation of an emergency stop switch
–
actuation of the ”lower end stop” switch (11S34)
–
actuation of the ”pile support plate limitation” switch (11S39)
–
actuation of the ”pile stop” button (11S26)
–
actuation of the ”main pile up” button (11S24)
11S25 (no self-stopping mode) Main pile down, slow 11S34 Main pile stop
An interrupted pile transport can only be continued after elimination of the cause.
Sequence of main pile down and passing both speed ranges
131
Feeder pile control
Function
Transport of auxiliary pile Preconditions The auxiliary pile can only be transported if the switch ”switching off the auxiliary pile” (11S56) is clear. (Only with Preset) Auxiliary pile up 11S28
The auxiliary pile can only be moved up manually, if the automatic pile height control of the auxiliary pile is not active.
11S36
fast
The upwards movement of the auxiliary pile is controlled via the button ”auxiliary pile up” (11S28) on the feeder operation panel. The auxiliary pile moves upwards at a constant speed. When it reaches the ”upper auxiliary pile limitation” (11S36), the transport mechanism of the auxiliary pile stops. The upwards movement of the auxiliary pile is interrupted if one of the following conditions is met:
Switching points of auxiliary pile up Auxiliary pile up Permissible starting point 11S28 (keep pressed) Auxiliary pile up 11S36 Auxiliary pile stop
Sequence of auxiliary pile up
132
–
actuation of an emergency stop switch
–
actuation of the ”suction head limitation” switch (11S31)
–
actuation of the ”upper pile safety” (11S32)
–
actuation of the ”pile stop” button (11S26)
–
actuation of the ”auxiliary pile down” button (11S29)
–
sheeter is in operation (extra accessory)
An interrupted pile transport can only be continued after the respective cause has been eliminated.
Feeder pile control
Function
Auxiliary pile down 11S29
The downwards movement of the auxiliary pile is controlled via the button ”auxiliary pile down” (11S29) on the delivery operation panel. The auxiliary pile moves downwards at a constant speed. When it reaches the ”bottom auxiliary pile limitation” (11S37), the transport mechanism of the auxiliary pile stops. fast
The downward movement of the auxiliary pile is stopped if one of the following conditions is met: 11S37
Switching points of auxiliary pile down Auxiliary pile down
–
actuation of an emergency stop switch
–
actuation of the ”upper main pile limitation” sensor (11B33) (only in case of Preset with non-stop)
–
actuation of the ”pile stop” button (11S26)
–
actuation of the ”auxiliary pile up” button (11S28)
–
sheeter is in operation (extra accessory)
Permissible starting point 11S29 (keep pressed)
An interrupted pile transport can only be continued if the respective cause has been eliminated.
Auxiliary pile down 11S37 Auxiliary pile stop
Sequence of auxiliary pile down
133
Feeder pile control
Function
Non-stop operation (Preset) Preconditions The non-stop operation on the Preset feeder requires the following preconditions: –
The press is in production mode
–
The toggle switch (11S27) is in position ”auxiliary pile off”
–
The non-stop bar is unhinged so that the switch ”switching off the auxiliary pile” (11S56) is clear
–
The non-stop bar is at the level of the pile board (starting position for inserting the support rods)
Basic function The non-stop operation on the Preset feeder consists of the following sub-steps:
134
–
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.
Feeder pile control
Main pile
Function
Auxiliary pile
Automatic pile height control of main pile on
Automatic pile height control of auxiliary pile off
Inserting support rods
Inserting support rods
Pile transfer
11S27 auxiliary pile on Auxiliary pile up, slow 11B11 damped
11B11 damped
– 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 – Main pile stop – Centering main pile (automatically) 11S25 (no self-stopping mode) Main pile down, slow 11S34
Pile change
Main pile stop (loading) 11S24 Main pile up, fast
– Main pile stop – Aligning main pile (manually) 11S24 Main pile up, fast 11B11 not damped Automatic pile height control of main pile on 11S27 auxiliary pile off Automatic pile height control of auxiliary pile off
Pile merging
Removing support rods
Removing support rods 11S29 Auxiliary pile down 11S37 Auxiliary pile stop
Sequence of non-stop operation (Preset) 135
Feeder pile control
Function
Pile transfer The support rods are inserted (manually) and the toggle switch (11S27) is brought into the position ”auxiliary pile on”. The auxiliary pile moves upwards until the sensor ”auxiliary pile detection” (11B11) is damped. This activates the automatic pile height control on the auxiliary pile and deactivates it on the main pile. When reaching the starting point (dependent on the automatic pile height control of the auxiliary pile), the main pile moves automatically downwards. Pile change The main pile stops when reaching the ”pile support plate limitation” (11S39). In this position, the pile support plate is automatically centered (max. duration: 25 s). When actuating the button ”main pile down” (11S25), the main pile moves further downwards at slow speed. When reaching the ”bottom limit position” (11S34), the main pile stops and can be loaded. When actuating the button ”main pile up” (11S24), the pile moves back upwards. The main pile must be aligned manually just before it reaches the auxiliary pile. Pile merging When reaching the auxiliary pile, the sensor ”auxiliary pile detection” (11B11) is no longer damped, whereupon the automatic pile height control of the main pile is activated again. The toggle switch is put into the position ”auxiliary pile off” (11S27), this deactivates the automatic pile height control on the auxiliary pile. The support rods are pulled out (manually). Upon actuation of the button ”auxiliary pile down” (11S29) the non-stop bars move downwards. When reaching the ”bottom auxiliary pile limitation” (11S37), the non-stop bars stop (starting position).
136
Feeder pile control
Function
Non-stop operation (standard) Preconditions The non-stop operation on the standard feeder requires the following preconditions: –
The press is in production mode.
–
The toggle switch is in position ”auxiliary pile off” (11S27)
–
The non-stop bar is at the level of the pile support board (starting position for inserting the support rods)
Basic function The non-stop operation on the standard feeder consists of the following sub-steps: –
Pile transfer: Inserting support rods creates main and auxiliary pile. The auxiliary pile takes over the automatic pile height control
–
Pile change: The (empty) main pile moves downwards. There it is loaded and moves back up to the auxiliary pile
–
Pile merging: Main and auxiliary pile are merged by pulling out the support rods. The main pile takes over the automatic pile height control again.
137
Feeder pile control
Function
Main pile
Auxiliary pile
Automatic pile height control of main pile on
Automatic pile height control of auxiliary pile off
Inserting support rods
Inserting support rods
Pile transfer
11S28 Auxiliary pile up, slow 11S27 Auxiliary pile on Automatic pile height control of main pile off
11S27 auxiliary pile on Automatic pile height control of auxiliary pile on
11S25 (self-stopping mode) Main pile down, fast 11S39 Main pile stop 11S25 (no self-stopping mode)
Pile change
Main pile down, slow 11S34 Main pile stop (loading) 11S24 Main pile up, fast Height of auxiliary pile reached Main pile stop
11S27 auxiliary pile off
11S27 auxiliary pile off
Automatic pile height control of main pile on
Automatic pile height control of auxiliary pile off
Removing support rods
Removing support rods
Pile merging
11S29 Auxiliary pile down 11S37 Auxiliary pile stop
Sequence of non–stop operation (standard)
138
Feeder pile control
Function
Pile transfer The support rods are inserted (manually). Through actuation of the ”auxiliary pile up” button (11S28), the non-stop bars are moved upwards (until the support rods are slightly lifted). The toggle switch (11S27) is brought into position ”auxiliary pile on”, this activates the automatic pile height control on the auxiliary pile and deactivates it on the main pile. Pile change When actuating the button ”main pile down” (11S25), the main pile moves in self-stopping mode downwards at fast speed. The main pile stops when reaching the ”pile support plate limitation” (11S39). When actuating the button ”main pile down” (11S25) once more, the main pile (without self-stopping mode) moves downwards at slow speed. When reaching the ”bottom limitation” (11S34) the main pile stops and can be loaded. When actuating the button ”main pile up” (11S24), the main pile moves upwards at fast speed. The main pile must be moved up to the auxiliary pile, so that the auxiliary pile is relieved. Pile merging The toggle switch is put into position ”auxiliary pile off” (11S27), this reactivates the automatic pile height control on the main pile and deactivates it on the auxiliary pile. The support rods are pulled out (manually). When actuating the button ”auxiliary pile down” (11S29), the non-stop bars move downwards. When reaching the ”bottom limitation of auxiliary pile” (11S37), the non-stop bars stop (starting position).
139
Feeder pile control
11M1 Main pile motor (Preset)
11M1 Main pile motor (Preset) Place of installation 11M1
Place of installation of main pile motor (Preset)
Layout
Layout of main pile motor (Preset)
140
Motor electronics Motor and brake Gear unit Male connector
Feeder pile control
11M1 Main pile motor (Preset)
Task and function The main pile motor moves the main pile upwards and downwards by means of pile chains. A brushless motor is used which can perform the following functions: –
Speed control
–
Changeover between two different speed levels (”fast” and ”slow”)
–
Electric deceleration (controlled by the respective power part)
–
Stopping or emergency braking by means of the brake installed
The motor is provided with the following internal functions for the purpose of controlling and monitoring: –
Commutation and speed detection by means of Hall signals
–
Temperature detection through resistor
–
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)
Technical specifications
141
Feeder pile control
11M1 Main pile motor (Preset)
Pin assignment
1 2 3 4 5
A B C
1 2 3 4 5
Pin assignment on main pile motor (Preset)
Pin
Function
A1
X1 motor line (slow)
B1
Y1 motor line (slow)
C1
Z1 motor line (slow)
A2
X2 motor line (fast)
B2
Y2 motor line (fast)
C2
Z2 motor line (fast)
C5
Brake (reference potential DC)
B5
Brake (DC +24 V)
B4
Hall 1
A5
Hall 2
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)
11M1 Main pile motor (standard) Place of installation 11M1
Place of installation of main pile motor (standard)
Layout
Motor electronics Motor and brake Gear unit Male connector
Layout of main pile motor (standard)
143
Feeder pile control
11M1 Main pile motor (standard)
Task and function The main pile motor moves the main pile upwards and downwards by means of the pile chains. A three-phase induction motor is used which carries out the following functions: –
Changeover between two different speed levels (”fast” and ”slow”)
–
Stopping and emergency braking by means of the brake installed
The motor is provided with the following internal functions for the purpose of controlling and monitoring: –
Speed detection via Hall signals
–
Temperature detection via resistor
–
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)
Technical specifications
144
Feeder pile control
11M1 Main pile motor (standard)
Pin assignment Pin
Function
A1
Winding U1 (slow)
B1
Winding V1 (slow)
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
A5
Hall 2
C3
Resistor code
B3
PTC (temperature monitoring)
C4
Auxiliary voltage of motor electronics UH
A4
Ground auxiliary voltage
A B C
pin assignment of main pile motor (standard)
PE conductor
145
Feeder pile control
11M2 Auxiliary pile motor
11M2 Auxiliary pile motor Place of installation
11M2
11M2
Preset feeder
Standard feeder
Place of installation of auxiliary pile motor
Layout
Layout auxiliary pile motor 146
Motor electronics Motor and brake Gear unit Male connector
Feeder pile control
11M2 Auxiliary pile motor
Task and function The auxiliary pile motor moves the auxiliary pile upwards and downwards by means of the pile chains. A three-phase induction motor is used which can execute the following functions: –
Changeover between two different speed levels (”fast” and ”slow”)
–
Stopping and emergency braking by means of the brake installed
The motor is provided with the following internal functions for the purpose of controlling and monitoring: –
Speed detection via Hall signals
–
Temperature detection via resistor
–
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)
Technical specifications
147
Feeder pile control
11M2 Auxiliary pile motor
Pin assignment Pin
Function
A1
Winding U1 (slow)
B1
Winding V1 (slow)
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
A5
Hall 2
C3
Resistor code
B3
PTC (temperature monitoring)
C4
Auxiliary voltage motor electronics UH
A4
Ground auxiliary voltage
A B C
Pin assignment main pile motor (standard)
PE conductor
148
Feeder pile control
11B11 Auxiliary pile detection
11B11 Auxiliary pile detection Place of installation
11B11
Place of installation 11B11 (Preset feeder)
Layout
Sensor Cable
Sensor 11B11 with cable
149
Feeder pile control
11B11 Auxiliary pile detection
Task and function The inductive sensor 11B11 monitors whether the non-stop bar is loaded. In case of a loaded non-stop bar, the auxiliary pile presses a trip bar downwards. The sensor detects the trip bar (metal). Switching output: normally open contact
Connection
11B11
Core colour
Function
Terminal
brown
+ 24V DC
12X2: +1
blue
24V DC
12X2: –1
black
signal
FEM64: XE11
Cable end sensor 11B11
Removal and installation The sensor is screwed down to a base plate which is located at the non-stop bar.
Removal and installation 11B11
150
Feeder pile control
11B11 Auxiliary pile detection
Setting
ÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁ
In its basic setting the sensor protrudes the base plate by 14 mm (see figure).
14 –0.2 mm
Setting 11B11
Checking the circuit state EAK_11 E11
The output signal of the sensor 11B11 reaches the EAK_11, input 11.
11B11
Signal flow
Position signal E11
The input signal E11 can be checked on the service display EAK: 0:
The sensor detects no metal (the trip bar is unloaded)
1:
The sensor detects metal (the trip bar is loaded)
Service display, signal E11
151
Feeder pile control
11B33 Upper main pile limitation
11B33 Upper main pile limitation Place of installation
11B33
Place of installation 11B33 (Preset feeder)
Layout
Sensor 11B33 with cable
152
Sensor Cable
Feeder pile control
11B33 Upper main pile limitation
Task and function The inductive sensor 11B33 monitors whether the pile support plate has reached the uppermost position. The sensor detects the pile support plate (metal). Switching output: normally closed contact
Connection
11B33
Core colour
Function
Terminal
brown
+ 24V DC
12X2: +1
blue
24V DC
12X2: –1
black
signal
FEM64: XE33
Cable end sensor 11B33
Removal and installation The sensor is screwed down to the non-stop bar.
Removal and installation 11B33
153
Feeder pile control
11B33 Upper main pile limitation
Setting In its normal position the sensor protrudes the non-stop bar by 24 mm (see figure).
24 mm
Setting 11B33
Checking the circuit state EAK_11 E33
The output signal of the sensor 11B33 reaches EAK_11, input 33.
11B33
Signal flow
Position signal E33
The input signal E33 can be checked on the service display EAK:
Service display, signal E33
154
0:
The sensor detects metal (the pile support plate is located at level of the sensor)
1:
The sensor detects no metal (the pile support plate is located below the sensor)
Feeder pile control
11B35 Automatic pile transport
11B35 Automatic pile transport Place of installation
11B35
Place of installation 11B35 (Preset feeder)
Layout
Sensor Cable
Sensor 11B35 with cable
155
Feeder pile control
11B35 Automatic pile transport
Task and function The capacitive sensor 11B35 detects whether the upper edge of the pile (paper) is at the respective height. Switching output: normally open contact
Connection
11B35
Core colour
Function
Terminal
brown
+ 24V DC
12X2: +1
blue
24V DC
12X2: –1
black
signal
FEM64: XE35
Cable end sensor 11B35
Removal and installation The sensor 11B35 is screwed down to the pile support frame in a special holder. When installing the cable make sure that no moveable parts are touched (risk of wearing through). The tape driving shaft is particularly critical.
Removal and installation 11B35
156
Feeder pile control
11B35 Automatic pile transport
Checking the circuit state EAK_11 E35
The output signal of the sensor 11B35 reaches EAK_11, input 35.
11B35
Signal flow
Position signal E35
The input signal E35 can be checked on the service display: 0:
The sensor does not detect an object (the upper edge of pile is below the sensor)
1:
The sensor detects an object (the upper edge of pile is at the level of the sensor)
Service display, signal E35
157
Feeder pile control
11S34 Bottom main pile limitation
11S34 Bottom main pile limitation Place of installation 11S34 11S34
Components
Preset feeder
Standard feeder
Place of installation 11S34
Task and function The position switch 11S34 deactivates the pile drive when the main pile has reached its lowest position. There is a trip cam at the pile change which actuates the position switch via a shifter mechanism.
158
Feeder pile control
11S34 Bottom main pile limitation
Setting To set the ”bottom main pile limitation”, the main pile chains must be shortened or lengthened accordingly. The position switch 11S34 must not be changed. Basically the following procedure for shortening or lengthening the main pile chains applies. Furthermore, the instructions and safety hints of the ”service manual for the mechanics” are to be obeyed.
Lower the pile support plate of the feeder until the pile support plate rests on the floor or on an elevation (e.g. pallets) and the pile chains are relaxed Lengthen or shorten the main pile chains accordingly
Checking the circuit state EAK_11 E34
The output signal of the switch 11S34 reaches EAK_11, input 34.
11S34
Signal flow
Position signal E34
The input signal E34 can be checked on the service display EAK: 0:
switch is actuated
1:
switch is not actuated
Note: The signal is also displayed on the service display SEK. Service display, signal E34
159
Components
Feeder pile control
160
11S34 Bottom main pile limitation
Delivery pile control
Block diagrams
Delivery pile control Block diagrams Block diagram (Preset)
Pile height
Switches and sensors
Controls
SEK
Safety circuit
Outputs
EAK_12
Press control
REK2
ESK
Auxiliary drive control
A
HAK_01 B
C
A A
LTK500 BAK
Main pile
A
HAK_02 B
C
B B
A
LTK50
B
M
M
12M1
12M2
Auxiliary pile
Preset delivery with auxiliary pile
161
Delivery pile control
Block diagrams
Block diagram (standard)
Pile height
Switches and sensors
Controls
SEK
Safety circuit
Outputs
EAK_12
Press control
REK2
ESK
Auxiliary drive control
A
HAK_01 B
C
A
HAK_02 B
C
A
STK1
B
A
LTK50
B
M
M
12M1
12M2
Main pile
Standard delivery with auxiliary pile
162
Auxiliary pile
Delivery pile control
Layout
Layout Overview The pile control of the delivery is used to control main pile and auxiliary pile and other outputs (solenoid-operated valves). It consists of the following functional units: –
Press control: recording and evaluating input signals for controlling the pile drives and outputs
–
Safety circuit: recording and evaluating safety-relevant signals for emergency shutdown of pile drives
–
Auxiliary drive control: control of pile motors
The following components are part of the pile control: SEK
Safety input board
EAK_12 Input/output board on board slot 12 (signal acquisition delivery) REK2
Processor board on board slot 2 (press control)
ESK
Input/output control board
HAK_01 Auxiliary drive board on board slot 1 HAK_02 Auxiliary drive board on board slot 2 STK1
Pile control board on board slot 1
BAK
Brake control board
LTK500
Power part board 500W
LTK50
Power part board 50W
163
Delivery pile control
Layout
Press control Inputs
Outputs
EAK_12
REK2
ESK
Auxiliary drive control
Press control
The press control records the signals of the switches and sensors on the delivery and the delivery controls via the inputs of EAK_12. REK2 evaluates these signals and generates control signals for the pile motors and solenoid-operated valves. The solenoid-operated valves are controlled via the outputs of EAK_12. The control signals for the pile motors are passed on to the auxiliary drive control via the ESK. The ESK has the following operation set for controlling the individual pile motors: –
Pile stop (pile height control off)
–
Pile up (slow)
–
Pile down (slow)
–
Pile up, fast (only for main pile)
–
Pile down, fast (only for main pile)
–
Pile height control on
–
Rack mode (parameter: rack height)
Safety circuit
Inputs
The SEK detects the signals of the safety-relevant switches on the delivery. It evaluates these signals and if necessary it generates control signals for the emergency shutdown of pile drives. These control signals are passed on directly to the auxiliary drive control.
SEK The signals of the safety circuit take priority over the signals of the press control. Auxiliary drive control
Safety circuit
164
The ESK is provided with the following operation set for controlling the individual pile motors: –
Pile drive enabled
–
Pile up blocked
–
Pile down blocked
Delivery pile control
Layout
Auxiliary drive control
Safety circuit
Press control
HAK_01
HAK_02
The auxiliary drive control prepares the control signals of SEK and ESK and controls the individual pile drives. Each drive is assigned with a control section (component of a HAK) and a power part (dependent on the motor used). Depending on the press version, the assignments listed below are possible - see also ”block diagrams”.
LT
LT
LT
Drive
Control section
Power part
M
M
M
Main pile (Preset)
HAK01 Part B
BAK+LTK500 Part B
Main pile (standard)
HAK01 Part B
STK1 Part B
Auxiliary pile (with auxiliary pile at feeder)
HAK02 Part A
LTK50 Part A
Auxiliary pile (no auxiliary pile at feeder)
HAK01 Part C
LTK50 Part A
12M1 12M2 12M2
Auxiliary drive control
The signal of the capacitive sensor for the automatic pile height control is prepared in the power part of the main pile. The prepared signals is passed on to the power part of the auxiliary pile. Both power parts pass the signal on to the corresponding control section. See chapter ”control systems / auxiliary drive control” for further details about the auxiliary drive control.
165
Delivery pile control
Overview of components
Overview of components Operator side
12S130 12S55
12B69
12S56
12Y14/15
12S34 12S131
12S42 12S41 12B129a
12S33
12S35
12Y60/61 12S34b 12B129 12S42
12S117
12B65
Components on the operator side
166
12Y49
12Y11 12Y13
Delivery pile control
Overview of components
Drive side
12M1 12M2 12S39
12S55a
12S130a 12Y62
12S36 12S34a 12S38
Components on the drive side
167
Delivery pile control
Overview of components
Motors Equipment
Function
12M1 12M1 12M2
Main pile drive (Preset) Main pile drive (standard) Auxiliary pile drive
with nonstop D
Preset without nonstop D
Standard with without nonnonstop stop
Preset without nonstop
Standard with without nonnonstop stop D D D D D D
D
D D
D
Remarks
Brushless motor Three-phase a.c. motor
Switches and sensors Equipment
Function
12S33 12S34 12S34a
Upper main pile limitation Bottom main pile limitation Bottom main pile limitation
D D
D D
12S34b
Bottom main pile limitation
D
D
D
D
12S35 12S36 12S38 12S39 12S41 12S42
Sheet jogger 1 Sheet jogger 2 Overshooting control Monitoring suction drum Pile rake stop Pile rake down
D D D D D D
D D D D
D D D D D D
D D D D
12S55 12S55a
Upper auxiliary pile limitation Upper auxiliary pile limitation
D D
12S56 12B65 12B69 12S117
D D D D
12B129 12B129a
Bottom auxiliary pile limitation Changeover fast/slow Pile height control – switching point 1: changeover fast/slow – switching point 2: upper main pile limitation Upper edge of pile at delivery Upper edge of pile at delivery
12S130 12S130a
Angular stop O.S. Angular stop D.S.
D D
D D
D D
D D
12S131
Pile down, slow
D
D
D
D
168
with nonstop
D D
same function as 12S55
D D
only with raised delivery, same function as 12S34 only with raised delivery, same function as 12S34
– with board fitting on D.S. – with rake fitting on O.S.
D D D D D
Remarks
D
D D
Receiver (light barrier) Transmitter (light barrier) same function as 12S130
Delivery pile control
Overview of components
Solenoid-operated valves Equipment
Function
12Y11 12Y13 12Y14 12Y15 12Y49 12Y60 12Y61 12Y62
Sheet stop Sheet catcher Supporting cross bar on Supporting cross bar off Locking of sheet stops Rack delivery on Rack delivery off Suction air sheet catcher
with nonstop D D D D D D D D
Preset without nonstop D D D D
Standard with without nonnonstop stop D D D D D D D D D D D D
Remarks
only with rake only with rake only with board only with board
169
Delivery pile control
Function
Function Automatic pile height control The automatic pile height control on the delivery is automatically activated as soon as one of the following conditions is met: –
The height control for the main pile at the feeder is on
–
The automatic pile height control for the auxiliary pile control on the feeder is on
–
The paper run is switched on
–
The sheeter is in operation (extra accessory)
12B69
The automatic pile height control on the feeder is stopped under the following circumstances:
Switching points of the automatic pile height control
–
Actuation of the ”pile stop” button (12S124)
–
Actuation of the ”main pile up” (12S45) or ”main pile down” (12S46) button (main pile only)
–
Actuation of the ”auxiliary pile up” (12S53) or ”auxiliary pile down” (12S54) button (auxiliary pile only)
–
Opening of the sheet stop (12Y11)
Automatic pile height control Permissible start condition 12B69 detects paper Pile down (by 2 mm)
Sequence of automatic pile height control
Under normal circumstances the automatic pile height control refers to the main pile. In addition, the automatic pile height control at the auxiliary pile is activated and deactivated in non-stop operation (see chapter ”non-stop operation”). The automatic pile height control controls the pile in such a way that the upper edge is always at the level of the sensor ”automatic pile height control” (12B69). As soon as the sensor detects the upper edge of the pile (paper), the pile is lowered by 2 mm. In case the sensor ”automatic pile height control” (12B69) fails to work, an emergency control is automatically activated. With this emergency control, the delivery pile is moved downwards synchronously to the feeder pile.
170
Delivery pile control
Function
Transport of main pile (Preset) On the Preset version, the main pile is driven by a brushless motor by means of which three speed levels are passed. Main pile up 12S45
12S117/2 12B69
slow
12S117/1 12B65
The upwards movement of the main pile is controlled by means of the button ”main pile up” (12S45) on the delivery operation panel. Depending on the position of the main pile, the speed is changed (fast/slow). When reaching the ”upper main pile limitation” (12S117/switching point 2) or the ”automatic pile transport” (12B69), the transport mechanism of the main pile stops. The upwards movement of the main pile is interrupted under the following circumstances:
fast 12S131
–
Actuation of an emergency stop switch
–
Actuation of the ”overshooting control” switch (12S38)
–
Actuation of the ”sheet jogger” switch (12S35 or 12S36)
–
Actuation of the ”monitoring suction drum” switch (12S39)
–
Actuation of the ”angular stop” switch (12S130)
–
Opening of the sheet stop (12Y11) (only if no non-stop operation)
–
Actuation of the ”main pile down” button (12S46)
slow
Switching points of main pile up (Preset) Main pile up Permissible start condition 12S45 (keep pressed) Main pile up, slow 12S131 Main pile up, fast 12B65 or 12S117/1
The continuation of an interrupted pile transport is only possible after elimination of the respective cause.
Main pile up, slow 12B69 or 12S117/2 Main pile stop
Sequence of main pile up and passes through all three speed levels (Preset)
171
Delivery pile control
Function
Main pile down 12S46 12S124
slow 12S117/1 12B65 fast
The downward movement of the main pile is controlled by means of the button ”main pile down” (12S46) on the delivery operation panel. Depending on the position of the main pile, the speed is changed (fast/slow). The button ”main pile down” (12S46) is equipped with a self-stopping mode. If the button was actuated for more than 1.5 s, the main pile moves down to the ”bottom main pile limitation” (12S34). The self-stopping mode can be interrupted by means of the button ”pile stop” (12S124). The downward movement of the main pile is interrupted under the following circumstances:
12S131 slow 12S34
Switching point of main pile down (Preset)
–
Actuation of an emergency stop switch
–
Actuation of the ”pile stop” button (12S124)
–
Actuation of the ”main pile up” button (12S45)
Main pile down Permissible start condition 12S46 (self-stopping mode after 1.5 s) Main pile down, slow 12B65 or 12S117/1 Main pile down, fast 12S131 Main pile down, slow 12S34 Main pile stop
Sequence of main pile down and passing through all three speed levels (Preset)
172
The interrupted pile transport can only be continued after elimination of the respective cause.
Delivery pile control
Function
Transport of main pile (standard) On the standard version the main pile is driven by a three-phase a.c. motor, by means of which two speed levels are passed. Main pile up 12S45
The upwards movement of the main pile is controlled by means of the button ”main pile up” (12S45) on the delivery operation panel. The main pile moves upwards at a constant speed (fast). When reaching the ”upper main pile limitation” (12S33) or the ”automatic pile transport” (12B69), the transport mechanism of the main pile stops.
12S33 12B69
The upwards movement of the main pile is interrupted under the following circumstances: fast
Switching points of main pile up (standard) Main pile up
–
Actuation of an emergency stop switch
–
Actuation of the ”overshooting control” switch (12S38)
–
Actuation of the ”sheet jogger” switch (12S35 or 12S36)
–
Actuation of the ”monitoring suction drum” switch (12S39)
–
Actuation of the ”angular stop” switch (12S130)
–
Opening of the sheet stop (12Y11) (only if no non-stop operation)
–
Actuation of the ”main pile down” button (12S46)
Permissible start condition 12S45 (keep pressed) Main pile up, fast 12S33 or 12B69 Main pile stop
An interrupted pile transport can only be continued after elimination of the respective cause.
Sequence of main pile up (standard)
173
Delivery pile control
Function
Main pile down 12S46 12S124
fast
12S131 slow 12S34
Switching points of main pile down (standard)
Main pile down Permissible start condition 12S46 (self-stopping mode after 1.5 s) Main pile down, fast 12S131 Main pile down, slow 12S34 Main pile stop
Sequence of main pile down and passing through both speed levels (standard)
174
The downward movement of the main pile is controlled by means of the button ”main pile down” (12S46) on the delivery operation panel. Depending on the position of the main pile, the speed is changed (fast/slow). When reaching the ”bottom limit position” (12S34), the transport mechanism of the main pile stops. The button ”main pile down” (12S46) is provided with a self-stopping mode. If the button was actuated for more than 1.5 s, the main pile moves down to the ”bottom main pile limitation” (12S34). The self-stopping mode can be interrupted by means of the button ”pile stop” (12S124). The downward movement of the main pile can be interrupted under the following circumstances: –
Actuation of an emergency stop switch
–
Actuation of the ”pile stop” button (12S124)
–
Actuation of the ”main pile up” button (12S45)
An interrupted pile transport can only be continued after elimination of the respective cause.
Delivery pile control
Function
Transport of auxiliary pile Auxiliary pile up 12S53
12S55
The upward movement of the auxiliary pile is controlled by means of the button ”auxiliary pile up” (12S53) on the delivery operation panel. The auxiliary pile moves upwards at a constant speed. When reaching the ”upper auxiliary pile limitation” (12S55), the transport of the auxiliary pile stops. The upward movement of the auxiliary pile is interrupted under the following circumstances: –
Actuation of an emergency stop switch
–
Actuation of the ”overshooting control” switch (12S38)
–
Actuation of the ”sheet jogger” switch (12S35 or 12S36)
–
Actuation of the ”monitoring suction drum” switch (12S39)
–
Actuation of the ”angular stop” switch (12S130)
–
Triggering of the sensor ”automatic pile height control” (12B69)
–
Opening of the sheet stop (12Y11) (only if no non-stop operation)
–
Actuation of the ”auxiliary pile down” button (12S54)
Switching points of auxiliary pile up Auxiliary pile up Permissible start condition 12S53 (keep pressed) Auxiliary pile up 12S55 Auxiliary pile stop
An interrupted pile transport can only be continued after elimination of the respective cause.
Sequence of auxiliary pile up
175
Delivery pile control
Function
Auxiliary pile down 12S54
The downward movement of the auxiliary pile is controlled by means of the button ”auxiliary pile down” (12S54) on the delivery operation panel. The auxiliary pile moves downwards at a constant speed. When reaching the ”bottom auxiliary pile limitation” (12S56), the transport mechanism of the auxiliary pile stops. The downward movement of the auxiliary pile is interrupted under the following circumstances:
12S56
Switching points of auxiliary pile down Auxiliary pile down Permissible start condition 12S54 (keep pressed) Auxiliary pile down 12S56 Auxiliary pile stop
Sequence of auxiliary pile down
176
–
Actuation of an emergency stop switch
–
Actuation of the ”angular stop” switch (12S130)
–
Actuation of the ”auxiliary pile up” button (12S53)
An interrupted pile transport can only be continued after elimination of the respective cause.
Delivery pile control
Function
Non-stop operation Basic function The separation of pile occurs in non-stop operation by means of rake or board in the main pile and auxiliary pile. The auxiliary pile takes over the automatic pile height control, the main pile executes a pile change or a rack formation. After that the two piles are remerged. The rack function is a special version of the non-stop operation which is selected and adjusted (if available) by means of the control console. Besides main and auxiliary pile further components are involved in the non-stop operation: –
Sheet catcher
–
Sheet stop front edge (only with rake)
–
Supporting cross bar (only with rake)
–
Guide rails (only with board)
177
Delivery pile control
Main pile Permissible start condition
Function
Auxiliary pile Permissible start condition
12S42
Pile separation
Main pile down, fast – Pile change: 12S41 or 12B129 – Rack: adjusted rack height Main pile stop (insert rake/board) 45 mm paper on auxiliary pile Automatic pile height control of main pile on
(insert rake/board) 45 mm paper on auxiliary pile Automatic pile height control of auxiliary pile on
12S46 (self-stopping) Main pile down, fast 12S131
Pile change (rack)
Main pile down, slow 12S34 Main pile stop (unloading) 12S45 Main pile up, slow 12S131 Main pile up, fast
Pile merging
– Rake: 12B129
– Rake: 12B129
– Board: 12S41 free
– Board: 12S41 free
Automatic pile height control of main pile off (pull out rake/board) Time delay 10 s
Automatic pile height control of auxiliary pile off (pull out rake/board) – Rake: 12S42 free – Board: 12S10 actuated
Automatic pile height control of main pile on
Auxiliary pile up 12S55 (starting position) Auxiliary pile stop
Sequence of non-stop operation
178
Delivery pile control
Function
Note: The following must be observed with the sequence of the non-stop operation (see figure): –
The steps for unloading are omitted with the rake function
–
Not all speed alterations are executed in case of the standard version
Pile separation When putting on the rake/board (12S42), the main pile moves downwards at fast speed. The main pile stops under the following circumstances: 12S41 12B129
12S42 12S41
Switching points for pile separation and pile merging
–
Pile change: Inserting the rake/board (12S41) or lowering the upper edge of pile until it is at the level of the light barrier (12B129)
–
rake: When reaching the preset rake height (the rake height can be adjusted on the ZID between 20 mm and 300 mm in increments of 10 mm)
As soon as 45 mm of paper are placed on the auxiliary pile, main and auxiliary pile execute pile height regulations. Pile change The main pile moves downwards in self-stopping mode by pressing the button ”main pile down” (12S46, for more than 1.5 s). After the main pile has been emptied it moves back to the level of the auxiliary pile when actuating the button ”main pile up” (12S45). When moving upwards and downwards the main pile runs through the same speed levels as described in the paragraph ”Transport of main pile”. Rack After positioning the rack, the main pile moves back to the level of the auxiliary pile by actuation of the button ”main pile up” (12S45) .
179
Delivery pile control
Function
Pile merging The main pile moves upwards until the corresponding condition is met. –
Rake: the upper edge of the pile has reached the height of the light barrier (12B129)
–
Board: the main pile lifts the board from underneath (12S41 free)
The automatic pile height control for main and auxiliary pile is interrupted for 10 seconds. Within this period, the rake/ board can be pulled out. Then the main pile takes over the automatic pile height control again. The auxiliary pile frame moves upwards back into its basic position. In case of the version with board, the guide rails must be retracted in addition - see paragraph ”guide rails”. Sheet catcher When separating the pile, the sheet catchers retain the paper coming from above, this activity is supported by suction air activated in addition. When putting on the rake/board (12S42), the main pile moves downwards (see ”pile separation”). If the preset moment of application is reached, the sheet catchers extend (12Y13) and the suction air is switched on (12Y62). The moment of application can be adjusted on the ZID within a range of 1 to 9 press rotations.
Extending and retracting sheet catcher Sheet catcher Permissible start condition 12S42 Main pile down Moment of application reached – Extending sheet catcher (12Y13) – Suction air on (12Y62) 12S41 – Suction air off (12Y62) – Retracting sheet catcher (12Y13)
Sequence of extending and retracting sheet catcher 180
When inserting the rake/board (12S41), the suction air is switched off (12Y62) and the sheet catchers retract (12Y13).
Delivery pile control
Function
Front edge sheet stop (with rake) The front edge sheet stop is locked during the entire non-stop operation with rake. The locking facility can also be operated manually on the control console. After putting on the rake (12S42), the locking facility is switched on (12Y49). When pulling out the rake (12S42 free), the locking facility is switched off again (12Y49).
Front edge sheet stop Front edge sheet stop Permissible start condition 12S42 Sheet stop locked (12Y49) 12S42 free Sheet stop released (12Y49)
Sequence of front edge sheet stop
181
Delivery pile control
Function
Supporting cross bar (with rake) The supporting cross bar is needed for the non-stop operation with rake to put on the rods of the rake. Dependent on the press-specific version, there are two different options for controlling the supporting cross bar.
Extending and retracting supporting cross bar Cross bar without delay time Permissible start condition 12S42 Extending cross bar (12Y14) Pile change or forming a rack 12S41 and 12S42 free Retracting cross bar (12Y15)
Sequence of extending and retracting supporting cross bar (without delay time) Cross bar with delay time Permissible start condition 12S41 and 12S42 – Await time (3 s) – Extending cross bar (12Y14) Pile change or forming a rack 12S41 and 12S42 free Retracting cross bar (12Y15)
Sequence of extending and retracting supporting cross bar (with delay time)
182
–
Without time delay: When putting on the rake (12S42), the supporting cross bar extends (12Y14). When pulling out the rake (12S41 and 12S42 free) the supporting cross bar retracts again (12Y15).
–
With time delay: When inserting the rake (12S41 and 12S42) the supporting cross bar extends after 3 seconds (12Y14). When pulling out the rake (12S41 and 12S42 free) the supporting cross bar retracts again (12Y15).
Delivery pile control
Function
Guide rails (with board) 12S10
The guide rails are needed for the non-stop operation with board to act as a lateral support of the board. By pressing the button ”pile board on/off” (12S10) the guide rails extend (12Y60). After that the board can be inserted in the guide rails. After completion of the unloading process or after insertion of spacer angles for a rack, the main pile moves back to the height of the auxiliary pile (12S41 becomes clear). By pressing the button ”pile board on/off” (12S10) the guide rails retract (12Y61).
Extending and retracting guide rails Guide rail Permissible start condition 12S10 Extending guide rail (12Y60) Pile change or forming a rack 12S41 free and 12S10 Retracting guide rail (12Y61)
Sequence of extending and retracting guide rails
183
Delivery pile control
Function
Removal of sample sheet 12S11
The removal of sample sheet is controlled by means of the button ”sample sheet removal” (12S11) on the delivery operation panel. When the button is actuated, the automatic pile height control is interrupted. The sheet catchers extend (12Y13), for reason of better adhesion it is possible to additionally activate suction air (optional) (12Y62). The stop shaft swings up (12Y11) and the sheet can be removed. Actuating the button ”sample sheet removal” (12S11) again, cancels the removal of sample sheet, the pile executes the automatic pile height control. When removing a sample sheet the locking of the front edge sheet stop (12Y49) is deactivated if it was activated beforehand.
Removal of sample sheet
Removal of sample sheet Permissible start condition 12S11 – Extending sheet catcher (12Y13) – Suction air on (12Y62) - optional – Swinging up stop shaft (12Y11) 12S11 – Suction air off (12Y62) - optional – Retracting sheet catcher (12Y13) – Swinging back stop shaft (12Y11)
Sequence of sample sheet removal
184
Delivery pile control
Function
Paper blockage Paper blockage Permissible start condition
In case of a paper blockage, the paper supply is blocked at the feeder. To trigger a paper blockage, either main pile or auxiliary pile must meet one of the following stop conditions.
Stop condition Paper supply at feeder blocked
Sequence of paper blockage
Main pile: (Only if the delivery is not in non-stop operation) –
Switch ”pile down slow” (12S131) overshot
–
Switch ”bottom main pile limitation” (12S34) reached
Auxiliary pile: –
Switch ”bottom auxiliary pile limitation” (12S56) reached
–
Maximum paper height in non-stop operation reached (depending on paper thickness between 1500 and 4000 sheets)
The paper blockage is only cancelled after elimination of the respective cause.
185
Delivery pile control
12M1 Main pile motor (Preset)
12M1 Main pile motor (Preset) Place of installation
12M1
Place of installation of main pile motor (Preset)
Layout
Layout of main pile motor (Preset)
186
Motor electronics Motor and brake Gear unit Male connector
Delivery pile control
12M1 Main pile motor (Preset)
Task and function The main pile motor moves the main pile upwards and downwards via the pile chains. A brushless motor is used which can execute the following functions: –
Speed control
–
Changeover between two different speed levels (”fast” and ”slow”)
–
Electrical deceleration (controlled by the corresponding power part)
–
Stopping or emergency braking by means of installed brakes
The motor is provided with the following internal functions for the purpose of control and monitoring: –
Commutation and speed recording via Hall signals
–
Temperature recording via resistor
–
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)
Technical specifications
187
Delivery pile control
12M1 Main pile motor (Preset)
Pin assignment
1 2 3 4 5
A B C
1 2 3 4 5
Pin assignment of main pile motor (Preset)
Pin
Function
A1
X1 motor line (slow)
B1
Y1 motor line (slow)
C1
Z1 motor line (slow)
A2
X2 motor line (fast)
B2
Y2 motor line (fast)
C2
Z2 motor line (fast)
C5
Brake (reference potential DC)
B5
Brake (DC +24 V)
B4
Hall 1
A5
Hall 2
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)
12M1 Main pile motor (standard) Place of installation
12M1
Place of installation of main pile motor (Standard)
Layout
Motor electronics Motor and brake Gear unit Male connector
Layout of main pile motor (standard)
189
Delivery pile control
12M1 Main pile motor (standard)
Task and function The main pile motor moves the main pile upwards and downwards by means of the pile chains. A three-phase induction motor is used which can execute the following functions: –
Changeover between two different speed levels (”fast” and ”slow”)
–
Stopping and emergency braking by means of the installed brake
The motor is provided with the following internal functions for the purpose of controlling and monitoring: –
Speed recording via Hall signals
–
Temperature recording via resistor
–
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)
Technical specifications
190
Delivery pile control
12M1 Main pile motor (standard)
Pin assignment Pin
Function
A1
Winding U1 (slow)
B1
Winding V1 (slow)
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
A5
Hall 2
C3
Resistor code
B3
PTC (temperature monitoring)
C4
Auxiliary voltage of motor electronics UH
A4
Ground auxiliary voltage
A B C
Pin assignment of main pile motor (standard)
PE conductor
191
Delivery pile control
12M2 Auxiliary pile motor
12M2 Auxiliary pile motor Place of installation
12M2
Place of installation of auxiliary pile motor
Layout
Layout of auxiliary pile motor
192
Gear unit Motor Motor electronics Circular connector
Delivery pile control
12M2 Auxiliary pile motor
Task and function The auxiliary pile motor moves the auxiliary pile upwards and downwards by means of the pile chains. A brushless motor is used which can execute the following functions: –
Speed control
–
Electric deceleration (controlled by the corresponding power part)
–
Deceleration through the self-locking gear unit
The motor is provided with the following internal functions for the purpose of controlling and monitoring: –
Commutation and speed recording via Hall signals
–
Output: 30 Watt
–
Power supply: DC 48 V
–
Speed (gear unit): 1 min–1
–
Ratio: 2564:1
–
Resistor code: 5 (5.6 kW)
Technical specifications
193
Delivery pile control
12M2 Auxiliary pile motor
Pin assignment
Pin assignment auxiliary pile motor
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
–
13
–
14
– PE conductor
194
Delivery pile control
12B65 Changeover fast/slow
12B65 Changeover fast/slow Place of installation
12B65
Place of installation 12B65
Layout
Sensor Cable
Sensor 12B65 with cable
195
Delivery pile control
12B65 Changeover fast/slow
Task and function The ultrasonic sensor 12B65 monitors whether the upper edge of the pile (paper, pallet or pile support plate) is at the corresponding height. The output signal is used to change the speed to fast/slow. Switching output: normally closed contact
Connection
12B65
Core colour
Function
Terminal
brown
+ 24V DC
12X2: +1
blue
24V DC
12X2: –1
black
signal
12X2: 116
Cable end sensor 12B65
Removal and installation The sensor 12B65 is fixed to the control lever by means of two screws. When installing the cable there must be enough room for the rotary movement of the lever.
Removal and installation 12B65
196
Delivery pile control
12B65 Changeover fast/slow
Checking the circuit state EAK_12 E65
The output signal of the sensor 12B65 reaches EAK_12, input E65 via the switch 12S117/switching point 1 (at the control lever).
12B65 12S117/1
Signal flow
Position signal E65
The input signal E65 can be checked on the service display EAK:
Service display, signal E65
0:
The sensor 12B65 detects an object (the pile is at the level of the sensor) or 12S117/ switching point 1 is actuated (the pile support plate presses the control lever upwards)
1:
The sensor 12B65 does not detect any object (the pile is below the sensor) or 12S117/switching point 1 is not actuated (the control lever is not actuated)
197
Delivery pile control
12B69 Pile height control
12B69 Pile height control Place of installation
12B69
Place of installation 12B69
Layout
Sensor 12B69 with cable
198
Sensor Cable
Delivery pile control
12B69 Pile height control
Task and function The capacitive sensor 12B69 monitors whether the upper edge of the pile (paper) is level with the sheet stop. Based on this sensor signal, the control systems regulates the position of the delivery pile. Switching output: normally open contact
Connection
12B69
Core colour
Function
Terminal
brown
+ 24V DC
12X2: +1
blue
24V DC
12X2: –1
black
signal
12X2: 69
Cable end sensor 12B69
Removal and installation The sensor 12B69 is fixed to the support on the sheet jogger shaft by means of a screw. When installing the cable there must be enough room for the rotary movement of the stop shaft and for the adjustment of the sensor at the support. The cable must not be fixed to movable parts (except for the sheet jogger shaft). These are in particular the following points: –
Sheet catcher hose
–
Non-stop frame
Removal and installation 12B69
199
Delivery pile control
12B69 Pile height control
Setting
approx. 50 mm
In the normal position the sensor is fixed in the bottom third of the oblong hole (see figure) and the rack height is adjusted to 70 mm. Depending on the condition of the pile or the printing material, this position can be altered.
Note: A repositioning of the sensor needs to be considered in non-stop operation for the rack height (adjustable on the control console)
Normal setting
Checking the circuit state EAK_12 E70
The output signal of the sensor 12B69 reaches EAK_12, input 70 and the HAK control sections of the main and auxiliary pile drive (exact assignment see block diagram).
HAK_01 12B69 HAK_02
Signal flow
Position of signal E70
The input signal E70 can be checked on the service display EAK:
Service display, signal E70
200
0:
The sensor detects no object (the pile is below the sensor)
1:
The sensor detects an object (the pile is located at the level of the sensor)
Note: The signal is also displayed as status signal on the service display of the two respective HAK control sections.
Delivery pile control
12B129 Delivery upper edge of pile
12B129 Delivery upper edge of pile Place of installation
12B129a
12B129
Place of installation 12B129 and 12B129a
Layout
Sensor Cable
12B129
12B129a
Sensor 12B129 and 12B129a with cable
201
Delivery pile control
12B129 Delivery upper edge of pile
Task and function The light barrier 12B129 monitors whether the upper edge (paper, pallet or pile support plate) of the main pile is located at the respective level underneath the auxiliary pile. By means of this sensor signal, the separation and merging of the pile is controlled in non-stop operation with board. The light barrier consists of a transmitter (12B129a) and a receiver (12B129). Switching output: dark switching
Connection 12B129 12B129
Cable end sensor 12B129
Core colour
Function
Terminal
brown
+ 24V DC
12X2: +1
blue
24V DC
12X2: –1
black
signal
FAM64:XA29
Core colour
Function
Terminal
brown
+ 24V DC
12X2: +1
blue
24V DC
12X2: –1
12B129a 12B129a
Cable end sensor 12B129a
202
Delivery pile control
12B129 Delivery upper edge of pile
Removal and installation Transmitter and receiver of the light barrier are screwed down to the support (metal plate). Both supports can be relocated in height through the oblong holes. Both supports must be at the same level.
D.S.
When installing the cable there must be enough room for the upward and downward movement of the non-stop frame.
12B129a O.S.
In its normal position, the light barrier should be set as high as possible to prevent a lowering of the pile below the rear edge stop.
12B129
Removal and installation 12B129
Checking the circuit state EAK_12 E77 12B129a
The output signal of the sensor 12B129 (receiver) reaches EAK_12, signal E77.
12B129
Signal flow
Position of signal E77
The input signal E77 can be checked on the service display EAK: 0:
The light barrier is not interrupted
1:
The light barrier is interrupted
Service display, signal E77
203
Delivery pile control
12S34 Bottom main pile limitation
12S34 Bottom main pile limitation Place of installation
12S34
Place of installation 12S34
Task and function The position switch 12S34 switches the main pile drive off when the main pile has reached its lowest position. There is a pin on the pile chain which actuates the position switch via a shifter mechanism. Principle of operation: normally closed contact
204
Delivery pile control
12S34 Bottom main pile limitation
Setting
Lower the pile support plate of the delivery until the pile support plate rests on the floor and the pile chains are relaxed. Slacken the fixing bolt .
at the control plate
Adjust the control plates so that the position switch 12S34 is actuated in this position of the delivery pile support plate.
Position switch 12S34
Mounting plate with (actuated) position switch
205
Delivery pile control
12S34 Bottom main pile limitation
Checking the circuit state EAK_12 E34 12S34
12S34a
The output signal of the switch 12S34 reaches EAK_12, input 34 via the switches 12S34a and 12S34b (if available).
12S34b
Signal flow
Position of signal E34
The input signal E34 can be checked on the service display EAK:
Service display, signal E34
206
0:
at least one switch is actuated
1:
no switch is actuated
Sheet alignment
Block diagram
Sheet alignment Block diagram Double-sheet detector SM74 / 52 O.S. D.S. 1B66
Sheet alignment control
1B65
Double-sheet detector SM102/CD102
Pull lay control
D.S.
O.S.
D.S.
O.S.
1B13
1B49
1B9
1B10
1B11
RL12
RL12
SUM1 RL12
SUM1 RL12
DBE
1AUM1
Automatic misalignment control
Sheet stop finger
11M7
M
O.S . 1Y15
Automatic sheet arrival control SM102/CD102 = 11M3 SM74 = 1M7
Gripper opening
D.S . 1Y46
1Y16
SSM1 M
SSM1
SSK
EAK 1
IDS Displays
Legend:
SAK
ESK
REK1
REK2
Data line
SVM
MID11
MID12
DSK
DNK
ZID
Control lines
Block diagram of sheet alignment 207
Sheet alignment
The sheet alignment system consists of: –
the sheet alignment control BAK,
–
the pull lay control ZMK,
–
the double-sheet detector DBE,
–
the automatic sheet arrival control BAR (not on SM52),
–
the automatic misalignment control (only on SM102 with Preset and CD102).
As a result of mechanically controlled sequences of motions, the sheet is aligned with the sheet alignment system before it enters the first printing unit. At the same time, the electronic control system: –
registers the point of time of sheet arrival,
–
monitors sheet infeed,
–
detects double-sheets.
From different sensors the electronic control system receives information from the area of the front lays at certain interrogation points. The sensor signals are processed on the processor board 2 (REK2). The REK2 shows the result of the evaluation on the control console display ZID and the press displays MID. Simultaneously, the electronic control system activates various actuators (drives, valves etc.) in the press.
208
Block diagram
Sheet alignment
Block diagram
Degree values relevant to sheet alignment
BAK ZMK DBE
The illustration opposite shows the different interrogation points in the area of the front lays. The relation between the degree values and the processes in the press is explained in more detail on the next pages. To make the relation clear, the illustration shows the operation points ”Feeder ON” and ”Feeder OFF”. Table of degree values:
Feeder ON
Interrogation points
Feeder OFF
SM52
SM74
SM102 CD 102
230_
285_
192,0_1 170,0_1 222,0_ 200,0_
303_
208,0_1 186,0_1 238,0_ 216,0_
20_
330_
336,0_ 313,0_
40_
330_
15_
311,0_
289,0_
42,5_
72_
3,0_
341,5_
1 only for presses with Preset feeder
209
Sheet alignment
1B13/1B49 Sheet alignment control
1B13/1B49 Sheet alignment control Block diagram
BAK
and 20_ , – SM74 between 285_ and 40_ , – SM102 between 222_ and 336_ , – SM102 with Preset between 192_ and 336_ , – CD102 between 200_ and 313_ , – CD102 with Preset between 170_ and 313_ . The optimum sheet arrival of the electric is as –
FÜK Front lays
ANK
Paper
1B13/1B49
Interrogation points
Sheet alignment control D.S.
O.S.
1B13
1B49
1 LVT1 1EVM4 MID12
MID11
ZID
EAK 1
–
for SM74 at 303_,
–
for SM102 at 238_,
–
for SM102 with Preset at 208_,
–
for CD102 at 216_.
–
for CD102 with Preset at 186_.
The following applies to the degrees listed (see block diagram):
Displays
–
At and paper run: the ANK must not detect paper.
–
At and paper run: the ANK must detect paper.
– DNK
ESK
SVM
REK2
Legend:
Data line Control lines
Block diagram of sheet alignment control 210
SM52 between 240_
follows:
RL12
RL12
For correct sheet transfer from the feeder into the first printing unit, the sheet must be placed against the front lays as follows:
DSK
At and paper run: to analyze the information provided by the pull lay control (1B9/1B10) the ANK must detect paper.
The sensors (1B13 and 1B49) of the sheet alignment control register at which point of time the sheets arrive at the front lays. Each sensor housing contains an ANK and FÜK sensor. ANK = sensor for sheet alignment control FÜK = sensor for overshooting-sheet control
Note: Speedmaster SM52 is only equipped with one sensor (1B49) of the sheet alignment control.
Sheet alignment
1B13/1B49 Sheet alignment control
The signals of the sensors are transmitted to the amplifiers (RL12) where they are amplified. The signals from the amplifiers reach the processor board REK2 via –
the distribution box 1LVT1,
–
the input/output distributor module EVM (only SM52),
–
the input/ output board EAK and
–
the input/output control board ESK.
The REK2 analyzes the signals of the sheet alignment control. The evaluated signals are required for the following functions of the printing press: –
sheet alignment at the front lays,
–
misaligned-sheet display (trend display),
–
automatic sheet arrival control (servo-drive 11M3/1M7),
–
automatic misalignment control (servo-drive 11M7).
The REK2 shows the result of the evaluation on the control console display ZID and the press displays MID. D.S.
Circuit states of the ANK and FÜK sensors in the MID
O.S.
Circuit states displayed on the MID
FÜK display (sensor for overshooting control) ANK display (sensor for sheet alignment control)
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
The FÜK and ANK displays are visible when the switch ”Safe” on the control panel of the feeder is set to ”Safe” and the printing speed is x 3500 i.p.h.
Note: On Speedmaster SM52 the symbols of two sensors are displayed, even though only one sensor if fitted.
211
Sheet alignment
1B13/1B49 Sheet alignment control
Sheet alignment errors detected by the ANK sensors The ANK sensors detect: BAK SM52 240_ SM74 285_ SM102 222_ SM102 with Preset 192_ CD102 200_ CD102 with Preset 170_
Paper (first sheet)
–
early sheets (first sheet),
–
late sheets (missing sheets),
–
misaligned sheets.
An early sheet exists if the first sheet of the sheet stream already covers the ANK sensor at press angle . The feeder and press stop immediately. The sheets are held back on the feed table.
Early sheet
BAK SM52 20_ SM74 330_ SM102 336_ SM102 with Preset 336_ CD102 313_ CD102 with Preset 313_
A late sheet exists if none of the ANK sensors detects paper at press angle . The feeder stops and the remaining sheets are held back on the feed table. The sheets inside the press are printed and transported to the delivery. The press speed is then reduced to 3 000 i.p.h.
Late sheet
BAK SM74 330_ SM102 336_ SM102 with Preset 336_ CD102 313_ CD102 with Preset 313_
O.S.
Paper
Misaligned sheet 212
Paper
D.S.
A misaligned sheet exists if only one of the ANK sensors – either on the drive side or on the operator side – detects paper at press angle . The feeder stops and the remaining sheets are held back on the feed table. The sheets inside the press are printed and transported to the delivery. The press speed is then reduced to 3 000 i.p.h.
Note: On SM52 misalignment control is not required.
Sheet alignment
1B13/1B49 Sheet alignment control
Sheet alignment error detected by the FÜK sensors The FÜK sensors detect: BAK
Paper
Overshooting sheet
SM52 20_ SM74 330_ SM102 336_ SM102 with Preset 336_ CD102 313_
–
overshooting sheets.
Given a continuous sheet flow, an overshooting sheet exists if one of the FÜK sensors detects paper at press angle . The feeder and press stop immediately. The shingled sheets remain on the feed table.
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.
Extended functions The extended functions are only active with the inductive double-sheet detector of SM52 and SM74. During paper transport: The control system monitors the paper transport on the feed table. For this purpose, the control system needs the signal from the FÜK sensor and the measuring result of the double-sheet detector. If during paper run the FÜK sensors do not detect a sheet being fed in although the double-sheet detector has registered a good sheet (no double-sheet), the control system switches the feeder off. There is probably a paper jam on the feed table. In the case of a double-sheet: The control system stops the press immediately (emergency stop) if the FÜK sensors detect paper in the case of a double-sheet. Thus no multiple sheets are fed into the press.
213
Sheet alignment
1B13/1B49 Sheet alignment control
Misaligned-sheet display (trend display)
Display of misaligned sheet. Drive side advanced.
Good sheet Optimum sheet arrival Misaligned sheet, D.S. advanced Display of misalignment up to max. 18° Misaligned sheet, O.S. advanced Display of misalignment up to max. 18°
During paper run or production run, the misalignedsheet display appears on the MID. This display changes permanently and is a trend indication for the operator. The misaligned-sheet display does not intervene in press control. The ANK sensors of the sheet alignment control detect the misaligned sheet at the front lays. This misalignment between the drive side (D.S.) and operator side (O.S.) is determined and converted into a degree value. The degree value is represented as a line symbol on the MID (see ill.). The display is only visible if no –
settings and adjustments,
–
fault messages,
–
malfunctions
–
or other information
are indicated on the MID.
Note: The fault message ”Misaligned sheet” and the misaligned-sheet display are not identical.
214
Sheet alignment
1B13/1B49 Sheet alignment control
Place of installation The sensors of the sheet alignment control are located at the front lays.
1B13 1B49
Place of installation of sheet alignment control
Layout and task Running direction of paper FÜK ANK Reflex sensor
Amplifier
The reflex sensors on the drive side and operator side of the sheet alignment system serve for paper detection. Each reflex sensor has two optical sensors – ANK and FÜK – monitoring the sheet alignment. The FÜK and ANK sensors are fitted in a housing. Viewed in the running direction of the paper, the paper first covers the ANK sensor.
X2
ANK = sensor for sheet alignment control FÜK = sensor for overshooting sheet control
X1 To 1LVT1
In the amplifier of the reflex sensor, the sensor signals are amplified and transmitted to the electronic control system. The amplifiers of the two reflex sensors are located at the side frame on the O.S., under the feed table.
Reflex sensor with amplifier
Pin assignment ground free
free ANK–
+24K FÜK+
FÜK– ANK+
Pin assignment 1B49:X1/1B13:X1
215
Sheet alignment
1B13/1B49 Sheet alignment control
Removal and installation
1
2 1/2–1
–
Position the press: SM102: 100 ± 3 degrees CD102: 70 ± 3 degrees
–
3
Loosen the fixing bolt on the brass block (1/2–1 rev.).
4
O.S. D.S.
–
216
Pull off the reflex sensor with the brass block towards the front.
–
Remove the amplifier.
Sheet alignment
1B13/1B49 Sheet alignment control
5
–
6
Disconnect the cable leading to 1LVT1.
–
7
Remove the reflex sensor.
8
–
Slide the new reflex sensor into the guide of the holder.
Note: To fix the reflex sensor in position, carefully tighten the fixing bolt (tightening torque approx. 1 Nm). –
–
Turn the handwheel anticlockwise until the end stop comes to rest on the cross bar.
Tighten the fixing bolt.
217
Sheet alignment
9
1B13/1B49 Sheet alignment control
10
O.S.
–
Connect the cable coming from 1LVT1 to the amplifier.
11
–
D.S.
Fasten the amplifier.
12 1.5 – 2.0 mm
– –
218
Push the reflex sensor and brass block on the guide pins through to the stop. Check the distance (1.5 – 2.0 mm).
–
Tighten the fixing bolt on the brass block.
Sheet alignment
1B13/1B49 Sheet alignment control
Adjustment
1
2 0
1
3
2
ÁÁÁÁ –
Bring the bending in the ”0” position.
–
3
–
Press the pushbutton ”Forward” until the sheet stop fingers are raised.
4
Position the press: SM102: 333 ± 1 degree CD102: 310 ± 1 degree
–
Turn the handwheel anticlockwise until the end stop comes to rest on the cross bar.
219
Sheet alignment
1B13/1B49 Sheet alignment control
6
5
1
–
Turn the handwheel back by one revolution.
–
7
8
MID
–
MID
D.S.
D.S.
O.S.
O.S.
Turn the adjusting screw until the ANK symbol on the MID just lights up.
– –
220
Place a sheet of paper of max. width (102cm) and approx. 20cm length against the front lays.
Turn the adjusting screw until the ANK symbol on the MID just lights up. Both ANK symbols on the MID must be lit.
Sheet alignment
1B13/1B49 Sheet alignment control
9
10
2 1/6
–
Turn the handwheel clockwise for 1.3 mm +/–0.1 mm (2 1/6 revs), using the scale as a reference.
–
Both ANK symbols must be lit. The FÜK symbols must not be lit.
11
1.3 mm +/– 0.1 mm FÜK ANK
10 mm
Front lay
MID
D.S. O.S.
Paper
–
– Check the distance between the front lays and ANK sensor.
221
Sheet alignment
1B13/1B49 Sheet alignment control
Checking the circuit state 1B13 in the service display of the EAK: Input 13 = ANK (O.S.) Input 15 = FÜK (O.S.) 1B49 in the service display of the EAK: Input 49 = ANK (D.S.) Input 51 = FÜK (D.S.) 1 0
Service display ”Present input/output, input/output board EAK”
222
= sensor detects paper = sensor does not detect paper
Sheet alignment
1B9/1B10 Pull lay control
1B9/1B10 Pull lay control Block diagram The pull lay control (ZMK) monitors the entire pull procedure, i. e. the correct sheet infeed and the pull end position.
ZMK SM52 330_ SM74 15_ SM102 311_ CD102 289_
1B9/1B10
SM52 42.5_ SM74 72_ SM102 3_ CD102 341.5_ Paper
The following applies to the degrees listed (see block diagram): –
At and paper run: the ZMK must not detect any paper.
–
At and paper run: the ZMK and ANK must detect paper.
Interrogation points –
Pull lay control D.S.
O.S.
1B9
1B10 Audible signal device 12 H 55 SUM1 RL12
SUM1 RL12
Audible signal device 11 H 55
1 LVT 1 1EVM4
12 LVT 1 12EVM4
11 LVT 1 11EVM4
EAK 1
EAK 12
EAK 11
At and no paper run: the ZMK signal is not analyzed because the sheet alignment control does not detect paper.
The reflex sensors on the drive and operator sides serve for paper detection. Depending on the pull direction only one of the two reflex sensors is necessary for monitoring. The pull direction is entered under the command ”Presetting”. Only the reflex sensor of the active pull lay is interrogated. In the signal conversion modules SUM 1 the signals of the reflex sensors are amplified. The circuit state of each sensor is signalled by an LED on the corresponding SUM 1 (LED is lit = reflex sensor detects paper). SM52 only: On SM52 the signals are amplified by the amplifiers of the reflex sensors RL12.
ZID
The electronic control system evaluates the signals of the signal conversion modules. The signals from the amplifiers reach the processor board REK2 via
DNK
–
the distribution box 1LVT1,
–
the input/output distributor module EVM (SM52 only),
–
the input/ output board EAK,
–
the input/ output control board ESK.
Displays MID12
ESK
MID11
SVM
DSK
REK2 Legend: Data line
Control lines
Block diagram of pull lay control 223
Sheet alignment
1B9/1B10 Pull lay control
The REK2 analyzes the signals of the pull lay control. In the case of a pull or sheet infeed error, it passes the fault message to the control console display ZID, the press displays MID and the audible signal devices 11H55 and 12H55. For an acoustic fault message to be output, the function ”Audible signal device / pull lay control” must be switched on in the central control console. D.S.
O.S.
Circuit states displayed on the MID
Circuit states of the ZMK sensors on the MID
Display of pull lay control
With the help of the MID on the control panel of the feeder, the reflex sensors 1 B9 and 1 B10 can be monitored. The MID reflects the circuit state of the corresponding sensor. Symbol lit
= sensor detects paper
Symbol not lit
= sensor does not detect paper
The circuit states of the reflex sensors are visible when the switch ”Safe” on the control panel of the feeder is set to ”Safe” and the printing speed is x 3500 i.p.h.
When does a sheet infeed error/pull error exist? ZMK SM52 330_ SM74 15_ SM102 311_ CD102 289_ Paper
Sheet infeed error
224
A sheet infeed error exists if the sheet is already below the reflex sensor at the interrogation point. The sensor detects paper.
Sheet alignment
1B9/1B10 Pull lay control
ZMK SM52 42.5_ SM74 72_ SM102 3_ CD102 341.5_ 1B13/1B49
A pull error exists if, at the interrogation point: –
the ANK sensors (1B13/1B49) detect the print sheet and
–
the ZMK sensor does not detect the print sheet.
1B9/1B10 Paper
Pull error
225
Sheet alignment
1B9/1B10 Pull lay control
Place of installation The pull lays with the reflex sensors are fitted on two cross bars in front of the transfer gripper drum. One pull lay is fitted on the operator side (1B10) and one on the drive side (1B9).
1B9 1B10
Place of installation of pull lays
Signal conversion modules SUM1
Under the feed table, the two signal conversion modules SUM1 are fitted on a support bar. Each is allocated to one of the pull lays.
Place of installation of signal conversion modules
226
Sheet alignment
1B9/1B10 Pull lay control
Adjustment (Preset version) The adjustment must be made: –
for the first start-up
–
when changing the printing material (paper)
–
in the case of frequent fault messages.
1
2 3
4
5 Adjustment of pull lays a)
Pull direction of sheet of paper
b)
Running direction of paper
c) Edge for format adjustment
Enter the required sheet width in the command mode ”Presetting”. After command enabling, the control system positions the pull lay to the entered format. Set the selector switch ”Safe” on the control panel at the feeder to ”Safe”. Press the illuminated pushbutton ”Feeder”, so that the button is lit. Press the pushbutton ”Forward” until the sheet stop fingers are raised. Press the pushbutton ”Forward” until the pull lay stop is below the upper edge of the sheet metal plate. The pull rail must not have grabbed the sheet yet. The sheet can still be moved. Pull the sheet against the pull lay stop; the paper must be under the reflex sensor .
6
Turn the knurled head screw clockwise, until the green LED at the corresponding signal conversion module goes off.
7
Turn the knurled head screw anticlockwise, until the green LED just lights up.
8
Turn the knurled head screw anticlockwise for another 10 notch positions (= 0.3 mm; corresponds to approx. 1/4 rev. of ).
9
Take out the sheet. The LED of the reflex sensor goes off.
227
Sheet alignment
1B9/1B10 Pull lay control
Adjustment of pull lays
228
Adjust the spring pressure with the knurled head screw . The pressure the pull roll exerts on the printing material must be so strong that each sheet is pulled reliably to the pull lay stop. The locking nut prevents the pressure from changing once it has been set. Reflex sensor Knurled head screw Knurled head screw Locking nut
Sheet alignment
1B9/1B10 Pull lay control
Adjustment (standard version) The adjustment must be made:
1 mm
a
b
–
for the first start-up
–
when changing the printing material (paper)
–
in the case of frequent fault messages.
1
Loosen the tommy bar screw and position the pull lay so that it complies with the sheet size at the feeder.
2
Move the magnet cover plate with recess until it is approx. 1mm away from the pull lay stop .
Note: The pull lay stop must not lie on the magnet cover plate while the paper is being pulled.
3 4
+ -
c
5 Adjustment of pull lays a)
Pull direction of sheet of paper
b)
Running direction of paper
c) Edge for format adjustment
6 7
Set the selector switch ”Safe” on the control panel at the feeder to ”Safe”. Press the illuminated pushbutton ”Feeder”, so that the button is lit. Press the pushbutton ”Forward” until the sheet stop fingers are raised. Press the pushbutton ”Forward” until the pull lay stop is below the upper edge of the sheet metal plate. The pull rail must not have grabbed the sheet yet. The sheet can still be moved. Pull the sheet against the pull lay stop; the paper must be under the reflex sensor . Loosen the knurled head screw bit.
a little
8
Turn the knurled head screw clockwise, until the green LED at the corresponding signal conversion module goes off.
9
Turn the knurled head screw anticlockwise, until the green LED just lights up.
ß
Turn the knurled head screw anticlockwise for another 14 notch positions (= 0.4 mm; corresponds to approx. 1/4 rev. of ).
229
Sheet alignment
1B9/1B10 Pull lay control
q w e
ÉÉÉÉÉÉÉÉÉÉÉÉÉ
Retighten the knurled head screw . The LED of the corresponding reflex sensor must still be lit. Take out the sheet. The LED of the reflex sensor goes off. Adjust the spring pressure with the knurled head screw . The pressure the pull roll exerts on the printing material must be so strong that each sheet is pulled reliably to the pull lay stop. The locking nut prevents the pressure from changing once it has been set.
Pull lay
Checking the sensing distance of the reflex sensors This check must be carried out: –
for the first start-up
–
in the case of frequent fault messages.
The distance between the lower edge of the reflex sensor and the surface of the magnet cover plate must be 4.5 – 5 mm. When fitting the reflex sensor pay attention to this.
.
Sensing distance
230
Tommy bar screw Magnet cover plate Pull lay stop Reflex sensor Knurled head screw
Knurled head screw Paper Knurled head screw Locking nut Lower edge of reflex sensor
Sheet alignment
1B11 Double-sheet detector
1B11 Double-sheet detector Block diagram The double-sheet detector monitors sheet infeed at the feeder. It detects multiple sheets and irregularities in the sheet flow and thus prevents malfunctions.
Optical sensor system Transmitter 1āBā11āS
An optical sensor system consisting of a transmitter (1 B11 S) and a separate receiver (1 B11 E) transmits light through the paper. The receiver supplies a signal. The amplitude of the signal depends on the thickness and nature of the printing material.
Receiver 1āBā11āE
The control device DBE supplies the optical sensor system with operating voltage. Apart from this, the control device helps to process the sensor signal and to adjust the double-sheet detector to the printing material used.
Control device DBE 1āLVTā1
Shortly before the sheet enters the first printing unit, the electronic control system checks the amplitude of the signal supplied by the receiver.
Displays MID12
MID11
Monitoring occurs at the following press angles: ZID
EAK 1
DNK
ESK
SVM
REK2
Legend:
Data line Control lines
Block diagram of double-sheet detector
DSK
–
336 _ (SM102),
–
313_ (CD102).
If the light does not pass through the paper at this point, there are two or more sheets. The signal reaches the processor board REK2 via –
the distribution box 1 LVT1,
–
the input / output board EAK,
–
the input / output control board ESK.
The REK 2 analyzes the signals from the doublesheet detector. If there is a double-sheet, REK 2 stops the feeder. The electronic control system reduces the press speed to 3 000 i.p.h. Simultaneously, REK 2 transmits a fault message to the control console display ZID and the press displays MID.
231
Sheet alignment
1B11 Double-sheet detector
Fault messages in the case of a double-sheet Press display MID The fault symbol # appears under the pictogram for double-sheet.
MID after detection of a double-sheet Selection
Control console display ZID Selection of the display ”Entire press” (production run display).
Symbol ”Double-sheet detector”
The symbol ”Double-sheet detector” appears if the sensor 1B65 or 1B66 detects a double-sheet.
Selection and symbol Selection
Symbol ”Electronic double-sheet detector”
Selection and symbol
232
Selection of the display ”Feeder / warning”
The symbol ”Electronic double-sheet detector” appears if the sensor 1B65 or 1B66 detects a double-sheet.
Sheet alignment
1B11 Double-sheet detector
Place of installation The control device of the double-sheet detector is fitted near the signal conversion modules at the sheet alignment system.
Control device
Control device of double-sheet detector The sensor is fitted on the press centreline in the area of the front lays.
Sensor of double-sheet detector
Sensor of double-sheet detector
233
Sheet alignment
1B11 Double-sheet detector
Layout
Components of double-sheet detector
Control device of double-sheet detector DBE with operator’s controls 1 B11 S Transmitter with connecting cable and fixing bracket
Cable to distribution box 1LVT1 at PU 1. It comprises: the power supply for the control device DBE (+ 24 V)
–
the signal line from the control device DBE to the electronics.
234
The LED lights up as soon as there are two or more sheets. Selector switch for adjustment of paper thickness
1 B11 E Receiver with connecting cable and fastening element
–
Potentiometer for adjustment of sensitivity
Paper thick
Control device off
Paper thin
Sheet alignment
1B11 Double-sheet detector
Connection and pin assignment
1LVT1 at PU1
X1
X2
Control device
1B11 Transmitter
X3 1B11 Receiver
Connection principle Pin assignment of connector X1: Contact no. on X 1
Function
Core identification
Terminal in LVT
1
Ground 24 V
–1
X2: – 1
2 3 4 5
+24 V – Signal
+1 – XE 11
X2: + 1 –
–
–
FEM 64 XE 11 –
235
Sheet alignment
1B11 Double-sheet detector
Removal and installation The transmitter and receiver are each screwed to the fastening elements with one screw. Each fastening element is held in place by two screws. The distance between transmitter and receiver must be between 8 mm – 12 mm.
Note: The upper edge of the receiver 1 B11 E must be flush with the table edge. The transmitter and receiver must be in perfect alignment, i.e. arranged on the same centreline. The control device is screwed to the fixing bracket with 3 screws. The fixing bracket is screwed to the press with two screws.
Components of double-sheet detector
236
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
Sheet alignment
1B11 Double-sheet detector
Adjustment The adjustment must be carried out:
Attention:
–
each time the printing material changes,
–
if printed sheets are printed on again.
Prerequisite for adjustment:
1 2
3
4
–
press ready to run,
–
paper run possible.
Check the distance between the transmitter and receiver: required distance 8 – 12 mm. The receiver does not jut out from the table edge. Position the press to a press angle of 281 ± 1 degrees (CD102) or 304 ± 1 degrees (SM102) and place a sheet of maximum width against the front lays and pull lay stop. Set the selector switch for paper thickness 0 to and turn the potentiometer anticlockwise to the stop. The LED is lit. Turn the potentiometer slowly clockwise and watch the LED :
if..
.. LED
5
goes off:
Continue turning the potentiometer clockwise for another 10 scale marks. Continue with
8.
.. LED
5 6 7
8
does not go off:
Set the selector switch 0 to and turn the potentiometer anticlockwise to the stop. Turn the potentiometer clockwise until the LED goes off. Continue turning the potentiometer clockwise for another 10 scale marks.
Check the functioning of the double-sheet detector with a simulated double-sheet.
237
Sheet alignment
11M3 Automatic sheet arrival control
11M3 Automatic sheet arrival control possible sheet arrival BAK optimum sheet arrival 285_ 222_ 192_ 200_ 170_
330_ SM74 336_ SM102 336_ SM102 with Preset 313_ CD102 313_ CD102 with Preset
303_ 238_ 208_ 216_ 186_
The automatic sheet arrival control influences the transport of the sheets to the front lays. It regulates the shingle stream in such a way that the individual sheets are positioned against the front lays at a certain press angle (see illustration). By means of a servo-drive (11M3) the drive chain of the feeder is adjusted. Thus the point of time of sheet arrival is controlled.
Point of time of sheet arrival Sheet alignment control D.S.
O.S.
1B13
1B49
Displays MID11
ZID MID12
RL12
DNK DSK
RL12
1LVT1
EAK
ESK
SSK
SAK
SVM
REK2
1SSM1 11M3
M Automatic sheet arrival control
Legend:
Data lines Control lines
Block diagram of automatic sheet arrival control
238
The ANK sensors (1B13/1B49) register when the sheets arrive at the front lays. On the basis of the ANK signals the computer on the processor board REK2 determines the point of time of sheet arrival. If there is a deviation from the optimum sheet arrival, the shingle stream at the feeder must be regulated. REK2 passes the new reference values for sheet arrival to the servo-drive control board SSK. The SSK controls the servo-drive 11M3. If the automatic sheet arrival control reaches the end of its control range in the process, the symbol ”End of positioning range” appears on the press displays MID and on the control console display ZID (production run display). The press control is not affected by this.
Sheet alignment
11M3 Automatic sheet arrival control
The symbol ”End of positioning range” will, however, only disappear when the operator repositions the servo-drive manually. This can be done at the control console by means of the ”Sheet arrival control” function.
”End of positioning range” displayed on the press display MID
Activating and inactivating the automatic sheet arrival control
Selecting the automatic sheet arrival control
Symbol ”Automatic sheet arrival control on / off”
Inactivating and activating the automatic sheet arrival control: –
in the preselection display,
–
by means of the function button.
If the symbol is lit, the automatic sheet arrival control is active.
Preselection/coarse display
Sheet arrival control The sheet arrival control is automatically activated when the operator switches off the automatic sheet arrival control. Symbol of the sheet arrival control in the ... actual value / coarse display
For the sheet arrival control the operator enters a fixed value. The setting is made at the control console by means of the right-hand +/–buttons. Press model
actual value / fine display SM102 CD102 SM74
Setting range Standard Preset version version –2 to +18 –10 to +10 –10 to +10 –4 to +16
239
Sheet alignment
11M3 Automatic sheet arrival control
Graphical representation of sheet arrival The graphical representation of sheet arrival is only visible during paper run.
Selecting the fine display Deviation from optimum sheet arrival D.S. Mean value of the two deviations Deviation from optimum sheet arrival O.S.
Note: The display is updated with a delay. Actual value/fine display The misaligned-sheet display on the MID gives the operator information about sheet arrival. Optimum sheet arrival Sheet arrives at the front lays before the optimum sheet arrival
Misaligned-sheet display
240
Sheet arrives at the front lays after the optimum sheet arrival
Sheet alignment
11M3 Automatic sheet arrival control (standard version)
11M3 Automatic sheet arrival control (standard version) Place of installation
ÁÁÁ ÁÁÁ
Printing unit 1 and feeder
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 X13
X4
X14
11
Backplane of servo-drive plug-in unit SSR
11
11LVT1
1SSM2: X1
1SSM2: X2 X1 X3
X2
1SSM2
Servo-drive distributor module 1SSM2
11M3: X1
3
4 5
2
1
11M3
Servo-drive 11M3
+ – 10V 0V
242
Pin 1 Pin 2 Pin 3 Pin 4
X5: A1 X5: A2 X5: A3 X5: A4
X1: X1: X3: X3:
Pin 5
X5: A5
X3: 5
1 2 3 4
X10: B2 X10: D2 X11: 3 X11: 4 X11: 5
Motor + Motor – 10V Tap
Sheet alignment
11M3 Automatic sheet arrival control (standard version)
Removal and installation
1
2 1 0
1
2 2 1
3
4 1
1
3 1
2
2
243
Sheet alignment
5
11M3 Automatic sheet arrival control (standard version)
6 2
1 – 2 mm
1
7
8 1
3 1
2
22 5 4
244
0
1
Sheet alignment
11M3 Automatic sheet arrival control (standard version)
9
10
11
12
245
Sheet alignment
11M3 Automatic sheet arrival control (standard version)
13
Checking the operating range
Servo-drive ”Automatic sheet arrival control” 11M3 Input + 18 –2
Service display ”Values, incremental values servo-drives”
246
Incremental value 3134 " 4 inc 963 " 4 inc
Sheet alignment
11M3 Automatic sheet arrival control (Preset version)
11M3 Automatic sheet arrival control (Preset version) Place of installation
11M3
Operator side
Technical data Motor data –
U
=
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 X13
X4
X14
Backplane of servodrive plug-in unit SSR
11 11LVT1 1SSM1: X1 X3 X4
1SSM1: X3
X2 X1
X5
1SSM1
Servo-drive distributor module 1SSM1
3
11M3: X1
4 5
2
1
11M3
Servo-drive 11M3
+ – 10V 0V
248
Pin 1 Pin 2 Pin 3 Pin 4
X5: A1 X5: A2 X5: A3 X5: A4
X1: X1: X3: X3:
Pin 5
X5: A5
X3: 5
1 2 3 4
X10: B2 X10: D2 X11: 3 X11: 4 X11: 5
Sheet alignment
11M3 Automatic sheet arrival control (Preset version)
Removal and installation
1
2
–
Remove the servo-drive ”Automatic sheet arrival control” 11M3.
– –
2.0 mm (approx. 1 rev.)
Turn the mechanism against the upper stop. Set the distance ( 2.0 mm ).
3
01
3891 ± 2 11M3: X1
– – –
Fasten the servo-drive to the mounting plate. Insert plug 11M3: X1. Set to 3891"2 inc. 249
Sheet alignment
11M3 Automatic sheet arrival control (Preset version)
4
–
Install the servo-drive.
Checking the operating range
Servo-drive ”Automatic sheet arrival control” 11M3 Input + 10 – 10
Service display ”Values, incremental values servo-drives”
250
Incremental value 205 " 4 inc 3891 " 4 inc
Sheet alignment
11M7 Automatic misalignment control
11M7 Automatic misalignment control Sheet alignment control D.S.
O.S.
1B13
1B49
Displays MID11
ZID
The automatic misalignment control influences the position of the sheets in such a way that they arrive parallel to the front lays. Automatic control is effected through:
MID12 RL12
DNK DSK
RL12
–
the servo-drive 11M7,
–
the guide rail (D.S.) of the forwarding suckers at the suction head.
The misalignment is registered: –
1LVT1
by the ANK sensors on the D.S. and O.S.
The deviation between the registered values is an indication of the misalignment of the sheets in relation to the front lays (not to the feed table). EAK
SSK
ESK
SVM
SAK
If the misalignment exceeds three degrees, the automatic control compensates for the deviation. The automatic misalignment control does not intervene in press control.
REK2
1SSM1 11M7
M Automatic misalignment control
Legend:
Data lines Control lines
Block diagram of automatic misalignment control Position of guide rail D.S. at suction head
Position of sheet Front lays O.S.
The graphical representation on the left shows the mechanical principle of the misalignment correction.
D.S.
Principle of the misalignment correction 251
Sheet alignment
11M7 Automatic misalignment control
Activating and inactivating the automatic misalignment control
Selecting the automatic misalignment control
Symbol ”Automatic misalignment control on / off”
Inactivating and activating the automatic misalignĆ ment control: –
in the preselection display,
–
by means of the function button.
If the symbol is lit, the automatic misalignment control is active.
Misalignment control The misalignment control is automatically activated when the operator switches off the automatic misalignment control. Symbol of the misalignment control in the ... actual value/coarse display actual value/fine display
252
For the misalignment control the operator enters a fixed value. The setting is made at the control console by means of the right-hand +/– buttons. Setting range Press model SM102 CD102
–10 to +10 –10 to +10
Sheet alignment
11M7 Automatic misalignment control
Graphical representation of sheet arrival
Selecting the fine display The graphical representation of sheet arrival also gives the operator information about the misalignment of the sheets during paper run. Deviation from optimum sheet arrival D.S. Mean value of the two deviations Deviation from optimum sheet arrival O.S.
Actual value/fine display Note: The display is updated with a delay.
During paper run or production run, the misalignedsheet display appears in the MID. This display changes permanently and is a trend indication for the operator. Good sheet optimum sheet arrival Misaligned sheet, D.S. advanced Display of misalignment up to max. 18°
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
X13
X4
X14
SSR X13
Backplane of servodrive plug-in unit SSR
11 11LVT1 2SSM1: X1 X3 X4
2SSM1: X3
X2 X1
X5
2SSM1
Servo-drive distributor module 2SSM1
11M7: X1
3
4 5
2
1
11M7
Servo-drive 11M7
+ – 10V 0V
Pin 1 Pin 2 Pin 3 Pin 4
X5: A1 X5: A2 X5: A3 X5: A4
X1: X1: X3: X3:
Pin 5
X5: A5
X3: 5
1 2 3 4
X10: X10: X13: X13:
B10 D10 3 4
X13: 5
255
Sheet alignment
11M7 Automatic misalignment control
Removal and installation
1
2
O.S. D.S.
O.S.
D.S.
Guide rails –
Remove the servo-drive ”Automatic misalignment control” 11M7.
–
Position the guide rails of the forwarding suckers parallel to each other.
3 4)
05
2048 ± 2
11M7: X1 – – 256
Insert plug 11M7: X1. Set to 2048 ±2 inc.
Sheet alignment
11M7 Automatic misalignment control
4
–
Install the servo-drive.
Checking the operating range
Servo-drive ”Automatic misalignment control” 11M7 Input
Incremental value
–10
1434 " 2 inc
+10
2662 " 2 inc
Service display ”Values, incremental values servo-drives”
257
Sheet alignment
258
11M7 Automatic misalignment control
Sheet monitoring
1...nB48/1...nB48a Sheet travel monitor
Sheet monitoring 1...nB48/1...nB48a Sheet travel monitor The sheet travel monitor Paper run Reflex sensor 1...9B48
Paper
Control switch 1...9B48a
–
monitors the paper run,
–
is fitted in each printing unit,
–
consists of: the reflex sensor 1...9B48, the control switch 1...9B48a, the segment disk for the control switch.
Segment disk Impression cylinder
LED
The reflex sensor detects the front edge of the paper at the impression cylinder. The control switch and the segment disk determine the point of time of the interrogation. The signals from the reflex sensor and control switch are combined in the reflex sensor and transmitted to the control system.
Irregularity in paper run No paper
Signals during paper run (see illustration): –
The segment disk is within the operating range of control switch 1...9B48a.
–
At the same time, the reflex sensor 1...9B48 detects the front edge of the paper.
–
The LED on the reflex sensor 1...9B48 is lit.
–
No signal to the control system.
LED
1 LVT1
Signals in the case of irregularities in the paper run (see illustration):
Displays MID12
MID11
ZID
EAK 1 DNK
ESK
SVM
–
The segment disk is within the operating range of control switch 1...9B48a.
–
At the same time, the reflex sensor 1...9B48 does not detect paper.
–
The LED on the reflex sensor 1...9B48 is not lit.
–
Signal to control system.
–
REK2 intervenes in press control.
DSK
REK2
Legend:
Data line Control lines
Block diagram of sheet travel monitor 259
Sheet monitoring
1...nB48/1...nB48a Sheet travel monitor
The electronic control system analyzes the signals from the reflex sensor as long as there is paper in the press. Via the input/output board EAK of the corresponding printing unit and the input/output control board ESK the signals are transmitted to the processor board REK2. In the case of a fault, REK2 intervenes in press control and triggers various processes: –
press and feeder stop,
–
dampening systems and inking units are thrown off,
–
impression throw-off,
–
display of fault at printing unit, in press displays MID and control console display ZID.
In the MID, the position code of the corresponding printing unit appears under the fault symbol.
Fault display in MID Fault display in production run display (ZID) Symbol ”Blanket control detects paper” (fault display in ZID)
In the ZID (production run display), the fault symbol appears with the corresponding position code. Simultaneously, the symbol ”Blanket control detects paper” appears in the fault display. The fault can be acknowledged and deleted by pressing the button allocated to the symbol. The fault is eliminated: –
after removing the sheet from the base or
–
after removing the piece of sheet from the blanket and
–
after lifting the guard ”Plate cylinder”.
The electronic control system allows the press to continue running.
260
Sheet monitoring
1...nB48/1...nB48a Sheet travel monitor
Service display To check the input 48, select the service display ”Present input/output” (e.g. EAK2_02) of the corresponding printing unit. Buttons to be pressed for this selection:
1)
Service display ”EAK2_02” of PU2
2)
3)
4)
Circuit state of input 48: 1 = reflex sensor detects paper, no signal to the control system. 0 = reflex sensor does not detect paper, signal to control system.
Input 48 (sheet travel monitor 1...9B48)
261
Sheet monitoring
1...nB48/1...nB48a Sheet travel monitor
Place of installation 1...nB48 (middle of press)
1...nB48a (operator side)
Impression cylinder in printing unit
Speedmaster CD –operator side–
262
Sheet monitoring
1...nB48/1...nB48a Sheet travel monitor
Components Reflex sensor 1...nB48
Reflex sensor 1...nB48 detects does not paper detect paper 24V (LED lit)
LED
0V (LED not lit)
ca. 24V 3
2
4
1 0V
Reflex sensor Control switch 1...nB48a
Control switch
Adjustment Adjustment of reflex sensor 1...nB48
1
4
+
7
9
Adjustment of control switch 1...nB48a
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.
4
3
1.0_ LED LED LED
–
Turn the impression cylinder in the direction of printing (see arrow) so that the LED just lights up (reflex sensor detects cylinder surface).
5
–
Turn the impression cylinder back by 1.0° (see arrow). The LED is not lit.
–
6
1...nB48a 1...nLVT1 – –
264
Remove control switch 1...nB48a. Withdraw the plug from 1...nB48.
–
Fit the control switch and connect it with the reflex sensor (see circuit diagram).
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. Pay attention to both segments.
–
9
–
Select the service display ”Present input/ output” of the corresponding printing unit.
Direction of printing
2) 1
1) – – – –
Loosen the segment disk. Turn the segment disk in the direction of printing until input 48 changes from ”1” to ”0”. Fasten the segment disk. Check the adjustment.
265
Sheet monitoring
266
1...nB48/1...nB48a Sheet travel monitor
Plate clamping device
Autoplate
Plate clamping device Autoplate Method of functioning The main components of Autoplate are: – a modified plate cylinder with air supply and two pneumatic bars to open the front and rear clamping bars, –
a pressing bar which is brought into contact with the plate cylinder by two cylinders,
–
two position switches which monitor the position of the pressing bar,
–
four pneumatic valves which actuate the pneumatic bars, the two cylinders of the pressing bar and the control air for the air supply.
For actuation of the cylinders an operating pressure of approx. 6 bars is required. This pressure is generated by the pneumatic system compressor E4 and is kept at a constant level by the maintenance unit. The compressor is switched on after ”Main switch on”.
1
2
S
Control panel
Pressing bar
Operator side of printing unit
Air supply, connections: S – ”Control air, air supply” 1 – ”Opening the rear clamping bar” 2 – ”Opening the front clamping bar”
Position switch ”Finger guard 2”: n S 25 a – ”Monitoring the pressing bar D.S.” n S 25 b – ”Monitoring the pressing bar O.S.” Pneumatic n Y7 – n Y 61 – n Y 62 – n Y 63 –
valves from top to bottom: ”Pressing bar on / off” ”Control air, air supply” ”Opening the front clamping bar” ”Opening the rear clamping bar”
Note: Before the rear or front clamping bar is opened, control air must be admitted to the air supply facility in the plate cylinder. For this purpose, the plate cylinder must be at standstill; otherwise the gaskets could become subject to abrasion. This, in turn, could cause unintentional venting of the control line. Then the rear and front clamping bars cannot be opened anymore. 267
Plate clamping device
Autoplate
Fault display
Button sequence
Malfunctions in 2nd printing unit
268
The pressing bar and / or the upper finger protecting bar was actuated. The following position switches can be actuated: – ”Monitoring the pressing bar” n S 25 a (drive side) n S 25 b (operator side), – Monitoring finger guard 2” n S 25 (operator side).
Plate clamping device
Autoplate
Block diagram n Y7
E4
n S4
EAK15
EAKn
REK1
n Y 62
n Y 61
n S17
n S59 n H59
n Y 63
n S 25a / n S 25b
SEK
ESK
Legend: Parallel data line
DSK
REK2 Serial data line
DNK ZID
SAK
Control line Pneumatic line
Electronic control system
Block diagram Autoplate E4
– Pneumatic system compressor
n Y7
– Pneumatic valve ”Pressing bar on / off”
n Y61
– Pneumatic valve ”Control air, air supply”
n Y62
– Pneumatic valve ”Opening the front clamping bar”
n Y63
– Pneumatic valve ”Opening the rear clamping bar”
n S4
– Selector switch ”Safe”
n S17
– Pushbutton ”Position”
n S59 / n H59 – Illuminated pushbutton ”Plate clamping” n S25 a / b
– Position switch ”Monitoring the pressing bar D.S./O.S.” 269
Plate clamping device
Autoplate
Sequence of functions The indicated press angles are valid for printing unit 1. From unit to unit these values differ as follows: Speedmaster SM 102 – 74.57_ , Speedmaster CD 102 – 197.28 _.
Condition: The plate cylinder will only turn to the correct position for plate clamping/unclamping, if the coarse register is set to zero or if the coarse register sensor n B53 has acquired the current press angle (see also chapter ”Coarse register monitoring”).
Positioning the plate cylinder
Plate removal
Unclamping the rear edge of the plate
Unclamping / clamping the front edge of the plate
Plate insertion
Clamping the rear edge of the plate
Actuation of operator’s controls:
”Opening the rear clamping bar” n Y63 actuated
0.3 s
0.3 s
2.0 s 0.3 s
”Opening the front clamping bar” n Y62 actuated
1.0 s
2.0 s ”Air supply control air” n Y61 actuated
0.5 s
2.0 s
Enabling main motor
0.5 s Enabling main motor
Enabling main motor
0.5 s 1.8 s ”Pressing bar on / off” n Y7 actuated Press angle
270
264.8 _
322.6 _
297.5 _
0.5 s
Plate clamping device
1...nB53 ”Coarse register monitoring”
1...nB53 ”Coarse register monitoring” Place of installation
B53
The sensor ”Coarse register monitoring” B53 is fitted in each printing unit. It is located behind the servo-drive of the circumferential register where it is screwed to a fixing angle.
Place of installation of sensor ”Coarse register monitoring”
Layout/connection
Sensor Locking nut Connecting cable
Core
Function
brown
DC 24V
blue
ground 24V
black
output signal
Layout of sensor ”Coarse register monitoring 1...nB53”
271
Plate clamping device
1...nB53 ”Coarse register monitoring”
Task/function
Sensor and positioning bolt
Positioning bolt Sensor B53
The inductive sensor 1...nB53 registers the manual coarse adjustment of the circumferential register. After each coarse adjustment of the circumferential register, the operator must turn the press at crawl speed for at least one full revolution. Only then can the sensor register the adjustment and pass the corresponding adjustment value on to the press control system. While the press turns at crawl speed, the sensor sees the positioning bolt rotating past it. The zero position of the plate cylinder serves as a reference point for the sensor. If the sensor detects a deviation from the reference point with the help of the positioning pin, the value is passed on to the press control system. The deviation corresponds to the coarse adjustment of the register. The press control system determines the press angle on the basis of the adjustment value. Thus exact positioning of the plate cylinder is possible again (e.g. important for the function ”Autoplate”).
Note: To ensure that the sensor recognizes the manual coarse adjustment of the register, the press must turn at crawl speed for min. 1 revolution after every adjustment.
Removal and installation
1.0 mm ± 0.5 mm
Positioning bolt Sensor B53
The sensor must be installed in such a way that there is a distance of 1 mm ± 0.5 mm between the positioning bolt and the sensor. Tighten the sensor with the locking nut and carry out the ”Adjustment” (see next page).
Fitting the sensor ”
272
Plate clamping device
1...nB53 ”Coarse register monitoring”
Adjustment Note: The adjustment is necessary after every: – – – – –
1
2
installation and removal of the sensor, exchange of the software, exchange of the processor boards REK 1 / 2 and of the display control board DSK, basic initialization of REK 1 / 2 and DSK, first start-up. Set the circumferential register on all printing units manually to ”0”. Insert the positioning bolt at 52 mm . Also refer to the operating manual, chapter C Printing unit, circumferential register ”Setting to zero” .
Set the circumferential register to zero on CPC 1-04 (precision setting). Also refer to the operating manual for CPC 1-04.
3
Set perfector presses to straight printing.
4
Turn the press at crawl speed.
5
6
Select the function ”Coarse register adjustment value” for each printing unit at the control console (”Service display”, ”Printing unit”). The corresponding symbol lights up. The symbol cannot be deactivated anymore. The operator guidance disappears. The reference-point run starts. After the zero position of the coarse register has been detected by the sensor, the function becomes inactive. The sensor has determined the zero position and has passed it on to the press control system.
273
Plate clamping device
274
1...nB53 ”Coarse register monitoring”
Washup devices
Control by command ”Washup”
Washup devices Control by command ”Washup” Selection of functions Command ”Washup”
Actual value display
Service display
Printing unit selection
Printing unit selection
The command ”Washup” can be aborted any time with the button ”Delete”.
Input
Only with start-up warning
Control by command ”Washup” 275
Washup devices
Messages
Messages Faults at print start and during printing
Messages
Press not ready to run
Fault in the press. Washing cannot be carried out.
Note: Terminate the command ”Washup” with the button ”Delete”. To locate the fault select ”Entire press” and the fault display.
Paper in the press
On command initiation there is still paper in the press. Washing can only be carried out when the paper has been transported out of the printing units into the delivery.
Dryer waiting time
– Only applies to presses with UV dryer – The blanket and inking rollers may only be washed 180 s after the last drying. If the command is enabled earlier, the symbol will light up and the remaining waiting time will be indicated. The washup programme only starts after the waiting time.
276
Washup devices
Not enough water
Messages
Not enough water in the washup solution container E9: -
Not enough washup solution
Not enough washup solution in the washup solution container E9: -
Inking roller washup device monitoring of ink blade
Sensor B1 "Monitoring water" (blanket / inking roller washup device).
Sensor B54 "Monitoring washup solution, blanket washup device". Sensor B55 "Monitoring washup solution, inking roller washup device”.
In the displayed printing unit the ink blade is not fitted. The sensor nB43 is not damped.
277
Washup devices
Service display ”Washup”
Service display ”Washup” Functions of the blanket washup device GTW Button sequence
With the help of the ”Service display”, spray procedures with water and washup solution can be initiated. Apart from this, the washup blades can be thrown on/off. All functions can be activated during standstill of the press or during ”Run”. The functions can be activated either printing unit by printing unit or for all units simultaneously. The corresponding solenoid valves are then actuated in the printing units.
Functions of the washup devices Spraying with water
Solenoid valve 1...nY54 actuated.
Spraying with washup solution
Solenoid valves 1...nY52 and 1...nY55 actuated.
Washup blade on/off
Solenoid valve 1...nY53 actuated.
Functions of the impression cylinder washup device DZW Spraying with water
Solenoid valve 1...nY43 actuated. The washup brush motors M43, M50...M56 start up.
Spraying with washup solution
Solenoid valve 1...nY42 actuated. The washup brush motors M43, M50...M56 start up.
278
Washup devices
Service display ”Washup”
Functions of the inking roller washup device FWW Button sequence
With the help of the ”Service display”, spray procedures with water and washup solution can be initiated. Apart from this, the ink blades can be thrown on/off. All functions can be activated during standstill of the press or during ”Run”. The functions can be activated either printing unit by printing unit or for all units simultaneously. The corresponding solenoid valves are then actuated in the printing units.
Functions of the washup devices Spraying with water
Solenoid valve 1...nY44 actuated.
Spraying with washup solution
Solenoid valve 1...nY50 actuated.
Ink blade on/off
Solenoid valve 1...nY51 actuated.
279
Washup devices
Service display ”Washup”
Selecting the washup solution Button sequence
If you press the button ”Entire press” in the ”Service display”, you can choose between washing with mineral oil-based and vegetable oil-based washup solution. After a change, the parameters will be reset to default values.
Choosing between mineral oil-based and vegetable oil-based washup solution
Selectable functions Washing the blanket Washing the inking rollers Washing the impression cylinder
280
Mineral oil-based solution
Vegetable oil-based solution
Washup devices
Blanket washup device (GTW)
Blanket washup device (GTW) Block diagram
1...nY54
1...nY52
1...nY55
1...nY53
1...nY56
E4
E9
EAK Parallel data line Serial data line DSK
REK2
ESK
Control line Washup solution or water conduit
DNK2 Pneumatic line ZID
Block diagram ”Washing the blanket” E4
Pneumatic system compressor
Y55
Blanket, washup brush
E9
Washup solution container
Y56
Blanket, driving clutch
Y52
Blanket, washup solution
Y53
Blanket, washup blade
Y54
Blanket, water
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)
After the spray procedures with washup solution spraying with water occurs (nY54). The blade is in permanent contact with the wiper roller. The ink removed by the blade is collected in the ink trough and passed to a reservoir from there. Such a reservoir is provided on the drive side of each printing unit. After washing of the blanket, the press stays in operation (3000 i.p.h.).
283
Washup devices
Blanket washup device (GTW)
Setting the number of cylinder revolutions and spray procedures for water and washup solution Button sequence
The first actuation of the function button allocates the corresponding device to the right-hand and left-hand +/– buttons. After the allocation, the parameters can be changed with the +/– buttons. Pressing the function button again inactivates the device again.
Blanket washup device selected Changeover between settings for water (top) and for washup solution (bottom) with the 1st function button (above the left-hand +/– buttons). Enter the number of cylinder revolutions with the left-hand + / – buttons. – water from 0 to 50 – washup solution from 0 to 150. Enter the number of spray procedures with the right-hand +/– buttons. The setting range for the spray procedures goes from 10% to 100%. – 10% = 1 spray procedure. – 100% = 10 spray procedures.
284
Washup devices
Blanket washup device (GTW)
Example Setting for water: ¢ 10 cylinder revolutions ¢ 3 spray procedures
10 30%
Setting for washup solution: ¢ 40 cylinder revolutions ¢ 3 spray procedures
40 30%
Flow chart: ”Washing with washup solution and water” 1.2 s
Water (nY54) 0.7 s (0.3 s if vegetableĆbased)
Washup solution (nY52) 0.3 s
Blanket washup brush (nY55) Blanket driving clutch (nY6) Blanket washup blade (nY53) Revolutions
0 4
40
99
104 102
Flow chart: ”Washing with washup solution and water”
285
Washup devices
Inking roller washup device (FWW)
Inking roller washup device (FWW) Block diagram
1...nY44
1...nY50
1...nY9
1...nY10
1...nY11
1...nY51
E4
E9
EAK Parallel data line Serial data line DSK
REK2
ESK
Control line Washup solution or water conduit
DNK2
Pneumatic line
ZID
Block diagram ”Washing the inking rollers” E4
Pneumatic system compressor
Y44
Inking rollers, water
E9
Washup solution container
Y50
Inking rollers, washup solution
Y9
Inking form rollers
Y51
Ink blade
Y10
Ink ductor
Y11
Dampening rollers
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
The first actuation of the function button allocates the corresponding device to the right-hand and left-hand +/– buttons. After the allocation the parameters can be changed with the +/– buttons. Pressing the function button again inactivates the device again.
Changeover between settings for water (top) and for washup solution (bottom) with the 1st function button (above the left-hand +/– buttons). Enter the number of cylinder revolutions with the left-hand + / – buttons. Water: 0 ... 500 Washup solution: 150 ... 1000; if the ink fountain roller is washed in addition: 225 ... 1500. Enter the number of spray procedures with the right-hand + / – buttons. Setting possible from 0% ... 100%.
Setting 100% 90% 80% 70% 60% 50% L 0%
1 spray procedure every ... 16 20 24 28 32 36 L 56
revolutions
The first spray procedure lasts 0.8 s, the others 0.4 s.
288
Washup devices
Inking roller washup device (FWW)
Additional washing of printing plate and ink fountain roller Additional washing of printing plate Additional washing of ink fountain roller
Condition: Before selecting the function ”Additional washing of ink fountain roller”, remove the ink from the ink fountain and carry out an ink shut-off at CPC 1-04. The printing plate and ink fountain roller can be washed in addition via the inking roller washup device. The inputs are valid for the selected printing units.
Example Setting for water: 50 70%
¢ 50 cylinder revolutions ¢ one spray procedure every 28 revolutions
Setting for washup solution: 225 70%
¢ 225 cylinder revolutions ¢ one spray procedure every 28 revolutions
289
Washup devices
Inking roller washup device (FWW)
Flow chart: ”Washing with mineral oil-based washup solution without water” If printing plate is washed as well
Dampening rollers (n Y11) Inking form rollers (n Y9)
80% of preselected cylinder revolutions if printing plate is washed as well
Ink ductor (n Y10) Ink blade (n Y51)
66% of preselected cylinder revolutions if printing plate is washed as well
Water (nY44) Washup solution (n Y50) Revolutions
0.4 s 0.2 s
20
0.2 s
20
x
x
40
x
Preset spray procedures washup solution
Preselected cylinder revolutions washup solution
Flow chart: ”Washing with mineral oil-based washup solution without water”
Flow chart: ”Washing with mineral oil-based washup solution and water” Dampening rollers (n Y11) Inking form rollers (n Y9) Ink ductor (n Y10)
as 1st section above (without water)
Ink blade (n Y51) Water (nY44) Washup solution (n Y50)
0.4 s
0.4 s
0.2 s
x1
Revolutions
Preset spray procedures washup solution
Preselected cylinder revolutions washup solution
x2
x2
Preset spray procedures water
40
Preselected cylinder revolutions water
Flow chart: ”Washing with mineral oil-based washup solution and water” 290
30
20
30 20
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) Ink blade (nāYā51)
66% of preselected cylinder revolutions if printing plate is washed as well
Water (nY44) Washup solution (nāYā50) Revolutions
0.4 s
8 0.4 s
0.2 s
0.4 s
0.2 s
x1
x1
x1
x1
Preset spray procedures washup solution
Preselected cylinder revolutions washup solution
x2
x2
80
30 20
Preset spray procedures water
Preselected cylinder revolutions water
Flow chart: ”Washing with vegetable oil-based washup solution and water”
291
Washup devices
Impression cylinder washup device (DZW)
Impression cylinder washup device (DZW) Block diagram
1...nY43
1...nY42
1...nY41
M
M50 ... M56, M43
E4
E9
EAK Parallel data line Serial data line DSK
REK2
ESK
Control line Washup solution or water conduit
DNK2
Pneumatic line
ZID
Block diagram ”Washing the impression cylinder” E4
Pneumatic system compressor
1...nY41
Impression cylinder, washup brush
E9
Washup solution container
1...nY42
Impression cylinder, washup solution
1...nY43
Impression cylinder, water
M50 ... M56, M43 Washup brush motors
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
Impression cylinder washup device
Function Each printing unit has a washup brush which is connected with the washup brush motor via gears. The motor is located in the middle of the printing unit, under the impression cylinder. When the command has been enabled and the washup speed of 5000 i.p.h. has been reached, the following functions are initiated: –
starting up the washup brush motors M50 ... M56, M43
–
throwing on the washup brushes (1...nY41)
–
opening the spray tubes for washup solution (1...nY42)
–
opening the spray tubes for water (1...nY43).
The washup solution and water for the impression cylinder washup device come from the washup solution container E9 which also supplies the blanket washup device. After washing, the press stays in operation (3000 i.p.h.).
293
Washup devices
Impression cylinder washup device (DZW)
Setting the number of cylinder revolutions and the spray duration for water and washup solution Button sequence
The first actuation of the function button allocates the corresponding device to the right-hand and left-hand +/– buttons. After the allocation the parameters can be changed with the +/– buttons. Pressing the function button again inactivates the device again.
Impression cylinder washup device selected
Changeover between settings for water (top) and for washup solution (bottom) with the 1st function button (above the left-hand +/– buttons). Enter the number of cylinder revolutions for water and washup solution with the left-hand +/– buttons: –
Water:
0 and 30
–
Washup solution:
0, 50 and 100
Enter the spray duration for water and washup solution with the right-hand +/– buttons: Setting range from 0 to 100%. Dependent on the setting, the basic pulse duration for washup solution and water is shortened or lengthened.
Setting 0% 10% L 50% L 90% 100%
294
Change in basic pulse duration – 0.5 s – 0.4 s L 0 L + 0.4 s + 0.5 s
Washup devices
Impression cylinder washup device (DZW)
Example Setting for water: 0 50%
¢ 0 cylinder revolutions ¢ basic spray duration +/– 0 s
Setting for washup solution: 50 50%
¢ 50 cylinder revolutions ¢ spray duration 0 s
Flow chart: ”Washing with washup solution and water”
Washup brush motor (M43, M50...M56) Impression cylinder washup brush (n Y41)
3.0 s+/–x
Spray duration
2.0 s+/–x
1.0 s+/–x
Water (nY43) 2.0 s+/–x
0.7s+/–x
0.7 s+/–x
0.5 s+/–x
1,0 s
Washup solution (n Y42)
0.5 s
25
25
25
Revolutions Preselected cylinder revolutions washup solution
25
15
15
30
Preselected cylinder revolutions water
Flow chart: ”Washing with washup solution and water”
295
Washup devices
M43, M50...M56 Washup brush motors
M43, M50 ... M56 Washup brush motors Place of installation The washup brush motors are located in the middle of each printing unit, below the impression cylinder. They are accessible through the lower opening in the side frame on the O.S. These washup brush motors are only available for CD102.
Washup brush motor in printing unit
Pin assignment Pin
A B C 1
Function
A2
AC 400 / 480 V phase U
B3
AC 400 / 480 V phase V
C2
AC 400 / 480 V phase W
2 3 4 5
Plugs M43-X1, M50-X1 ... M56-X1
296
PE conductor
Washup devices
E9 Washup solution container
E9 Washup solution container Block diagram
15K4M
M4
E9
F70 B1
B54
Pressure reducer with check valve Safety valve
15K4M
Contactor, pneumatic system compressor
M4
Pneumatic system compressor
B1
Sensor ”Monitoring water”.
B54
Sensor ”Monitoring washup solution, blanket washup device”
B55
Sensor ”Monitoring washup solution, inking roller washup device”
E9
Washup solution container
F70
Pressure switch
B55
EAK
ESK
REK Pneumatic line Control line Parallel data line
Block diagram: washup solution container E9
297
Washup devices
E9 Washup solution container
Warnings Symbols appear in the following displays if there are malfunctions in connection with the washup solution container: – – –
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”.
Not enough water
Not enough water in the washup solution container E9. Sensor B1 ”Monitoring water”.
Insufficient pressure in the container
At an air pressure x 0.48 bars, pressure switch F 70 responds. In the control console display ZID both symbols appear: ”Not enough washup solution” and ”Not enough water”.
298
Washup devices
E9 Washup solution container
Place of installation
Place of installation of washup solution container E9
Washup solution container E9
The washup solution container is located under the footboard on the O.S. (on presses with up to 5 units at the 2nd unit, with 6 units at the 3rd unit; with 7 or more units one container at the 2nd unit and one at the 6th unit).
Layout Attention:
Only refill the washup solution container with the press switched off or the air supply shut off (stop-cock closed).
Refill opening with cover and sieve Pressure regulator with manometer Three-way stop-cock Solenoid valve Check valve Pressure switch F70 Safety valve Sensor B55 ”Monitoring washup solution, inking roller washup device” Sensor B1 ”Monitoring water” Sensor B54 ”Monitoring washup solution, blanket washup device” Terminal box with terminal strip E9-X1
Washup solution container E9 299
Washup devices
E9 Washup solution container
Task The washup solution container E9 supplies: –
the blanket washup device with water and washup solution,
–
the inking roller washup device with water and washup solution.
In order to deliver water and washup solution, the pressure in the container must be between 0.48 bars and 1.0 bar. The pressure reducer reduces the air pressure from the pneumatic system compressor M4 to 0.5 bars. If the pressure drops below 0.48 bars, the pressure switch F70 responds. A warning appears in the control console display ZID. If the air pressure rises above 1.0 bar, the safety valve opens. The sensors B1, B54 and B55 monitor the liquid levels. If the levels drop below the min. permissible values, a warning appears in the control console display ZID. The initiated washup procedure is completed, but a new washup procedure cannot be started anymore.
Pin assignment E9-X1
3
4 5
2
1
Pin
Function
1 2 3 4
DC 24 V 24 V ”Monitoring water” ”Monitoring washup solution, blanket washup device” ”Monitoring washup solution, inking roller washup device”
5
Plug E9-X1
300
Washup devices
B1, B54, B55 Sensors at the washup solution container
B1, B54, B55 Sensors at the washup solution container Place of installation
B1 Monitoring water B54 Monitoring washup solution, blanket washup device B55 Monitoring washup solution, inking roller washup device
Sensors at washup solution container
Connection Input at EAK : 0 ¢ level too low 1 ¢ level OK
Pin assignment Marking
Colour
Function
X1
white
signal
+1
brown
DC +24 V
301
Washup devices
B1, B54, B55 Sensors at the washup solution container
Removal and installation
Float Sensor Width across flats 27 with marking
All three sensors are of identical design. For removal loosen the thread and unscrew the sensor. For installation introduce the sensor into the threaded hole, position the thread carefully and screw it in. The sensor is sealed up by the tapered thread and the Teflon sealing tape around it. Tighten the sensor with 5 Nm.
Sensor at the washup solution container
Adjustment The mounting position of the sensor determines its switching function. Pay attention to the arrow on the flat face of the screw. Direction of arrow
Mounting position of sensor
302
Function
upward °
NC contact
downward ±
NO contact
Symbol
Washup devices
1...nB43 Monitoring the ink blade
1...nB43 Monitoring the ink blade Place of installation The inductive sensor is located on the inside of the side frame on the O.S. It is fitted in each printing unit at the paper outlet.
Sensor ”Monitoring the ink blade”
Layout
Sensor Nut and locking nut Connecting cable
Sensor ”Monitoring the ink blade” with nut and locking nut
303
Washup devices
1...nB43 Monitoring the ink blade
Task The inductive sensor ”Monitoring the ink blade 1...nB43 monitors the correct installation of the ink blade. When the ink blade is not fitted, automatic washing of the inking rollers is not possible.
Connection Core
Function
brown blue black
DC 24 V ă 24 V signal
Pin assignment Input 43 of EAKn: (n = corresponding printing unit) 0¢ 1¢
ink blade not fitted ink blade fitted
Removal and installation
4.0 mm
Blade Sensor Nut/locking nut Side frame
When fitting the sensor, screw it so far in the holder that the distance between ink blade and sensor is 4.0 mm. Tighten the nut and locking nut.
Installation of sensor Monitoring the ink blade”
304
Inking unit
Servo-drive ink fountain roller
Inking unit Servo-drive ink fountain roller Place of installation The servo-drives for the ink fountain rollers are located on the operator side of the printing units.
D.S.
O.S.
Place of installation of servo-drive for ink fountain roller O.S.
Layout and task The servo-drive for the ink fountain roller is a dc motor with brushes and potentiometer for position feedback. It is used for adjustment of the ink fountain roller stroke. Thus the ink stripe width can be influenced.
Servo-drive ink fountain roller
305
Inking unit
Servo-drive ink fountain roller
Technical data Motor data U = DC 12 V Potentiometer data U = DC 10 V R = 10 k
Terminal assignment Terminal black yellow beige yellow/green brown blue
6 5 4 3 2 1
6 5 4 3 2 1
black yellow beige yellow/green brown blue
6 5 4 3 2 1
6 5 4 3 2 1
black blue red black red
Terminal strip of servo-drive for ink fountain roller
306
1 2 4 5 6
Function DC 12 V (motor) DC 10 V (potentiometer) potentiometer Potentiometer tap
Inking unit
Servo-drive ink fountain roller
Removal and installation Attention:
Small parts can fall into the press during disassembly!
O.S.
Nut on servomotor
Gear wheel
Locking screw
Anti-rotation element
Retaining nut
1 2 3 4 5 Ink fountain roller O.S.
6 7
8
Zero position of ink fountain roller Turn the threaded rod against the left stop with the nut . Disconnect the potentiometer from the terminal strip. Loosen the locking screw potentiometer.
and take out the
Attach the anti-rotation element potentiometer.
to the new
Connect the new potentiometer and turn until the display on the central control console indicates 0,00. Install in reverse sequence. If you want to make a precision correction, loosen the retaining nut . Correct the value by slightly turning the potentiometer. Check the value displayed on the central control console.
307
Inking unit
Servo-drive diagonal register 1...nM6
Servo-drive diagonal register 1...nM6 Place of installation The servo-drives for the diagonal register are located on the operator side of the printing units.
D.S.
O.S.
Place of installation of servo-drive for diagonal register O.S.
Layout and task
Speedmaster SM 102
The servo-drive for the diagonal register is a dc motor with brushes and potentiometer for position feedback. It is used for cocking the plate cylinder.
Speedmaster CD 102
Servo-drive diagonal register on SM 102 and CD 102 308
Inking unit
Servo-drive diagonal register 1...nM6
Technical data Motor data U = DC 24 V
Potentiometer data U = DC 10 V R= 10 k
Pin assignment Pin
Function
1 2
3
4 5
3 4
2
1
1 2 3 4 5
DC 24 V (motor) DC 10 V (potentiometer) Potentiometer tap potentiometer
5
Plug of servo-drive of diagonal register
309
Inking unit
Servo-drive diagonal register 1...nM6
Removal and installation Attention:
Small parts can fall into the press during disassembly!
Plug 1...nM6-X1
Fixing bolts
Hexagon nut
Block
Upper stop of eccentric sleeve
Eccentric bolt
Servo-drive
1 2 3
4
Eccentric sleeve behind block
5
5mm
Servo-drive diagonal register, e.g. SM 102
310
Withdraw the plug
from the servo-drive .
Remove the servo-drive by loosening the four fixing bolts . Positioning the diagonal register to zero: Turn the hexagon below the block until the distance between the upper stop of the eccentric sleeve O.S. and the eccentric bolt is 5 mm. Setting the central position for the new servo-drive: Connect the plug to the servo-drive . Set the diagonal register display to 0,00 on the central control console. Alternatively, it is possible to set the variable voltage of the potentiometer to 5V at the servo-drive conversion module SSM in the distribution box of the printing unit. Installing the servo-drive: When installing the servo-drive, the backlash (flank clearance) is of no importance and can be neglected. When tightening the fixing bolts, pull the servo-drive outwards (away from the PU). Thus the backlash of the two pinions is adjusted.
Note: Do not loosen the eccentric bolt . After loosening the eccentric bolt, the plate cylinder and the dampening distributor must be adjusted parallel to each other again.
Inking unit
Servo-drive lateral register
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.
Place of installation of servo-drive for lateral register O.S.
Layout and task The servo-drive for the lateral register is a dc motor with brushes and potentiometer for position feedback. It is used for adjustment of the plate cylinder in lateral direction.
Servo-drive lateral register
311
Inking unit
Servo-drive lateral register
Technical data Motor data U = DC 12 V
Potentiometer data U = DC 10 V R = 10 k
Terminal assignment Terminal black yellow beige yellow/green brown blue
6 5 4 3 2 1
6 5 4 3 2 1
black red blue brown blue
Terminal strip of servo-drive for lateral register
312
1 2 4 5 6
Function DC 12 V (motor) DC 10 V (potentiometer) potentiometer Potentiometer tap
Inking unit
Servo-drive lateral register
Removal and installation Attention:
2.2...2.27 mm
2.2...2.27 mm
Small parts can fall into the press during disassembly!
Nut
Gear wheel
Nut
Nut
Anti-rotation element
Sleeve
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: Use a feeler gauge!
Lateral register O.S.
2 3 4 5 6 7 8
. Loosen the nut . Unscrew the nut
Take out the potentiometer and disconnect the cable from the terminal strip. Attach the anti-rotation element potentiometer.
to the new
Connect and install the new potentiometer and turn until the display on the central control console indicates 0,00. Install in reverse sequence. If you want to make a precision correction, loosen the nut . To correct the value insert a screw driver in the sleeve and turn the potentiometer axis slightly. Check the value displayed on the central control console.
313
Inking unit
Servo-drive circumferential register
Servo-drive circumferential register Place of installation The servo-drives for the circumferential register are located on the drive side of the printing units.
O.S.
D.S.
Place of installation of servo-drive for circumferential register D.S.
Layout and task The servo-drive for the circumferential register is a dc motor with brushes and potentiometer for position feedback. It is used for adjustment of the plate cylinder in circumferential direction.
Servo-drive for circumferential register D.S.
314
Inking unit
Servo-drive circumferential register
Technical data Motor data U = DC 12 V
Potentiometer data U = DC 10 V R = 10 k
Terminal assignment Terminal black yellow beige yellow/green brown blue
6 5 4 3 2 1
6 5 4 3 2 1
black red blue brown blue
1 2 4 5 6
Function DC 12 V (motor) DC 10 V (potentiometer) potentiometer Potentiometer tap
Terminal strip of servo-drive for circumferential register
315
Inking unit
Servo-drive circumferential register
Removal and installation Attention:
Small parts can fall into the press during disassembly!
6.2...6.3 mm 6.2...6.3 mm
Nut
Gear wheel
Locking screw
Anti-rotation element
Nut
1
Positioning the circumferential register to zero: Turn the gear wheel with the help of the nut until the distance of 6.2...6.3 mm is obtained.
Note: Use a feeler gauge!
2 Circumferential register D.S.
3 4 5 6 7
316
Disconnect the potentiometer from the terminal strip. Loosen the locking screw potentiometer.
and take out the
Attach the anti-rotation element potentiometer.
to the new
Connect and install the new potentiometer and turn until the display on the central control console indicates 0,00. Install in reverse sequence. If you want to make a precision correction, loosen the nut . Correct the value by slightly turning the potentiometer. Check the value displayed on the central control console.
Inking unit
Inking unit temperature control
Inking unit temperature control Activation and inactivation
Selecting the display The inking unit temperature control can be activated and inactivated at the central control console. Power supply is effected via plug E39-X1. On 7- and 8-colour presses, the required second inking unit temperature control is switched on and off via plug E39a-X1.
Actual valueā/āfine display of control console display (ZID) Inking unit temperature control on/off
317
Inking unit
E39 Inking unit temperature control
E39 Inking unit temperature control Connection Different models are available which differ in power. 7- and 8-colour presses require two inking unit temperature controls (E39 and E39a). The power supply for the unit(s) comes from the printing press. The illustration opposite is an example. The units differ in cabinet height and width.
Connection of inking unit temperature control E39
Pin assignment E39-X1 (only model 3/8) Pin
1
6
2
7
3
8
4
9
5
10
318
Function
3
Phase U
7
Phase V
9
Phase W PE conductor
Remaining pins
–
Inking unit
E39 Inking unit temperature control
Pin assignment E39-X1 (models 6/12; 6/16; 9/20 and 9/25) Pin
Function
1
Phase U
2
Phase V
3
Phase W PE conductor
Remaining pins
–
4Ćpole cable
319
Inking unit
320
E39 Inking unit temperature control
Dampening
1...nM1 Pan roller motors
Dampening 1...nM1 Pan roller motors Place of installation / plug connections
Connector 1...nM1-X3 ( power supply )
1...nM1-X3
2M1
1M1
3M1
Pan roller motors 1...nM1 at PU/CU on D.S.
Pin assignment 7
6
Pin
8
1
4 3
9 14
10 11
12
Function
5
13 2
Connector 1...nM1-X3, pins in plug insert
1
X motor line
2
Y motor line
3
Z motor line
4
Hall-effect sensor, signal C
5
Hall-effect sensor, tacho signal
6
Hall-effect sensor, signal B
7
DC 15 V
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
1...nM45 Blower motor for dampening system Place of installation and task
nM45
The blower combination with the motor 1...nM45 is located under the guard of the inking and dampening rollers. The motor is a dc motor with brushes. It is integrated in the middle of the blower bar and drives a cross-flow fan.
Place of installation of blower motor for dampening system
Pin assignment Pin
1 2 3
Plug of blower motor for dampening system
322
Function
1
Enable message
2
Ground 24 V
3
DC 24 V
Dampening
1...nB32 Sensor ”Dampening solution control”
1...nB32 Sensor ”Dampening solution control” Place of installation The capacitive sensor is located on the paper infeed side, D.S., in the dampening solution fountain.
nB32
Place of installation of sensor ”Dampening solution control”
Layout/connection Core
Function
brown
DC 24 V
blue
ground 24 V
black
message
Sensor ”Dampening solution control”
323
Dampening
1...nB32 Sensor ”Dampening solution control”
Task/function The capacitive sensor 1...nB32 monitors the level of the dampening solution in the fountain. The sensor works correctly when its sensing area is immersed in the dampening solution. With its sensing area immersed, the sensor is actuated. If the level of the dampening solution drops, the sensor will only change its circuit state if its sensing area is no longer in contact with the water film. The sensor is supplied with a stabilized direct voltage of DC 24 V.
324
Dampening
E40 Central dampening solution supply/ cooling and circulating unit
E40 Central dampening solution supply/cooling and circulating unit Layout of central dampening solution supply
X1
X2
ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ
The central dampening solution supply is in a separate cabinet. Generally, this cabinet is in the proximity of the central control cabinet. It is connected to the CP Tronic control system via a serial interface. The power supply and circuitbreakers are in the control cabinet of the printing press. For details please refer to the manufacturer’s manual. E40-X1: power supply E40-X2: serial interface
Central dampening solution supply Technotrans
Á Á
X2
Á Á X1
Central dampening solution supply Baldwin, rear view
325
Dampening
E40 Central dampening solution supply/ cooling and circulating unit
Pin assignment X1, central dampening solution supply Pin
1
6
2
7
3
8
4
9
5
10
Connector E40-X1, coming from the press
326
Function
3 7 9
Phase U Phase V Phase W PE conductor
Remaining pins
*)
–
380...415 V " 15V * ) AC AC 460...500 V " 15V
at 50Hz at 60Hz
Dampening
E40 Central dampening solution supply/ cooling and circulating unit
Layout of cooling and circulating unit The cooling and circulating units have no serial interfaces. The power supply and circuit-breakers are in the control cabinet of the printing press. A manufacturer’s manual is available. E40-X1: power supply
E40-X1
Cooling and circulating unit
Pin assignment X1, cooling and circulating unit Pin 2 4 1
6
2
7
3
8
4
9
5
10
Function AC 230 V Zero 230 V PE conductor
Remaining pins
–
Connector E40-X1, coming from the press
327
Dampening
E41 Dampening solution mixing unit
E41 Dampening solution mixing unit The dampening solution mixing unit is an additional unit for cooling and circulating devices without integral additive-mixing units. It admixes additives to the dampening solution. Power supply comes directly from the mains and not from the press. For details please refer to the manufacturer’s documentation.
Dampening solution mixing unit
328
Central lubrication
Basic concept
Central lubrication Basic concept Distinction Two lubrication systems supply the press with lubricant: –
grease lubrication system (for the delivery),
–
oil lubrication system (for the printing units, feeder and bearings on the D.S. and O.S. of the delivery chain sprocket shaft).
The grease lubrication system is divided into: –
lubrication circuit 1 (chain lubrication),
–
lubrication circuit 2 (bearing lubrication).
The oil lubrication system is divided into: –
the circular lubrication system (drive side),
–
the distributing lubrication system (operator side and some lubricating points on the drive side).
329
Central lubrication
Service display
Service display Button sequence
Oil lubrication Service display ”Oil lubrication”
330
Pressure monitoring 1bar, 1F33 (flashes if the pressure switch was not actuated). Pressure monitoring 12bars, 1F34 (flashes if the pressure switch was not actuated). Oil pump M44 (flashes if motor circuit-breaker 15Q44 has responded). Number of cylinder revolutions since the last distributing lubrication. After completion of lubrication the counter is automatically zeroed. Distributing lubrication initiated manually (only when press is on ”Run”). Number of cylinder revolutions at which automatic oil lubrication is initiated.
Central lubrication
Service display
Grease lubrication 7 8 9 ß
Service display ”Grease lubrication”
q w e r t
Sensor ”Lubrication monitoring 2” – 12 B77 (bearing lubrication) (flashes if sensor is not actuated). Sensor ”Lubrication monitoring 1” – 12 B47 (chain lubrication) (flashes if sensor is not actuated). Motor grease lubrication 12M47. Number of cylinder revolutions since the last chain lubrication. After completion of lubrication the counter is automatically zeroed. Number of cylinder revolutions since the last bearing lubrication. After completion of lubrication the counter is automatically zeroed. Chain lubrication initiated manually (lubrication circuit 1); (only when press is on ”Run”). Bearing lubrication initiated manually (lubrication circuit 2); (only when press is on ”Run”). Number of cylinder revolutions at which bearing lubrication is initiated automatically. Number of cylinder revolutions at which chain lubrication is initiated automatically.
331
Central lubrication
Fault messages
Fault messages Display ”Entire press/warning” Button sequence
Dependent on the press model, the fault display ”Entire press” / ”Warning” shows the fault symbols of the grease lubrication or oil lubrication system:
Oil lubrication not possible
Grease lubrication not possible
Motor circuit-breaker Q 44 has tripped The audible signal devices 11H55 and 12H55 give out a warning
332
Oil lubrication has not occurred. –
After main switch ”On” and changeover between circular and distributing lubrication, the oil pressure has not been built up within 3 minutes.
–
Pressure switch 1F33 (1 bar) or pressure switch 1F34 (12 bars) not actuated.
–
Filter unit clogged.
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 motor circuit-breaker has tripped. Oil pump M 44 not ready to run. While lubrication is in progress, a warning signal sounds if the printing speed is u 3 000 i.p.h.
Central lubrication
Grease lubrication
Grease lubrication Block diagram
15 Q 66 15 Q 47 12B47 15 K47 M
12M47
12Y78 12B77
11H55
12H55
Electronic control system Control line Power supply Grease line
Block diagram of grease lubrication
Pressure limiting valve (38 bars)
12M47
Motor ”Grease lubrication”
Metering elements
12Y78
Changeover grease lubrication
15Q66
Main switch
12B47
Lubrication monitoring 1 (chains)
15Q47
Motor circuit-breaker
12B77
Lubrication monitoring 2 (bearings)
11H55
Audible signal device (audio alert feeder)
12H55
Audible signal device (audio alert delivery)
15K47M Contactor
333
Central lubrication
Grease lubrication
Place of installation The motor for grease lubrication is located on the D.S. of the last printing unit. The sensors ”Lubrication monitoring” are fitted at the first progressive distributor behind the motor.
Layout
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)
Components of the grease lubrication system
Function When the press is switched on, the grease lubrication system is ready for operation. The motor for grease lubrication 12M47 delivers the lubricant to the progressive distributors via solenoid valve 12 Y78. Depending on the position of the solenoid valve, either the chains in the delivery (lubrication circuit 1) or the bearings (lubrication circuit 2) are supplied with lubricant. The progressive distributors pass the lubricant to the lubricating points via pistons. The progressive distributors are sequence-controlled and thus all pistons move uniformly. For this reason, only the movement of one piston is monitored per lubrication circuit.
334
Central lubrication
Grease lubrication
Monitoring the lubrication system
LED
Inductive sensors monitor the two lubrication circuits. Each is equipped with an LED and can assume two circuit states. –
–
Sensor with LED monitoring the lubrication circuit
Pin of progressive distributor extended, sensor damped: LED is lit. Pin of progressive distributor retracted, sensor not damped: LED is not lit.
On presses with standard delivery, the sensor 12 B47 (chain lubrication) is actuated twice while lubrication is in progress and three times on presses with extended delivery. The sensor 12 B77 (bearing lubrication) is actuated once while lubrication is in progress. If the sensors do not switch within 10 minutes after a lubrication process was triggered, the electronic control system shuts the motor for grease lubrication down. The warning ”Grease lubrication not possible” appears.
335
Central lubrication
Grease lubrication
Triggering a lubrication process When the press is switched on, the grease lubrication system is ready for operation. Lubrication is triggered either automatically:
chain lubrication every 2 500 to 30 000 cylinder revolutions; (after a basic initialization, the cycle is preset to 20 000 cylinder revolutions), bearing lubrication every 200 000 cylinder revolutions,
or manually by actuating the function button ”Manual chain or bearing lubrication”.
Central lubrication selected, press on ”Run”
Setting the lubrication cycle for lubrication circuit 1 (chain lubrication) Button sequence
Number of cylinder revolutions for automatic chain lubrication (lubrication circuit 1). The cylinder revolutions can be set in the range from 2 500 to 30 000 in steps of 2 500.
Note: To set the lubrication cycle an additional button must be fitted on the EAM (input/output module). Before fitting or removing this button, turn off the main switch 15 Q 66 on the central control cabinet ZSG! Number of cylinder revolutions set to 20000
336
Central lubrication
Grease lubrication
Even if the main switch is turned off, the press is not voltage-free and there are currentconducting components in the central control cabinet!
Attention:
The input/output module EAM is on the underside of the central control console. Plug the additional button into slot 7 of the EAM - X12.
EAM
EAM-X12 Group
Turn off the main switch 15Q66. Fit the button. Turn on the main switch 15Q66.
Now press the button you just fitted plus group button 2 on the central control console. Set the cylinder revolutions with the left-hand + / – buttons. –
2 500
Lubrication cycle for delivery
–
5 000
30000
–
L
–
25 000
–
30 000
Remove the button from slot 7 of the EAM - X12. Then check the cylinder revolutions for chain lubrication (lubrication circuit 1) in the service display ”Central lubrication” on the central control console.
Changing the lubrication cycle Note: The value for bearing lubrication (lubrication circuit 2) is set to 200 000 cylinder revolutions and is non-adjustable.
Pressure relief valve of the motor The motor for grease lubrication is protected by a pressure relief valve. In the case of malfunctions, this valve prevents the building up of impermissible high pressures in the lubrication system and opens at a pressure of 150 bars.
337
Central lubrication
Oil lubrication
Oil lubrication Block diagram
15 Q 66 15 Q 44 1F33 15X3
M44
Y67 1F34
11H55
12H55
Electronic control system Control line Power supply Oil line
Block diagram of oil lubrication
Pressure relief valve (18 bars)
Y67
Changeover oil lubrication
Metering elements
1F33
Pressure monitoring (1 bar)
15Q66
Main switch
1F34
Pressure monitoring (12 bars)
15Q44
Motor circuit-breaker
11H55
Audible signal device (audio alert feeder)
15X3
Plug
12H55
Audible signal device (audio alert delivery)
M44
Oil pump
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
Components of the oil lubrication system
339
Central 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
Oil lubrication
Central lubrication
Oil lubrication
Triggering a lubrication process Distributing lubrication is triggered:
automatically every 45 000 cylinder revolutions or by actuating the function button ”Manual distributing lubrication”.
For activation the printing press must be on ”Run” (3 000 i.p.h.).
Central lubrication selected, press on ”Run”
Filter unit
Optical differential pressure indicator
Filter housing with cartridge
The filter unit is fitted between the pump and the solenoid valve. The optical differential pressure indicator shows the degree of soiling of the filter cartridge:
Filter unit
–
Green: filter cartridge okay
–
Red: change filter cartridge
If the filter cartridge is soiled, the oil pressure between the oil pump and filter unit rises. The relief valve in the filter unit opens the bypass and the oil flows to the lubricating points without having been filtered. Change the filter at least every 6 months.
341
Central lubrication
Oil lubrication
Changing the filter
Changing the filter
Optical differential pressure indicator
The tightening torque for the filter housing must be 120 Nm +/– 15 Nm.
Pressure relief valve of the oil pump A pressure relief valve is installed to protect the oil pump. In the case of malfunctions, this valve prevents the building up of impermissible high pressures in the lubrication system. It opens at a pressure of 18 bars and the oil flows back into the coating unit guard or the oil reservoir.
342
Central lubrication
M44 Oil pump
M44 Oil pump Place of installation On presses with coating unit, the oil pump is located on the D.S. of the coating unit, below the footboard.
Location of oil pump on presses with coating unit, D.S.
On presses without coating unit, the oil pump is installed at the oil reservoir. The oil reservoir is located on the D.S. under the footboard (on presses with up to 5 printing units at the last printing unit).
Location of oil pump on presses with up to 5 PUs
343
Central lubrication
M44 Oil pump
On presses with 6 or more units, the oil reservoir is bigger and located in the middle of the press, under the footboard on the D.S.
Location of oil pump on presses with 6 or more PUs
Pin assignment Pin
Function
A2
AC 400 / 480 V phase U
B3
AC 400 / 480 V phase V
C2
AC 400 / 480 V phase W
A B C 1 2 3 4 5
Plug M44-X1
344
PE conductor
Central lubrication
12M47 Motor for grease lubrication
12M47 Motor for grease lubrication Place of installation The motor for grease lubrication 12M47 is located on the D.S. of the delivery.
Motor for grease lubrication with grease reservoir
Pin assignment Plug 12M47-X1
3 1 2 PE
Pin
Function
1
DC 24 V
2
Grease lubrication delivery chains
3
–
PE
–
Plug 12M47-X1
345
Central lubrication
1F33 Pressure monitoring oil lubrication 1bar
1F33 Pressure monitoring oil lubrication 1bar Place of installation The pressure switch ”Pressure monitoring oil lubrication 1 bar” 1F33 is located on the drive side of the first printing unit, under the sheet alignment system. It is accessible through the door between the feeder and first printing unit on the O.S.
Place of installation ”Pressure monitoring oil lubrication 1 bar”, 1F33
346
Central lubrication
1F34 Pressure monitoring oil lubrication 12bars
1F34 Pressure monitoring oil lubrication 12bars Place of installation The pressure switch ”Pressure monitoring oil lubrication 12 bars” 1F34 is located on the O.S. of the first printing unit, under the feeder. It is accessible through the door between the feeder and first printing unit on the O.S.
Place of installation ”Pressure monitoring oil lubrication 12 bars”, 1F34
347
Central lubrication
12B47 Lubrication monitoring 1 12B77 Lubrication monitoring 2
12B47 Lubrication monitoring 1 and 12B77 Lubrication monitoring 2 Layout The sensor 12 B47 for chain lubrication monitoring and the sensor 12 B77 for bearing lubrication monitoring are of identical design.
LED Sensor Locking nut Receptacle Plug Stop pin Sleeve Distributor
12B47 Lubrication monitoring 1 and 12B77 lubrication monitoring 2
Connection Input 47 or 77 at EAK 12: 0 ¢ sensor not damped (LED off) 1 ¢ sensor damped (LED lit)
348
Central lubrication
12B47 Lubrication monitoring 1 12B77 Lubrication monitoring 2
Pin assignment Marking
Colour
Function
47 or 77
black
signal
+1
brown
DC 24 V
–1
blue
Sensor ”Lubrication monitoring”
Removal and installation To fit the sensor screw the receptacle into the sleeve using a copper disk and tighten it up. In doing so, align the receptacle in such a way that the sensor can be screwed in parallel to the longitudinal axis of the distributor. Screw the sensor manually into the receptacle until it contacts the stop pin and secure it with the locking nut. Then close the threaded hole of the receptacle from the bottom using the plug.
349
Central lubrication
350
12B47 Lubrication monitoring 1 12B77 Lubrication monitoring 2
Pneumatic system
15Y11 Admission of pressure, pneumatic system
Pneumatic system 15Y11 Admission of pressure, pneumatic system Place of installation The solenoid valve ”Admission of pressure, pneumatic system” 15Y11 is fastened to the side frame on the O.S. of the feeder and accessible through the protecting door.
15Y11
Admission of pressure, pneumatic system 15Y11 with plug
Task When the pressure has been built up ( u5 bars ), the solenoid valve switches the pneumatic energy through the piping.
351
Pneumatic system
15Y11 Admission of pressure, pneumatic system
Pin assignment Plug 15Y11-X1
1 3 PE 2
Plug 15Y11-X1
352
Pin
Function
1
DC 24 V
2
Signal 4 mA ... 20 mA
3
–
PE
–
Pneumatic system
15B14 Pressure sensor ”Pneumatic system”
15B14 Pressure sensor ”Pneumatic system” Place of installation
The pressure sensor ”Pneumatic system” 15B14 is located at the side frame on the O.S. of the feeder where it measures the air pressure in the pneumatic piping.
15B14
Place of installation of pressure sensor ”Pneumatic system” 15B14
353
Pneumatic system
15B14 Pressure sensor ”Pneumatic system”
Pin assignment Plug 15B14-X1
3 1 2 PE
Pressure sensor and connector
354
Pin
Function
1
DC 24 V
2
Sensor signal 4 mA ... 20 mA
3
–
PE
–
Pneumatic system
E4 Pneumatic system compressor
E4 Pneumatic system compressor Technical data Technical data, see operating instructions 71.102.9100
Pin assignment Pin
Function
A2
AC 400 / 480 V phase U
B3
AC 400 / 480 V phase V
C2
AC 400 / 480 V phase W
3
C4
DC 24 V
4
A5
Pressure switch F45
5
B5
Blow-off valve Y68
A B C 1 2
PE conductor
Plug E4-X1
355
Pneumatic system
356
E4 Pneumatic system compressor
Suction and blast air
1M9 Blast air regulation at the feeder
Suction and blast air 1M9 Blast air regulation at the feeder Block diagram Displays MID11
ZID 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: – the thickness of the stock (e.g. paper calliper); – the production speed (preset speed).
IDS
EAK
SSK
ESK
In the operator program of CPTronic the blast air regulation can be switched on and off.
SVM
SAK
REK2
1SSM1 1M9
M Blast air regulation
Legend:
The blast air regulation at the feeder adapts the blast air pressure at the suction head to the press speed and ensures that the printing material is fanned.
Data lines Control lines
Block diagram: blast air regulation at the feeder
”Automatic blast air regulation switched on” means: characteristic-curve-dependent blast air regulation. The blast air pressure is automatically adapted by the CPTronic operator program on the basis of the entered paper thickness and the preset press speed. By pressing the right-hand +/– buttons on the control console the characteristic curve stored in the CPTronic control system can be modified manually. ”Automatic blast air regulation switched off” means: manual blast air setting. The blast air pressure is set independently of the paper thickness and preset speed. It can be modified with the right-hand +/– buttons on the control console. The blast air regulation at the feeder does not intervene in the press control.
357
Suction and blast air
1M9 Blast air regulation at the feeder
Characteristic-curve-dependent blast air regulation
Selection of the characteristic-curve-dependent blast air regulation Function button ”Blast air regulation at the feeder on / off” If the background of the symbol is light, the characteristicĆcurveĆdependent blast air regulation is switched on. The characteristic curves are stored in the CPTronic operator program. The operator program automatically selects a suitable characteristic curve dependent on the thickness of the stock and the press speed.
358
Suction and blast air
1M9 Blast air regulation at the feeder
Selection: manual change of characteristic-curvedependent blast air regulation Function button ”Changing the slope”
When you switch over to the actual value display and the background of the symbol is light, you can set the slope of the characteristic curves manually (and thus deviate from the CPTronic-values). The setting is made at the control console with the right-hand +/– buttons.
Manual change of the characteristicĆcurveĆdepenĆ dent blast air regulation p [bar]
For a 0.05 mm thick paper the setting range for the slope is as follows for SM 102 and CD 102:
1.0
Minimum:
0% (corresponds to the 0%-characteristic curve) Maximum:100% (corresponds to the 100%-characteristic curve)
0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0
3000
6000
9000
12000 15000 n [sheets / h]
Field of characteristic curves for a printing paper with a thickness of 0.05 mm (corresponds to a paper weight of approx. 50 g/m2)
359
Suction and blast air
1M9 Blast air regulation at the feeder
Manual blast air setting
Selection: changing the manual blast air setting Function button ”Manual setting of blast air at feeder” actuated (ON) The manual blast air setting is activated automatically when the characteristic-curve-dependent blast air regulation is switched off. It does not depend on the paper thickness or preset speed. In this mode you can enter a percent value which is displayed on the control console display ZID. The setting is made at the control console with the right-hand +/– buttons.
The setting range for SM 102 and CD 102 is as follows:
p [bar]
Minimum: 20% (corresponds to 0.2 bar above atmospheric pressure) Maximum:100% (corresponds to 1.0 bar above atmospheric pressure)
1.0
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.
Blast air regulation at the feeder
361
Suction and blast air
1M9 Blast air regulation at the feeder
Layout and task Dependent on the thickness of the printing material and the production speed, the blast air regulation at the feeder adapts the blast air pressure at the suction head and thus ensures that the printing material is fanned. The blast air regulation at the feeder consists of the following components:
Servo-drive 1M9 with dc motor with brushes, flange-mounted gear unit and potentiometer for position feedback. Motor bracket with protecting cover and threaded spindle inside Adjustable relief valve Manometer measuring the pressure above atmospheric (at feeder frame)
The servo-drive and relief valve are connected with each other by means of a mechanical coupling.
Servo-drive with adjustable relief valve
Manometers at feeder frame for pressure above atmospheric and low pressure
362
Suction and blast air
1M9 Blast air regulation at the feeder
Technical data Motor data U = DC 24 V P=5W Potentiometer data U = DC 10 V R = 10 k
Pin assignment Contact +
M
– +
2 3 4
–
1 2 3 4 5
1
3 4 2
1
Assignment Motor, + (DC 24 V) Motor, – (DC 24 V) Potentiometer, + (DC 10 V) Potentiometer wiper Potentiometer, – (DC 10 V)
5
5
Pin assignment: blast air regulation at the feeder
363
Suction and blast air
1M9 Blast air regulation at the feeder
Removal and installation
Attention:
Small parts can fall into the press during disassembly!
1 2 3
Inch the press until all blast air ducts at the rotary valve in the suction head are closed. Turn off the main switch. Loosen the four fixing bolts the protecting cover .
and remove
(4×)
4 (4×)
5
364
Unscrew the connector 1M9–X1 and withdraw it from the servo-drive . Loosen the four fixing bolts and remove the servo-drive together with the sleeve . Turn on the main switch (blast air is present).
Suction and blast air
1M9 Blast air regulation at the feeder
6
7 8 9
ß
Turn the threaded spindle manually until the manometer measuring the pressure above atmospheric at the feeder indicates 0.6 bar. Check whether all blast air ducts at the rotary valve in the suction head are closed. Turn off the main switch. Connect the connector with the new servo-drive and tighten up the bolts. Turn on the main switch.
Switch off the automatic blast air regulation (this activates the manual blast air setting).
Note: Also refer to the section ”Manual blast air setting”.
q
Operate the servo-drive with the right-hand +/– buttons at no-load until the value 60% is indicated on the control console display ZID.
Note: While doing this, do not place the servodrive on the threaded spindle .
365
Suction and blast air
1M9 Blast air regulation at the feeder
w
Push the servo-drive onto the threaded spindle so that the pin engages with two slots of the sleeve .
Note: Take care that the pin of the threaded spindle is not turned more than "90° while doing this. (4×)
e
r
Fasten the servo-drive fixing bolts .
with the four
Let the servo-drive run over the entire operating range with the right-hand +/– buttons (i.e. from 20% to 100%).
Note: See also the next section ”Checking the operating range”.
t (4×)
366
Put the protecting cover back in place and fasten it with the four fixing bolts .
Suction and blast air
1M9 Blast air regulation at the feeder
Checking the operating range
Selecting the service display Incremental values for the servo-drive ”1M9 Blast air regulation at the feeder”
Operating range for SM 102 and CD 102: Incremental value [n] 768 (min.) 2048 3328 (max.)
ZID display Air pressure [%] [bar] 20 0.2 60 0.6 100 1.0
Note: The incremental values may differ from the displayed percent values / air pressure by up to "4 increments. When you have finished checking, switch on the characteristic-curve-dependent blast air regulation.
367
Suction and blast air
368
1M9 Blast air regulation at the feeder
Other components
E4a Varnish supply unit
Other components E4a Varnish supply unit Connections The varnish supply unit receives 3AC 380 V and AC 230 V from the printing press. Both voltages pass through plug E4a-X1. The varnish sensor is located at the coating pan on the O.S. of the coating unit. It is connected to the distribution box at the coating unit. From there a cable leads to the varnish supply unit, plug E4a-X21.
E4a-X21
The varnish supply unit is remotely controlled with a cable. This cable is connected to plug E4a-X22.
E4a-X22
The varnish supply unit is located under the footboard on the D.S. of the coating unit.
E4a-X1
A manufacturer’s manual is available.
Varnish supply unit
Pin assignment E4a-X1 Pin A B C 1 2 3 4 5
Plug E4a-X1, coming from the control cabinet
A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 C1 C2 C3 C4 C5
Function – Phase L1 – AC 230 V – – – Phase L2 – – – Phase L3 – – Zero 230 V PE conductor
369
Other components
E4a Varnish supply unit
E4a-X21 Pin 2
3 4 6
1
5
Plug E4a-X21, control lines
Function
1
DC 24 V (+1) for fault message
2
Fault message
3
Analog sensor signal: 0 ... 5 V
4
Conductive level sensor
5
DC 24 V
6
Ground
voltage for sensor
Fault messages If the sensor ”Level in coating pan” B32 detects that the level is too low and if the operating mode ”Varnish circulation” has been selected for the coating unit, a fault message is transmitted to the CPTronic control system and the audible signal devices 11H55 and 12H55 output a warning. It is possible that the fault message is caused by the height adjustment of the level controller ( coating pan insert ).
Sensor ”Level in coating pan” and level controller
370
Other components
L-B32 Level in coating pan
L-B32 Level in coating pan Place of installation The sensor ”Level in coating pan” is located at the coating pan on the O.S. of the coating unit.
Sensor ”Level in coating pan”
Connection, pin assignment Plug E4a-X2: 3 2 1
183 170 171
blk
br
L-B32
4 6
E4a-X2
Pin
Colour
1
brown
2
grey
3
yellow
4
–
5
green
DC 24 V
6
white
Ground
5
L-LVT1-X2
bl Sensor
Function DC 24 V (+1) for fault message Fault message Analog sensor signal: 0 ...5 V Conductive level sensor voltage for sensor
Connection of sensor ”Level in coating pan”
371
Other components
L-B32 Level in coating pan
Layout, adjustment 108 mm
approx. 10 mm
Mounting dimensions of sensor ”Level in coating pan”
372
Coating pan Pan roller Sensor Sensor holder Level controller Adjusting screws
Adjust the sensor so that the distance between the upper edge of the sensor and the upper edge of the sensor holder is 108 mm. The height of the level controller can be regulated by means of the adjusting screws. This influences the level in the coating pan. The immersion depth of the pan roller in the varnish should be approx. 10 mm.
Other components
12E2 Powder spray unit
12E2 Powder spray unit Place of installation, layout
Powder spray device Powder tube Blower motor with suction filter
The powder spray device is located on the O.S. of the delivery. The motor is fitted on the O.S. of the delivery, on the inside of the press. Different types of powder spray devices can be connected to the printing press. We distinguish between:
Powder spray device, powder tube and motor at delivery
–
powder spray devices without serial interface,
–
powder spray devices with serial interface.
In the case of powder spray devices with serial interface, the motor is connected directly to the control box of the powder spray device.
Powder spray device with serial interface Pin assignment 12E2-X1 Pin
Function
A2
L2
B3
L1
C2
L3
A4
AC 230 V
C5
Zero 230 V PE
Plug 12E2-X1, coming from the press
373
Other components
12E2 Powder spray unit
Powder spray device without serial interface Pin assignment 12E2-X2 The plug 12E2-X2 is at the distribution box of the delivery. Instead of the mechanical switch 12S68 a proximity switch can be fitted in the feeder (e.g. Betatronic powder sprayers). This switch is then connected directly to the powder spray device and is not led via the distribution box or plug 12E2-X2.
Pin
A1
Switch ”Powder on” 12S68, switch contact 2 (not with proximity switch)
A2
DC 24 V for test button
A3
AC 230 V
A4
Switch ”Powder on” 12S68, switch contact 1 (not with proximity switch)
A5
Impression on ( AC 230 V)
B1
Test ( DC 24 V)
B2
Zero 230 V
B3
PE conductor
B4
Press turns ( AC 230 V)
B5
–
C1 – C5
–
Plug 12E2X2, coming from the press, distribution box at delivery
Function
PE
Pin assignment of proximity switch 12S68
3 4 5
Plug of proximity switch
374
2 1
Pin
Function
1
Ground
2
DC 24 V
3
Signal
4
Ground
5
–
Other components
12E2 Powder spray unit
Correcting the beginning of powdering Settings The following settings are only required for powder spray devices with serial interface. Control panel at last printing unit / coating unit
1
Selector switch ”Safe”
2
Pushbutton ”Forward”/ ”Backward”
Set the selector switch ”Safe” to ”Safe”.
Inch the press until the front edge of the sheet is below the spray nozzles of the powder tube.
Sheet of paper
Required position of front edge of sheet
Positioning the sheet of paper Control panel at delivery Press display MID
3
Read off the degree value indicated on the press display MID.
Display of degree value
Indication on the MID while press is in inching mode
375
Other components
12E2 Powder spray unit
Service display ”Delivery”
4
Variable degree can be changed by entering another degree value.
Standard degree – cannot be changed – depends on the press model.
Service display ”Delivery”
5
Entering the degree value
With the right-hand " buttons the degree value read off at the press display MID under 3 can be entered. When the function button is pressed, the variable degree jumps back to the standard degree value .
SM102 ( CD102)
+ extended + coating unit + coating unit High-pile delivery high-pile delivery + high-pile delivery + extended high-pile delivery
2 PUs
132° 101 )
225° 102
83° 176
84° 177
4 PUs
166° 250
259° 251
118° 326
119° 326
5 PUs
3° 325
97° 326
315° 39
316° 40
6 PUs
201° 39
294° 40
152° 114
153° 115
7 PUs
38° 114
131° 115
349° 189
350° 189
8 PUs
235° 189
328° 189
188° 263
188° 264 )
+ 74.6° 74.6 for every further coating unit
Degree values for the beginning of powdering SM102 (CD102)
376
+ 74.6° 74.6 for every further coating unit
Other components
12M35 Blower motor for powder spray device
12M35 Blower motor for powder spray device Place of installation, filter change The motor is located at the delivery. It is mounted on the baseplate on the inside of the side frame, on the O.S. To change the suction filter, open the hinged cover above the footboard.
12E2-X1
Blower motor for powder spray device at delivery
Layout
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
4
Compressor motor M35
377
Other components
12M35 Blower motor for powder spray device
Changing the rotor vanes Remove the casing cover of the compressor motor M35.
Note: When you loosen the lower fixing bolts of the casing cover, the compressed-air cooler becomes loose as well. Hold it tight. The rotor vanes are accessible. If they are shorter than 27 mm (min. permissible length), they must be replaced.
27mm min.
Rotor vanes in motor 12M35
378
Other components
12S68 Switch ”Powdering cycle”
12S68 Switch ”Powdering cycle” Place of installation The switch ”Powdering cycle” 12S68 is located on the D.S. of the delivery. In the case of Betatronic from Grafix, Weko T 77Cs and Weko Ionomat Cs, the switch is connected directly to the powder spray device. With all other powder spray devices the switch is connected to the distribution box at the delivery.
Place of installation of switch ”Powdering cycle”, 12S68
379
Other components
12S9, -a, -b, -c Monitoring the IR slide-in dryer
12S9, -a, -b, -c Monitoring the IR slide-in dryer Place of installation Each IR slide-in dryer is equipped with a safety switch with NC and NO contacts. When the IR dryer is inserted, the switching element provided on the slide-in dryer actuates the safety switch on the drive side. Printing presses with several IR slide-in dryers (extended delivery) have 4 switches (12S9, 12S9a, 12S9b, 12S9c). The NC contacts of the safety switches are connected in series and the NO contacts in parallel.
ÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂ Place of installation of safety switch ”Monitoring the IR slide-in dryer”
Layout and connection
Sensor Openings for switching element Switching element (fitted on slide-in dryer) Marking
Function
21-22 13-14
NC contact NO contact
NC contact ( s ) at input 9 of EAK12: 0¢ 1¢
IR dryer(s) inserted IR dryer(s) removed
NO contact ( s ) at input 9 of SEK:
Sensor ”Monitoring the IR slide-in dryer”
380
1¢ 0¢
IR dryer(s) inserted IR dryer(s) removed
Other components
E8 Air supply cabinet
E8 Air supply cabinet Connections The air supply cabinet receives 2 AC 380 V and the control signal ”Compressor on” from the printing press. A thermostat in the control cabinet signals excessive temperatures to the CP Tronic control system. All cables are connected directly to terminal strips and are not led via plugs. For the exact terminal connections please refer to the circuit diagram and technical instructions of the manufacturer. Cable entries
Air supply cabinet, rear view
381
Other components
E39 Inking unit temperature control
E39 Inking unit temperature control Layout The supply voltage for the inking unit temperature control comes from the control cabinet and is connected via plug E39-X1. A manufacturer’s manual is available. E39-X1: power supply
Inking unit temperature control
Pin assignment E39-X1
6
1
7
2
8
3
9
4
10
5
Connector E39-X1, coming from the press
382
Pin
Function
3
AC 230 V, phase U
7
AC 230 V, phase V
9
AC 230 V, phase W PE
Other components
12E3 Static electricity eliminator
12E3 Static electricity eliminator
Attention:
Cut off the power supply before working on the device!
Place of installation
Place of installation of static electricity eliminator
Power supply for static electricity eliminator (D.S.) Neutralizer bar Ion blowers Air-supported neutralizer bar
The static electricity eliminator consists of a power supply unit with high-voltage transformer, a neutralizer bar at the feeder and an air-supported neutralizer bar at the delivery. Two ion blowers can be additionally attached to the suction head (optional).
Note: The static electricity eliminator is optional and therefore not fitted on all presses. For subsequent installation, threads are provided in the side frame as standard.
383
Other components
12E3 Static electricity eliminator
Layout
Mains switch Pilot lamp Power supply unit Power cable AC 230 V Ion blowers at feeder Neutralizer bar at delivery
Note: 2 different versions are available. Differences in the housing design do not affect the functions.
Static electricity eliminator 12E3 (ELTEX)
Static electricity eliminator, version 2 (SIMCO) 384
Other components
12E3 Static electricity eliminator
Task The unit consisting of the power supply with high-voltage transformer plus connected neutralizer bars and ion blowers eliminates static charges on the sheets of paper.
385
Other components
WSA Intercom
WSA Intercom Layout
Loudspeaker Microphone Volume controller Illuminated pushbutton
The WSA consists of one intercom at the control panel at the feeder and one at the control panel at the delivery. Each intercom has a microphone, loudspeaker, illuminated pushbutton, volume controller and two electronic boards (main and secondary boards). The electronic boards are directly in the intercom.
Intercom at feeder
Intercom at delivery
386
Other components
WSA Intercom
Function
Secondary board with terminal strip 11WSA-X2/ 12WSA-X2 Main board Connection for volume controller Connection for microphone Connection for secondary board 11WSAX1/ 12WSA-X1 Connection for illuminated pushbutton Changeover switch main/secondary intercom
The intercom is set in such a way that the main intercom (H) is at the delivery and the secondary intercom (N) at the feeder. When the illuminated pushbutton is pressed at the delivery, speaking at the feeder is interrupted. The priority between the two intercoms can be reversed any time by means of the changeover switch on the main board. The setting of the switch must then be changed at both intercoms.
Electronic boards of intercom
387
Other components
IDS Encoder
IDS Encoder Place of installation
Encoder IDS
Place of installation of encoder in 1st PU
Task The encoder is the basis for all speed- and degree-dependent functions. Examples of speed- and degree-dependent functions:
388
–
motor regulation,
–
interrogation points of sensors,
–
positioning for plate change.
Other components
IDS Encoder
Function Track A
Track B
Track 0
The encoder generates three pulse signals:
5V
–
track A,
0V
–
track B,
5V
–
track 0.
0V
Track B is staggered by 90° in relation to track A.
5V
Per revolution track 0 generates one zero pulse.
0V
The inverted signals are also available from all 3 tracks.
Pulse signals from the encoder
Tracks A and B each generate 1024 pulses per revolution.
Pin assignment
G
H
F
E
D
M J
L
C
A K
B
Pin
Function
M, G, H
DC+5V
A, L, D
5V
C
Track A/
B
Track A
F
Track 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. CD 102 Straight-printing presses On CD102 presses the IDS is always fitted in the 1st printing unit. SM102 Straight-printing presses IDS 1 SM102–2 SM102–2+L SM102–3 SM102–3+L SM102–4 SM102–4+L SM102–5 SM102–5+L SM102–6 SM102–6+L SM102–7 SM102–7+L SM102–8 SM102–8+L
Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing
unit unit unit unit unit unit unit unit unit unit unit unit unit unit
SM102 Perfector presses IDS 2
1 1 1 1 1 1 1 4 4 4 4 4 4 4
– – – – – – – – – – – – – –
IDS 1 SM102–2 SM102–2+L SM102–3 SM102–3+L SM102–4 SM102–5 SM102–5+L SM102–6 SM102–6+L SM102–7 SM102–7+L SM102–8 SM102–8 P5 SM102–8+L SM102–8+L P5 SM102–8+L
Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing Printing
Removal and installation 2
Encoder IDS 390
ÁÁÁÁ 3 ÁÁÁÁ ÁÁ 1 ÁÁ
1 2 3
Remove the plug. Loosen the stud. Remove the encoder.
unit unit unit unit unit unit unit unit unit unit unit unit unit unit unit unit
IDS 2 1 1 1 1 1 1 1 1 1 1 1 1 4 1 4 5
– – – – – – Printing Printing Printing Printing Printing Printing – Printing – –
unit unit unit unit unit unit
4/5 4/5 4/5 4/5 4/5 4/5/6
unit 4/5
Other components
IDS Encoder
4
Insert the gauge in printing unit 1.
4
Inserting the gauge
5
Line mark ”D”
Positioning to zero
5
8
0
1
6 7 8
Use the crank handle to turn the impression cylinder to the zero position (line mark ”D”). Fit the new encoder. Connect the encoder. Turn on the main switch 15Q66.
6 15Q66
Fitting the new encoder IDS
ÁÁ ÁÁ ÁÁ ÁÁ
7
391
Other components
IDS Encoder
9
ß
ß
Turn the shaft of the encoder until 000.0 is displayed in the MID. Tighten the stud.
Note: If the value 000.0 is not displayed in the MID, continue with step q. If the setting is correct, continue with r.
Á Á
9
Adjustment of the encoder IDS
w
ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ Á e Á q
q
Loosen the locking nut.
w
Turn the adjusting screw until 000.0 is displayed in the MID.
e
Tighten the locking nut.
r
Remove the gauge from PU 1.
Precision adjustment of the encoder IDS
r
Removing the gauge
392
Location diagrams
ZSG Central control cabinet
Location diagrams ZSG Central control cabinet Location and layout
Equipment zone E ”Swing frame” Equipment zone A ”Power supply” Equipment zone B ”Partition wall”
Equipment zone D ”Flat cable mounting plate” Equipment zone C ”Mounting rack / control devices”
Layout of central control cabinet 393
Location diagrams
ZSG Central control cabinet
Equipment zone A ”Power supply” This equipment zone contains the components necessary for connection to the power supply. The chapter ”Control systems” describes how the press is connected to the power mains.
15M1
Fan ”Power components”
15L1
Power choke - power converter
15R120
Load resistor (only for presses with Preset)
15R48
Load resistor (only for presses with auxiliary pile at the delivery)
15F2
Semiconductor fuses ”Armature circuit M1”
15Q66
Main switch
15Z2
EMC filter
15F1
Semiconductor fuses ”Mains”
15X1
Terminal strip
PE
PE conductor
15Z1
EMC filter
15T1
Control transformer
Equipment zone ”Power supply”
394
Location diagrams
ZSG Central control cabinet
Equipment zone B ”Partition wall”
SLT
GRM5
15Q61
15Q62
GRM24
15Q37
15K37M
15Q38
GRM48
Converter power part
GRM5
Rectifier module
GRM24
Rectifier module
GRM48
Rectifier module
GRM120-2
Rectifier module
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 ”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 connecting part of power converter”
15Q2
Motor circuit-breaker ”Air supply cabinet E 8”
15Q65
Motor circuit-breaker ”Transformer protection, primary”
GRM120-2
15Q65
15K48A
15K38M
SLT
15Q2
Equipment zone ”Partition wall”
SLT Converter power part The converter power part SLT contains the power electronics for driving the main drive. The chapter ”Control systems”, subchapter ”Direct-current main drive” lists the components of the converter power part. SLT
Converter power part 395
Location diagrams
ZSG Central control cabinet
GRM Rectifier modules The equipment zone B ”Partition wall” contains four rectifier modules.
F6 F8
F3 F4
F5
F7
GRM5
Rectifier module
GRM24
Rectifier module
GRM48
Rectifier module
GRM120-2 Rectifier module
The rectifier modules GRM24 and GRM48 are of identical design and interchangeable. Fuses: F6, F7, F8 (GRM5)
Rectifier modules GRM
– 15 A, quick-acting, 6.3 x 32 mm
F5, F4 (GRM24 / GRM48) – 20 A, quick-acting, 6.3 x 32 mm ca. AC 24 V
3 x ca. AC 35 V
3 x ca. AC 26 V
3 x ca. AC 100 V
ca. DC 36 V
ca. DC 120 V
ca. DC 33 V
ca. DC 50 V
Voltages at the rectifier modules GRM
396
F3 (GRM120)
– 32 A, slow-blowing
Location diagrams
ZSG Central control cabinet
Equipment zone C ”Mounting rack / control devices”
Q.... Motor circuit-breakers Q2a
Q4
Q4a
Q22
Q24
Q28
Q33
Q33a
Q35
Q39
K....M Main contactors 22M
Q39
Q39a
Q40
K22M K33M K33aM K35M K39M
Q44
Q22a
Q80 IWM
K39M
Earth-leakage monitor module
K22aM
K40M
K39M K39aM K46A K61A K50M K51M K52M K53M K54M K55M K56M K43M
Terminal amplifier module Flat-cable output module 64 outputs KVM
BAM
BKM
SPM
VSM
SVM
SVM
FAM 64
FEM 64
Flat-cable input module 64 inputs
ESM FEM10 AUM
Optocoupler 15U2 15X4
Terminal strips 15X3
Analog conversion module Flat-cable input module 10 inputs Interference suppressor module Interface distributor module Amplifier module Memory analog board module Brake coupling module Brake control module
Equipment zone ”Mounting rack / control devices” 397
Location diagrams
ZSG Central control cabinet
Equipment zone D ”Flat cable mounting plate” 15V1
I/O 1 I/O 2
I/O 3 I/O 4
13,15 5, 6 3, 4 1, 2 11,12 Flat cables from the press units
Equipment zone ”Flat cable mounting plate”
398
The rectifier reduces the voltage from the power supply board NTK 24 (in the REE) to the supply voltage (22 V) for the signal lamps. Leading to the swing frame: backplane of input/output plug-in unit EAR / input/output auxiliary drive plug-in unit EHR From each press unit, input and output cables lead to the swing frame. The input/output cables are fastened on the flat cable mounting plate. Cable routing as shown in the sketch opposite. Fixing clips
Location diagrams
ZSG Central control cabinet
Equipment zone E Swing frame” Equipment of swing frame for presses with:
ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ
–
REE2
2 - 5 PUs, without Preset REE2
Computer plug-in unit 2
EHE2
Input/output auxiliary drive plug-in unit 2
LTE
Power part plug-in unit
SSE2 Servo-drive plug-in unit 2
EHE2
LTE
Swing frame for presses with 2- 5 PUs
–
2 - 5 PUs, with Preset REE2
Computer plug-in unit 2
EHE2
Input/output 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
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
ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ
ZSG Central control cabinet
Equipment of swing frame for presses with: –
REE2 EAE
HAE2 LTE
– –
Swing frame for presses with 6- 8 PUs
6 - 7 PUs, without Preset 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 Servo-drive plug-in unit 2
6 - 7 PUs, with Preset, 8 PUs, with Preset, without non-stop 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/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
ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ
ZSG Central control cabinet
Equipment of swing frame for presses with: –
REE2 EAE
EHE2 LTE
Swing frame for presses with ≥ 9 PUs
9 PUs, with Preset, without non-stop delivery REE2
Computer plug-in unit 2
EAE
Input/output plug-in unit
EHE2
Input/output 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
9 PUs, with Preset, with auxiliary pile at the delivery REE2
Computer plug-in unit 2
EAE
Input/output plug-in unit
EHE2
Input/output 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 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.
401
Location diagrams
ZSG Central control cabinet
Computer plug-in unit REE 2
Computer plug-in unit REE
NTK24 Power supply board NTK5 Power supply board REK386 Processor board 386 ESK_2 Input/ output control board SAK2 Memory analog board ESK_1 Input/ output control board REK1 Processor board SRK Power converter board
Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , input / output control boards ESK 2). Boards of the same type are interchangeable.
ESK_2 Input/ output control board The input/ output control board ESK_2 is required for presses with ≥ 9 printing units.
REK386 Processor board 386 EPROM module
Computer motherboard
The processor board 386 REK 386 consists of the computer motherboard RGP 3, the EPROM module EPM and the RGPĆcomputer module RRM.
RGPĆcomputer module
Layout of computer unit RGP3+RRM REK1 Processor board EPROM module
The processor board REK 1 consists of the computer motherboard RGP 2 and the EPROM module EPM. Computer motherboard
Layout of processor board REK1
402
Location diagrams
ZSG Central control cabinet
Input/output auxiliary drive plug-in unit EHE 2 The input/output auxiliary drive plug-in unit EHE 2 is required for presses with: – 2 - 5 printing units, – ≥ 9 printing units.
Input/output auxiliary drive plug-in unit for presses with 2- 5 printing units
Input/output auxiliary drive plug-in unit for presses with ≥ 9 printing units
NTK5 Power supply board HAK2 Auxiliary drive board SEK
Safety input board
EAK2 Input/output board from right to left for: – feeder, – delivery, – central control cabinet, – printing units 1 to 5. EAK2 Input/output board for printing unit 9
Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , auxiliary drive boards HAK 2, input/ output boards EAK 2). Boards of the same type are interchangeable.
Input/output plug-in unit EAE The input/output plug-in unit EAE is required for presses with: – ≥ 6 printing units.
.
Input/output plug-in unit for presses with ≥ 6 printing units
NTK5 Power supply board SEK
Safety input board
EAK2 Input/output board from right to left for: – feeder, – delivery, – central control cabinet, – printing units 1 to 8.
Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , input / output boards EAK 2). Boards of the same type are interchangeable.
403
Location diagrams
ZSG Central control cabinet
Auxiliary drive plug-in unit HAE 2 The auxiliary drive plug-in unit HAE 2 is required for presses with: – 6 - 8 printing units.
Auxiliary drive plug-in unit for presses with 6- 8 printing units
404
NTK5 Power supply board HAK2 Auxiliary drive board
Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , auxiliary drive boards HAK 2). Boards of the same type are interchangeable.
Location diagrams
ZSG Central control cabinet
Power part plug-in unit LTE
ÍÍ ÍÍ ÅÅ ÅÅ
Í ÍÅ Å
ÍÍ ÍÍ Å Å
The power part plug-in unit LTE is required for all presses.
Í ÍÅ Å
Power part plug-in unit for presses with ≤ 7 printing units, without Preset, with auxiliary pile at feeder and delivery
ÍÍ ÍÍ Å Å
Í ÍÅ Å
ÍÍ ÍÍ Å Å
Í ÍÅ Å
ÍÍ ÍÍ Å Å
Power part plug-in unit for presses with 8- 9 printing units, with Preset, with auxiliary pile at the feeder
ÍÍ ÍÍ Å Å
Í ÍÅ Å
ÍÍ ÍÍ Å Å
Í ÍÅ Å
ÍÍ ÍÍ Å Å
Power part plug-in unit for presses with 8- 9 printing units, with Preset, without auxiliary pile at the feeder
LTK500
Power part board
LTK50
Power part board
STK_2
Pile control board
STK_1
Pile control board
Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power part boards LTK50, power part boards LTK500). Boards of the same type are interchangeable.
LTK50 Power part board The power part board LTK50 is only used for presses with: – 2 - 7 printing units, with Preset, with auxiliary pile at the delivery, – ≤ 7 printing units, without Preset, with auxiliary pile at the delivery
STK_1 Pile control board The pile control board STK_1 is used for all presses except for those with: – 8 - 9 printing units, with Preset, without auxiliary pile at the feeder.
STK_2 Pile control board The pile control board STK_2 is only used for presses: – without Preset, with auxiliary pile at the feeder.
405
Location diagrams
ZSG Central control cabinet
Servo-drive plug-in unit SSE2 The servo-drive plug-in unit SSE2 is required for presses with:
Servo-drive plug-in unit for a press with 2- 7 PUs, without Preset
–
2 - 4 PUs, without Preset (only one SSK 2),
–
2 PUs, without Preset, without CPC,
–
5 - 7 PUs, without Preset,
NTK24
Power supply board
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.
Servo-drive plug-in unit 2 / power part plug-in unit for brushless pile motors SSE 2/ LSE
Í Í Å Å Servo-drive plug-in unit/power part plug-in unit for brushless pile motors for presses with 6- 7 PUs, with Preset
The servo-drive plug-in unit / power part plug-in unit for brushless pile motors SSE 2/ LSE is required for presses with: –
2 - 5 PUs, with Preset (only one NTK 24 and two SSK 2s),
–
2 PUs, with Preset, without CPC,
–
6 - 7 PUs, with Preset,
–
8 - 9 PUs, with Preset, without non-stop delivery
NTK24 Power supply board SSK2 Servo-drive control board LTK500 Power part board BAK Brake control board
Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , servo-drive control boards SSK 2). Boards of the same type are interchangeable.
406
Location diagrams
ZSG Central control cabinet
Servo-drive plug-in unit 2 / power part plug-in unit for brushless pile motors SSE 2/ LSE
Í Í Å Å Servo-drive plug-in unit/power part plug-in unit for brushless pile motors 2 for presses with 8 - 9 PUs, with Preset, with auxiliary pile at the delivery
The servo-drive plug-in unit / power part plug-in unit for brushless pile motors SSE 2 / LSE2 is required for presses with: –
8 - 9 PUs, with Preset, with auxiliary pile at the delivery
NTK24 Power supply board SSK2 Servo-drive control board LTK50 Power part board LTK500 Power part board BAK Brake control board
Note: All electronic boards of the same type in the swing frame are identical in design (e.g. power supply boards NTK , servo-drive control boards SSK 2). Boards of the same type are interchangeable.
407
Location diagrams
ZSP Central control console
ZSP Central control console Layout
Fixing bolts for console plate
Console plate
Display control board DSK
Input / output module EAM Display unit consisting of: –
display power supply board DNK
–
display support plate
–
control console display ZID
Support plate for: A – transformer 13T1 B – connector 13X1 C – terminal strip 13X2
Hinged cover with opening for cables Casing of central control console
Door
Overall view
408
Location diagrams
Position switches
Position switches 2S29
1S29
2S28
11S37
1S28
11S34
11S31 11S65 11S56
2S26
2S25 2S25a 2S25b 2S24
1S25 1S25a 1S25b 1S24 2S20
1S26
11S40 11S38 11S38a
1S40a
2S37
1S40
11S32 11S4
11S38b 11S36
2S31
11S39
Preset feeder, printing units 1 and 2
12S55
12S55a 3...9S28
12S40 12S44 12S56
12S38
12S35 12S36 12S422) 12S130a 12S41 12B129a 12B129
Version with rake
2
Version with board
12S37
12S34 12S130
12S421)
1
12S39 12S33
3...9S29 3...9S24
12S9
12S65a
3...9S20
12S117 12S34b 12S34a
3...9S37
12S43
Delivery with coating unit Legend: Equipment O.S. Equipment D.S. Equipment which can be allocated neither to the D.S. nor to the O.S.
409
Location diagrams
Position switches
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 12S55
12S55a
12S68
12S35
12S42
3...9S28
12S40
12S44
12S56 12S36 12S39
12S37
12S34
12S9
3...9S29
3...9S24
12S37a
12S65a
12S411) 12S412)
12S65
3...9S20
3...9S37
12S34b 12S34a
12S43
12S9c
1
Version with rake
2
Version with board
Extended delivery with coating unit Legend: Equipment O.S. Equipment D.S. Equipment which can be allocated neither to the D.S. nor to the O.S.
410
12S9b
12S9a
Location diagrams
Solenoid valves
Solenoid valves
2Y56
1Y56
11Y74 1Y45
11Y66 11Y16
15Y11
1Y15 11Y15 2Y12
1Y12 1Y16
2Y48
2Y2 2Y9 2Y10 2Y11 2Y13 2Y53
1Y48
2Y63 2Y62 2Y61 2Y7 2Y51 2Y39/2Y40
1Y2 1Y9 1Y10 1Y11 1Y13 1Y53 1Y47
back 1Y63 1Y62 1Y61 1Y7 1Y51 1Y39/1Y40
1Y50 1Y52 1Y55 1Y42
1Y44 1Y54 1Y43 front or back
1Y52 1Y55 1Y42 1Y54 1Y43
front
Preset feeder, printing units 1 and 2 Legend: Equipment O.S. Equipment D.S. Equipment which can be allocated neither to the D.S. nor to the O.S.
411
Location diagrams
Solenoid valves
12Y14/ 12Y15 12Y60/ 12Y61
12Y11 12Y49 12Y13 12Y4
3...9Y12 12Y78
4...9Y67 3...9Y48
12Y62
Delivery with coating unit
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 12Y14/ 12Y15
12Y60/ 12Y61
12Y11
12Y49
12Y13
3...9Y12
12Y4
4...9Y67
12Y78
12Y62
Extended delivery with coating unit Legend: Equipment O.S. Equipment D.S. Equipment which can be allocated neither to the D.S. nor to the O.S.
412
3...9Y48
Location diagrams
Motors
Motors 2MD
1MD 11M11 1M45
2M45 Lateral register
11M2
11M12 11M1
Lateral register 11M6 2M1
2M6
1M1
1M6
1M4
11M7 11M5
1M8 2M5 Circumferential register
1M5 Circumferen1M7 tial register 11M3
M52
M51
1M4
1M2 1M3 11M9 11M8 1M9
Preset feeder, printing units 1 and 2
12M2 12M5 12M7
12M6
3...9M2
12M1
12M3 12M47
M44
Delivery with coating unit Legend: Equipment O.S. Equipment D.S. Equipment which can be allocated neither to the D.S. nor to the O.S.
413
Location diagrams
Motors
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 12M2
12M5
12M7
12M6
3...9M2
12M1
12M3
12M47
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
M44
Location diagrams
Sensors
Sensors
2B43
2B32
1B43
1B32
15B14
11B10 11B35
1B11 1B13 2B48
1B48 2B48a
1B48a
11B55
1B9
1B10 HWI 1B49
11B33 11B11
Preset feeder, printing units 1 and 2
3...9B32 12B129 12B69 12B129a
12B65 12B77
12B47
Delivery with coating unit Legend: Equipment O.S. Equipment D.S. Equipment which can be allocated neither to the D.S. nor to the O.S.
415
Location diagrams
Sensors
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 3...9B32
12B129
12B69
12B129a
12B65
12B77
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
12B47
Location diagrams
Control panels
Control panels
F
F C
C
D
D
A
B
Preset feeder, printing units 1 and 2
H C
F
G
Delivery with coating unit
417
Location diagrams
Control panels
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ H
C
G
Extended delivery with coating unit
418
F
Location diagrams
Control panels
Feeder
A
Press control
B
Pile control
Preset feeder
419
Location diagrams
Control panels
Printing unit/coating unit C
Printing unit control O.S.
D
Printing unit/ coating unit control D.S.
F
Dampening system control
G
Coating unit control D.S.
Printing unit/coating unit
420
Location diagrams
Control panels
Delivery H
Press control
H
Pile control
H
Press display MID
Preset version
421
Location diagrams
H
Dampening system control
H
Fan and dryer control
Preset version
422
Control panels
Location diagrams
Operator’s controls
Operator’s controls
Description
Feeder
Pushbutton ”Run”
11S2
12S2
Pushbutton ”Stop”
11S30
12S8
Pushbutton ”Production run”
11S19
12S60
”Emergency stop” button
11S1
Illuminated pushbutton ”Compressor on/off”
11S3 11H3
11S58 11H58
Illuminated pushbutton ”Feeder on/off”
11S7 11H7
12S59 12H59
Illuminated pushbutton ”Paper run on/off”
11S5 11H5
12S57 12H57
Pushbutton ”Fast”
11S20
12S6
Pushbutton ”Slow”
11S21
12S7
Pushbutton ”Forward”
11S17
1...nS3 (O.S.) 1...nS6 (D.S.)
12S3
Selector switch ”Safe”
11S18
1...nS4 (O.S.) 1...nS7 (D.S.)
12S4
1...nS5 (O.S.) 1...nS8 (D.S.)
12S5
Pushbutton ”Backward”
Signal lamp ”Malfunction press”
11H51
Signal lamp ”Malfunction feeder” ”Malfunction delivery” ”Malfunction printing/coating unit” ”Malfunction dryer”
11H1
Printing/coating unit
1...nS1 (O.S.) 1...nS2 (D.S.)
Delivery
Remark
12S1
12H9
1...nH1
12H1
423
Location diagrams
Description
Operator’s controls
Feeder
Printing/coating unit
Illuminated pushbutton ”Job counter on/off”
12S63 12H63
Pushbutton ”Crawl speed”
1...nS23
Pushbutton ”Position”
1...nS17
Illuminated pushbutton ”Plate mounting”
1...nS59 1...nH59
Pushbutton ”Auxiliary pile down”
11S29
12S54
Pushbutton ”Auxiliary pile up”
11S28
12S53
Toggle switch ”Auxiliary pile on/off”
11S27
Pushbutton ”Main pile down”
11S25
12S46
Pushbutton ”Main pile up”
11S24
12S45
Pushbutton ”Pile stop”
11S26
12S124
Pushbutton ”Pile board on/off”
12S10 12H10
Pushbutton ”Removal of inspection sheet”
12S11 12S11a
Press display MID Illuminated pushbutton ”Inking form rollers on/off”
424
Delivery
1...nS57 1...nS57
Remark
Location diagrams
Description
Operator’s controls
Feeder
Printing/coating unit
Illuminated pushbutton ”Ink ductor on/off”
1...nS58 1...nH58
Pushbutton ”+ dampening”
1...nS22
Delivery
Remark
12S17... 12S24
„Washing dampening/varnishing rollers” Illuminated pushbutton ”– dampening”
12S25... 12S32
Selector switch ”Adjusting dampening rollers”
1...nS21
Pushbuttons ”Blast air regulation”
11S117 11S118
Pushbuttons ”Suction head height”
11S44 11S44a 11S45 11S45a
Pushbuttons ”Suction head format”
11S46 11S47
Pushbuttons ”Main pile centering”
11S58 11S58a 11S59 11S59a
Pushbuttons ”Auxiliary pile centering”
11S59 11S60
Pushbutton ”Pile stops – larger format”
11S63
Pushbutton ”Pile stops – smaller format”
11S62
Pushbutton ”Pile stops D.S.”
11S9
Pushbutton ”Pile stops O.S.”
11S10
Pushbuttons ”Format wheels”
11S48 11S57
Pushbuttons ”Sheet slowdown format”
12S68 12S69
425
Location diagrams
Description
Operator’s controls
Feeder
Delivery
Pushbuttons ”Sheet slowdown speed”
12S61 12S62
Pushbuttons ”Sheet jogger D.S.”
12S73 12S74
Pushbuttons ”Sheet jogger O.S.”
12S75 12S76
Potentiometer to regulate the displayed fans
DSM5
Potentiometer to regulate the displayed fans
DSM3
Potentiometer to regulate the displayed fans
DSM6
Potentiometer to regulate the displayed fans
DSM2
Potentiometer to regulate the displayed fans
DSM1
Potentiometer to regulate the displayed fans
DSM4
Pushbutton ”Dryer on/off”
Selector switch for dryer
Potentiometer to regulate dryer output Volume controller
Illuminated pushbutton ”Intercom” Pushbutton ”Lifting the sheet stop fingers”
426
Printing/coating unit
11S8
Remark
Location diagrams
Operator’s controls
Description
Feeder
Illuminated pushbutton ”Dampening rollers”
11S6 11H6
Pushbutton ”Suction air for suction tape +”
11S41
Pushbutton ”Suction air for suction tape –”
11S42
Illuminated pushbutton ”Turning the ink fountain roller”
Printing/coating unit
Delivery
Remark
1...nS45
Varnish circulation
Varnish pump ON/OFF
Turning the pan roller
Draining the coating pan
Varnish flow rate to varnish pump
Spraying
Rinsing
Stopping the pan roller
Potentiometer ”Blast air at front lays”
2...nS57 2...nH57 11R1
427
Location diagrams
428
Operator’s controls
Location diagrams
ZSP Control panel of control console
ZSP Control panel of control console
7
8
9
4
5
6
1
2
3
0
CPC
Control panel of central control console ZSP
Selector buttons ”Unit” (from left to right): – Entire press – Delivery – Printing unit – Feeder
Preselection display Actual value display Fine display of preselection/actual value display
Fault display: – Press not ready to run – Warning Service display: – Central lubrication – Service 1 – Service 2 Colour buttons Function buttons
”Emergency stop” button Button ”Stop” Command buttons (from left to right): – Presetting – Job change – Progressives (colour separations) – Washup Command control buttons Signal lamps (from left to right): – Malfunction press (red) – Malfunction control console (blue) – Malfunction production run (yellow) Button ”Page up/down” in the display Control console display Numeric keypad CPC keys (for presses without CPC equipment)
Adjustment buttons
429
Location diagrams
430
ZSP Control panel of control console
Abbreviations
Abbreviations Abbreviation
Description
Abbreviation
Description
AEM
Drive extension module
EAE
Input/output plug-in unit
ANZ
Display board
EAK
Input/output board
ATV
Display and key distribution board
EAM
Input/output module
EAR
ASE
Job memory card unit
Backplane of input/output plug-in unit
AUM
Analog signal distribution module
EE
Electronic plug-in unit
EEM
AVM
Control and distributor module
Single-fault fail-safe extension module
EGK
External equipment board
EHE
Auxiliary drive input/output plug-in unit
EHR
Backplane of auxiliary drive input/output plug-in unit
ELK
Mains discharge board
ELR
Backplane of electronic plug-in unit
BAK
Brake control board
BAM
Brake control module
BEK
Control unit board
BFM
Filter module of brushless power part
BKM
Brake/ clutch module
BLT
Brushless power part
EPM
EPROM module
BSM
Control unit interface module
ESG
Extension control cabinet
BVM
Control unit distributor module
ESK
Input/output control board
ESM
Interference suppressor module
EVG
Electronic ballast
EVK
Front-corner alignment control
CSM
CPC3 interface module
CVK
CPC3 distributor board
DAM
EVM
Input/output distributor module
Double-sheet indication module
EWK
Extension board
DAK
Digital output board
EWM
Extension module
DAS
Speed ratio display system
EXK
External equipment supply board
DBE
Double-sheet detector
DGP
Display motherboard
DLW
Diskette drive
FAM
Flat-cable output module
DNK
Display power supply board
FCA
Adaptor between telediagnosis board and CPC2S
DSK
Display control board
FCK
Flash memory controller board
DSM
Speed control module ”Fans”
FDK
Telediagnosis board
431
Abbreviations
Abbreviation
Description
Abbreviation
Description
FEM
Flat-cable input module
LDM
Air pressure sensor module
FKK
Ink fountain board
LG
Light pen
FKV
Ink fountain distributor
LLM
Power logic module
FÜK
Sensor for overshooting-sheet control
LPM
Varnish pump control module
LRM
Power part control module
FVM
Flat-cable connection module
LS
Light barrier
FZA
Ink zone display board
LSE
FZT
Distribution board for ink zone keys
Power part plug-in unit for brushless pile motors
LSM
Lamp control module
LSR
Backplane of power part plugin unit for brushless pile motors
GKM
Compact rectifier module
GRM
Rectifier module
LTE
Power part plug-in unit
GSM
Rectifier module with fuses
LTK
Power part board
LTM
Power part module
LTR
Backplane of power part plugin unit
HAE
Auxiliary drive plug-in unit
HAK
Auxiliary drive board
LUM
Interconnection module
HAR
Backplane of auxiliary drive plug-in unit
LVM
Air distributor module
HLM
Auxiliary drive logic module
LVT
Distribution box
HSK
Main drive control board
HSQ
Sheeter
MAE
Motor drive plug-in unit
HTM
Auxiliary drive driver module
MAR
Motor drive backplane
HVK
Main current distributor board
MCM
Microcontroller module
HWI
Encoder
MEE
Motor drive/electronic plug-in unit
MID
Press display
IDS
Encoder
MK
Measuring head
ITF
Terminal interface
MOT
Motor drive board
ITM
IGBT driver module
MRK
Motor regulation board
IWM
Earth-leakage monitor module
MRM
Measuring bar computer module
KID
Compact information display
MSK
Motor control board
KKM
Heat sink module
MSM
Measuring bar sensor module
KLM
Compact power module
MWE
Measured-value acquisition board
KNT
Compact power supply unit
MZK
State indication board
KOK
Communication board
KVM
Terminal amplifier module
KVT
Heat sink unit
432
Abbreviations
Abbreviation
Description
Abbreviation
Description
NAM
Mains connection module
SBM
Power bridge module
NEK
Electronics supply board
SDM
Servo-drive pushbutton module
NSM
Supplementary module of power supply unit
SEK
Safety input board
SEM
Interface input module
NTE
Power supply plug-in unit
SIK
NTK
Power supply board
Actual current measuring board
NTM
Power supply module
SLA
Suction air control
NTR
Power supply backplane
SLM
Pile power module
NVK
Mains supply board
SLT
Converter power part
NVM
NV-RAM module
SM
Stepper motor
NVTE
Power distributor of electronic plug-in unit
SMM
Current measuring module
SMR
Stepper motor control board
SNT
Chopper-type power supply unit
SPM
Memory analog board module
SPR
Voltage regulator
SPW
Voltage selector switch
PBK
Back-up battery board
PD
Printer
PEK
Extension board for plate image reader
PRZ
Processor board
SRK
Power converter board
PRM
Plate position detection module
SSA
Serial interface adapter
PSL
Positioning lamps
SSE
Servo-drive plug-in unit
PSM
Profibus interface module
SSK
Servo-drive control board
PU
Printing unit
SSM
Servo-drive distributor module
SSR
Backplane of servo-drive plugin unit
STA
Interface adapter
STK
Pile control board
STL
Pile power part
STM
Pile control module
REE
Computer plug-in unit
REK
Processor board
REM
Register module
RER
Backplane of computer plug-in unit
RGP
Computer motherboard
STS
Vacuum cleaner
RRM
RGP computer module
STT
RSK
Plug-on control board
Supporting element of power converter
RSM
Plug-on control module
SUM
Signal conversion module
RWK
Backplane
SVK
Control voltage distributor board
SVM
Interface distributor module
SVT
Connecting part of power converter
SW
Voltage fluctuation relay
SWM
Setpoint module
SAK
Memory analog board
SAM
Interface output module
SAS
Busbar system
433
Abbreviations
Abbreviation
Description
Abbreviation
Description
TAM
Button and display module
ZRM
ZSK computer module
TEM
Tacho input module
ZSG
Central control cabinet
TLK
Transistor power board
ZSK
Central control board
TML
Terminal
ZSP
Central control console
TMP
Buttons for manual positioning of measuring head
ZT
Zenith terminal
ZTK
Central control board
TRK
Transistor control board
TRM
Transistor control module
TSK
Driver/interface board
TSM
Dryer control module
TTK
Transistor driver board
TUM
Keyboard coding module
TVK
Key distributor board
TVM
Encoder distribution module
TVS
Tacho signal distribution system
UFK
Filter board
USM
Interconnection module
UVM
Converter and distributor module
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
WDM
Resistance decade module
ZID
Control console display
ZMM
Double current-measuring module
434
Equipment identification
Equipment identification To be able to clearly identify the electrical equipment, the following equipment identification is used:
Press model Position code Where on the press ... ?
Identification letter or abbreviation Which equipment ... ?
Number Distinguishes equipment of the same type
Example 1: 1LVT1
1
LVT
1
PU1
Distribution box
1st distribution box (main distributor)
S
3
Example 2: 1S3
1 Printing unit 1
Switch here: pushbutton ”Forward”
Consecutive number of switch on PU 1
Example 3: E4
Blank Cannot be allocated to any unit
E Other equipment: motor / pneumatic system compressor
4 Consecutive number
Note: – If a field of the equipment identification is not required or not defined, it is left blank. –
In most cases the consecutive number corresponds to the inputs or outputs of the associated EAK.
435
Equipment identification
436
Position codes
Position codes Overview of position codes
The position code indicates on which unit of the press the equipment in question is located. The position codes 1 to 10 are reserved for the printing units or the coating unit. 1
Printing unit 1
2
Printing unit 2 or coating unit
3
Printing unit 3 or coating unit
4
Printing unit 4 or coating unit
5
...
11
Feeder
12
Delivery
13
Central control console
14
Sheeter HSQ
15
Central control cabinet ZSG
16
Extension control cabinet ESG
20
Dryer
101
Control unit CPC1
10
Example: Position codes on a Speedmaster
15 4
3
2
1
12 101
13
11
Speedmaster SM102
437
Position codes
438
Index
Index A Abbreviation, 435 Abbreviations, 431 Adjustment of format wheels 11M4, 47 – Checking the operating range, 52 – Fault message, 47 – Interconnection diagram, 49 – Place of installation, 48 – Removal and installation, 50 – Technical data, 48 Adjustment of pile support plate 11M8, 31, 33 – Checking the operating range, 37 – Interconnection diagram, 34 – Place of installation, 33 – Removal and installation, 35 – Technical data, 33 Adjustment of printing pressure 1...nM5, 85 – Checking the operating range, 95 – Interconnection diagram for CU, 89 – Interconnection diagram for PU, 88 – Place of installation, 87 – Removal and installation of motor, 90 – Removal and installation of potentiometer, 92 – Technical data, 87 Adjustment of pull lays 1M7/1M8, 96 – Automatic positioning, 96 – Checking the operating range, 103 – Interconnection diagram 1M7, 99 – Interconnection diagram 1M8, 100 – Place of installation, 98 – Precision adjustment of pull lay, 97 – Removal and installation, 101 – Technical data, 98 Admission of pressure, pneumatic system 15Y11 – Pin assignment, 352 – Place of installation, 351 – Task, 351 Air supply cabinet E8, 381 Automatic misalignment control 11M7 – Activation and inactivation, 252 – Block diagram, 251 – Checking the operating range, 257 – Graphical representation, 253 – Interconnection diagram, 255 – Place of installation, 254 – Removal and installation, 256 – Sheet alignment, 251 – Technical data, 254 automatic pile transport 11B35 – checking the circuit state, 157 – connection, 156 – Layout, 155 – place of installation, 155 – -removal and installation, 156 – task and function, 156
Automatic sheet arrival control 11M3 – Activation and inactivation, 239 – Block diagram, 238 – Graphical representation, 240 – Preset version, 247 – Checking the operating range, 250 – Interconnection diagram, 248 – Place of installation, 247 – Removal and installation, 249 – Technical data, 247 – Sheet alignment, 238 – Sheet arrival control, 239 – Standard version, 241 – Checking the operating range, 246 – Interconnection diagram, 242 – Place of installation, 241 – Removal and installation, 243 – Technical data, 241 Autoplate, 267 – Block diagram, 269 – Fault display, 268 – Method of functioning, 267 – Sequence of functions, 270 auxiliary pile detection 11B11 – checking the circuit state, 151 – connection, 150 – layout, 149 – place of installation, 149 – removal- and installation, 150 – setting, 151 – task and function, 150 auxiliary pile motor 11M2 – layout, 146 – pin assignment, 148 – place of installation, 146 – task and function, 147 – Technical specifications, 147 auxiliary pile motor 12M2 – layout, 192 – pin assignment, 194 – place of installation, 192 – Task and function, 193 – Technical specifications, 193
B Blanket washup device GTW, 281 Blast air regulation at feeder 1M9, – Manual blast air setting, 360 Blast air regulation at the feeder 1M9 – Block diagram, 357 – Characteristic–curve–dependent blast air regulation, 358 – Checking the operating range, 367 – Layout and task, 362 – Pin assignment, 363 – Place of installation, 361 – Removal and installation, 364 – Technical data, 363 Block diagram, – Sheet alignment, 207 Blower bar, – see blower motor for dampening system, 322
1
Index
Blower motor for dampening system M45, 322 Blower motor for powder spray device 12M35, 377 bottom main pile limitation 11S34 – checking the circuit state, 159 – place of installation, 158 – setting, 159 – task and function, 158 bottom main pile limitation 12S34 – checking the circuit state, 206 – place of installation, 204 – setting, 205 – task and function, 204 Brushless main motor from 37KW, 12
C Central control cabinet ZSG, 393 – Equipment zone A ”Power supply”, 394 – Equipment zone B ”Partition wall”, 395 – Equipment zone C ”Mounting rack / control devices”, 397 – Equipment zone D ”Flat cable mounting plate”, 398 – Equipment zone E ”Swing frame”, 399 – GRM Rectifier module, 396 – Location and layout, 393 Central dampening solution supply E40, 325 Central lubrication, 329 – Basic concept, 329 – Fault messages, 332 – Grease lubrication – Block diagram, 333 – Function, 334 – Layout, 334 – Monitoring the lubrication system, 335 – Motor for grease lubrication 12M47, 345 – Place of installation, 334 – Pressure relief valve of the motor , 337 – Settings, 336 – Triggering a lubrication process, 336 – Oil lubrication – Block diagram, 338 – Changing the filter, 342 – Distributing lubrication, 340 – Filter unit, 341 – Function, 340 – Layout, 339 – Place of installation, 339 – Pressure relief valve of oil pump, 342 – Triggering a lubrication process, 341 – Service display, 330 changeover fast/slow 12B65 – checking the circuit state, 197 – connection, 196 – layout, 195 – place of installation, 195 – -Removal and installation, 196 – task and function, 196 Circumferential register SM/CD 102, 314 Coarse register monitoring, 271 Adjustment, 273 Connection, 271 Layout, 271
2
Place of installation, 271 Removal and installation, 272 Coarse register monitoring 1...nB48, – Task/function, 272 Coating unit, – Position code, 437 Control console – Layout, 408 – Location diagrams, 408 Control panel ZSP, – Location diagrams, 429 Control panels – Delivery, 421 – Feeder, 419 – Location diagrams, 417 – Printing unit/coating unit, 420 Cooling and circulating unit E40, 325 Cover guide height adjustment 1M4, 67 – Checking the operating range, 76 – Interconnection diagram, 70 – Place of installation, 69 – Positioning, 67 – Removal and installation of motor, 71 – Removal and installation of potentiometer, 73 – Technical data, 69
D Dampening, 321 Dampening solution mixing unit E41, 328 Dampening system – Blower motor, 322 – Dampening solution sensor, 323 Delivery, – Position code, 437 delivery pile control – automatic pile height control, 170 – auxiliary drive control, 165 – block diagram (Preset), 161 – block diagram (standard), 162 – non–stop operation, 177 – overview (Layout), 163 – overview of components (drive side), 167 – overview of components (operator side), 166 – overview of motors, 168 – overview of solenoid–operated valves, 169 – overview of switches and sensors, 168 – paper blockage, 185 – press control, 164 – removal of sample sheet, 184 – safety circuit, 164 – Transport of auxiliary pile, 175 – transport of main pile (Preset), 171 – transport of main pile (standard), 173 delivery upper edge of pile 12B129 – checking the circuit state, 203 – connection, 202 – layout, 201 – place of installation, 201 – -removal and installation, 203 – task and function, 202 Diagonal register SM/CD 102, 308 Double–sheet detector 1B11 – Adjustment, 237 – Block diagram, 231
Index
– Connection, 235 – Fault messages, 232 – Layout, 234 – Pin assignment, 235 – Place of installation, 233 – Removal and installation, 236 – Sheet alignment, 231
E Encoder, – Place of installation, 388 Encoder IDS, 388 – Installation variants, 390 – Pin assignment, 389 – Removal and installation, 390 Equipment identification, 435 Extension control cabinet ESG, 437
F Feeder, – Position code, 437 Feeder pile control – block diagram (Preset), 119 – block diagram (Standard), 120 – Overview of components (Standard), 125 feeder pile control – automatic pile height control of auxiliary pile , 129 – automatic pile height control of main pile (standard), 128 – auxiliary drive control, 123 – non–stop operation (Preset), 134 – non–stop operation (standard), 137 – overview (layout), 121 – Overview of components (Preset), 124 – overview of motors, 126 – overview of switches and sensors, 126 – pile height control of main pile (Preset), 127 – press control, 122 – safety circuit, 122 – transport of auxiliary pile, 132 – Transport of main pile, 130 Format adjustment – Adjustment of format wheels 11M4, 47 – Adjustment of printing pressure 1...nM5, 85 – Cover guide height adjustment 1M4, 67 – Pile stops 11M11/11M12, 59 – Sheet joggers 12M6/12M7, 110 – Sheet slowdown/format adjustment 12M5, 104 – Suction head/format adjustment 11M6, 53
G Grease lubrication, 333 – Lubrication monitoring 1 – 12B47, 348 – Lubrication monitoring 2 – 12B77, 348 GRM Rectifier module, – Central control cabinet ZSG, 396
I Identification letter, 435 Impression cylinder washup device DZW, 292 – Block diagram, 292 Inactivating pile centering 11B55, 28 Ink blade, – Sensor monitoring the ink blade 1...nB43, 303 Ink fountain roller motor SM/CD 102, 305 Inking roller washup device FWW, 286 Inking unit temperature control, 382 – SM/CD 102, 317 Inking unit temperature control E39, E39a, – SM/CD 102, 318 Intercom WSA – Function, 387 – Layout, 386 IR slide–in dryer, – Switches monitoring the IR slide–in dryer 12S9, –a, –b, –c, 380
L Lateral register SM/CD 102, 311 Level in coating pan L–B32, 371 Location diagrams, 393 – Control panel ZSP, 429 – Control panels, 417 – Delivery, 421 – Feeder, 419 – Printing unit/coating unit, 420 – Motors, 413 – Operator’s controls, 423 – Position switches, 409 – Sensors, 415 – Solenoid valves, 411 – ZSP Central control console, 408 Location diagrams , – Central control cabinet ZSG, 393 Lubrication monitoring 1 – 12B47, 348 Lubrication monitoring 2 – 12B77, 348
M M1 Direct–current main motor, 7 Main drive – Brushless main motor from 37KW, 12 – Direct–current main motor, 7 – Motor terminal board, 15 – Replacing the brake, 9 – Replacing the carbon brushes, 10 – Rotor position encoder, 13 main pile motor (Preset) 11M1 – layout, 140 – pin assignment, 142 – place of installation, 140 – task and function, 141 – technical specifications, 141 main pile motor (standard) 11M1 – Layout, 143 – pin assignment, 145 – place of installation, 143 – task and function, 144 – Technical specifications, 144
3
Index
main pile motor 12M1 (Preset) – layout, 186 – pin assignment, 188 – place of installation, 186 – Task and function, 187 – Technical specifications, 187 main pile motor 12M1 (standard) – layout, 189 – pin assignment, 191 – place of installation, 189 – Task and function, 190 – technical specifications, 190 Malfunctions in printing unit, 268 Misalignment control 11M7, – Misalignment control, 252 Monitoring the ink blade, sensor 1...nB43, 303 – Connection, 304 – Layout, 303 – Pin assignment, 304 – Place of installation, 303 – Removal and installation, 304 – Task, 304 Monitoring the IR slide–in dryer, – Switches 12S9, –a, –b, –c, 380 Motor for grease lubrication – Pin assignment, 345 – Place of installation, 345 Motor terminal board, 15 Motors – Blower motor for powder spray device 12M35, 377 – Location diagrams, 413 – Washup brush motors M43, M50 ... M56, 296 Motors / functional units, – Servo–drive diagonal register SM/CD 102, 308 Motors / motor–driven units – Servo–drive circumferential register SM/CD 102, 314 – Servo–drive ink fountain roller SM/CD 102, 305 – Servo–drive lateral register SM/CD 102, 311
N Number, 435
O Oil lubrication, 338 – Pressure monitoring oil lubrication 1F33 (1 bar), 346 – Pressure monitoring oil lubrication 1F34 (12 bars), 347 Oil pump M44, 343 – Pin assignment, 344 – Place of installation, 343 Operator’s controls, – Location diagrams, 423
P Pan roller motors 1...nM1, 321 Pile centering, 17 – Activation and inactivation, 18 – Block diagram, 17 – Sensor ”Inactivating pile centering” 11B55, 28 – Sensor ”Pile centering” 11B10, 19
4
– Sensor 11B10, 20 – Sensor 11B55, 29 – Servo–drive ”Pile centering” 11M9, 21 Pile centering 11M9, 23 – Checking the operating range, 27 – Interconnection diagram, 24 – Place of installation, 23 – Removal and installation, 25 – Technical data, 23 pile height control 12B69 – checking the circuit state, 200 – connection, 199 – Layout, 198 – place of installation, 198 – -removal and installation, 199 – setting, 200 – Task and function, 199 Pile merging, 31 – Adjustment of pile support plate 11M8, 31 Pile stops 11M11/11M12, 59 – Checking the operating range, 66 – Fault message, 60 – Interconnection diagram 11M11, 62 – Interconnection diagram 11M12, 63 – Place of installation, 61 – Prepiling, 60 – Removal and installation, 64 – Technical data, 61 Pin assignment – Servo–drive circumferential register SM/CD 102, 315 – Servo–drive diagonal register M4 SM/CD 102, 309 – Servo–drive ink fountain roller SM/CD 102, 306 – Servo–drive lateral register SM/CD 102, 312 Coarse register monitoring, 271 Plate clamping device – Autoplate, 267 1...nB53 Coarse register monitoring, 271 Pneumatic system, – Admission of pressure, pneumatic system 15Y11, 351 Pneumatic system compressor E4 – Pin assignment, 355 – Technical data, 355 Position code, 435 Position codes, 437 Position switches, – Location diagrams, 409 Potentiometer, 308 Powder spray unit 12E2, 373 Powdering cycle switch 12S68, 379 Pressure monitoring oil lubrication 1F33 (1 bar), – Place of installation, 346 Pressure monitoring oil lubrication 1F34 (12 bars), – Place of installation, 347 Pressure sensor pneumatic system 15B14 – Pin assignment, 354 – Place of installation, 353 Print–free margin 1M2/1M3 – Checking the operating range, 84 – Interconnection diagram, 79 – Place of installation, 78 – Removal and installation of motor, 80 – Removal and installation of potentiometer, 81 – Technical data, 78 Print–free margin D.S./O.S. 1M2/1M3, 77
Index
Printing unit, – Position code, 437 Pull lay control 1B9/1B10 – Block diagram, 223 – Checking the sensing distance, 230 – Place of installation, 226 – Sheet alignment, 223 – Sheet infeed error/pull error, 224 Preset version, – Adjustment, 227 Standard version, – Adjustment, 229
R Rotor position encoder, 13 – Layout, 13 – Pin assignment, 13
S Sensor ”Inactivating pile centering” 11B55 – Adjustment, 29 – Check, 29 – Place of installation, 29 Sensor ”Pile centering” 11B10, 20 – Check, 20 – Place of installation, 20 – Removal and installation, 20 Sensor for dampening solution control B32, 323 Sensors – Admission of pressure, pneumatic system 15Y11, 351 – at the washup solution container B1, B54, B55, 301 – Adjustment, 302 – Connection, 301 – Pin assignment, 301 – Place of installation, 301 – Removal and installation, 302 – Level in coating pan L–B32, 371 – Location diagrams, 415 – Monitoring the ink blade 1...nB43, 303 Sensors/switches, 1...nB53 Coarse register monitoring, 271 Service display – Grease lubrication, 331 – Oil lubrication, 330 Service display Washup, 278 – Functions of the blanket washup device, 278 – Functions of the impression cylinder washup device, 278 – Functions of the inking roller washup device, 279 Servo–drive – Adjustment of format wheels 11M4, 47 – Adjustment of pile support plate 11M8, 33 – Adjustment of printing pressure 1...nM5, 85 – Adjustment of pull lays 1M7/1M8, 96 – Automatic misalignment control 11M7, 251 – Automatic sheet arrival control 11M3 – Preset version, 247 – Standard version, 241 – Blast air regulation at the feeder 1M9, 357 – Cover guide height adjustment 1M4, 67 – Pile centering 11M9, 21, 23
– Pile stops 11M11/11M12, 59 – Sheet joggers 12M6/12M7, 110 – Sheet slowdown/format adjustment 12M5, 104 – Suction head height adjustment 11M5, 40 – Suction head/format adjustment 11M6, 53 Servo–drive circumferential register SM/CD 102, 314 Servo–drive diagonal register SM/CD 102, 308 Servo–drive ink fountain roller SM/CD 102, 305 Servo–drive lateral register SM/CD 102, 311 Sheet alignment, 207 – Automatic misalignment control 11M7, 251 – Automatic sheet arrival control 11M3, 238 – Block diagram, 207 – Degree values, 209 – Double–sheet detector 1B11, 231 – Pull lay control 1B9/1B10, 223 – Sheet alignment control, 210 Sheet alignment control – Adjustment, 219 – Block diagram, 210 – Misaligned–sheet display (trend display), 214 – Sheet alignment, 210 – Sheet alignment error – ANK sensors, 212 – FÜK sensors, 213 Sheet alignment control 1B13/1B49, 215 – Checking the circuit state, 222 – Layout and task, 215 – Pin assignment, 215 – Place of installation, 215 – Removal and installation, 216 Sheet joggers 12M6/12M7, 110 – Checking the operating range, 117 – Fault message, 111 – Interconnection diagram 12M6, 113 – Interconnection diagram 12M7, 114 – Place of installation, 112 – Removal and installation, 115 – Technical data, 112 Sheet monitoring, 259 – Sheet travel monitor 1...nB48/1...nB48a, 259 Sheet slowdown / format adjustment 12M5 – Checking the operating range, 109 – Interconnection diagram, 107 – Place of installation, 106 – Removal and installation, 108 – Technical data, 106 Sheet slowdown/format adjustment 12M5, 104 – Fault message, 105 Sheet travel monitor 1...9B48/1...9B48a, 259 – Adjustment, 263 – Components, 263 – Place of installation, 262 – Service display, 261 Size adjustment, 45 – Block diagram, 45 – Command ”Presetting”, 46 – Print–free margin D.S./O.S. 1M2/1M3, 77 Solenoid valves, – Location diagrams, 411 Static electricity eliminator 11E3, – Task, 385 Static electricity eliminator 12E3 – Layout, 384
5
Index
– Place of installation, 383 Suction head height adjustment 11M5, 39, 40 – Checking the operating range, 43 – Interconnection diagram, 41 – Place of installation, 40 – Removal and installation, 42 – Technical data, 40 Suction head height control, 39 – Suction head height adjustment 11M5, 39 Suction head/format adjustment 11M6, 53 – Checking the operating range, 58 – Fault message, 54 – Interconnection diagram, 56 – Place of installation, 55 – Removal and installation, 57 – Technical data, 55 Switches – Monitoring the IR slide–in dryer 12S9, –a, –b, –c, 380 – Powdering cycle 12S68, 379
– Settings, 294 – Inking roller washup device FWW – Additional washing of printing plate and ink fountain roller, 289 – Block diagram, 286 – Example, 289 – Flow chart, 290 – Function, 287 – Layout, 287 – Settings, 288 – Messages, 276 – Selection of functions, 275 – Service display, 278 – Washup solution container, – Warnings, 298 Washup solution container E9 – Block diagram, 297 – Layout, 299 – Pin assignment, 300 – Place of installation, 299 – Sensors B1, B54, B55, 301 – Task, 300 – Warnings, 298
T Temperature control, – SM/CD 102. Siehe Farbwerk–Temperierung
U upper main pile limitation 11B33 – checking the circuit state, 154 – connection, 153 – Layout, 152 – place of installation, 152 – removal and installation-, 153 – setting, 154 – task and function, 153
V Varnish supply unit E4a, 369
W Washup brush motors M43, M50 ... M56, 296 – Pin assignment, 296 – Place of installation, 296 Washup devices – Blanket washup device GTW – Block diagram, 281 – Example, 285 – Flow chart, 285 – Function, 282 – Layout, 282 – Settings, 284 – Control by command, 275 – Impression cylinder washup device DZW, 292 – Example, 295 – Flow chart, 295 – Function, 293 – Layout, 293
6
Z Zentralschmierung, – Oil lubrication, – Circular lubrication, 340 Zero position – Servo–drive circumferential register SM/CD 102, 316 – Servo–drive diagonal register SM/CD 102, 310 – Servo–drive ink fountain roller SM/CD 102, 307 – Servo–drive lateral register SM/CD 102, 313
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